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Overview of Production Methods

There are four main production methods: job production, batch production, flow production, and mass customization. Job production involves producing one-off customized products while batch production produces a limited number of identical products in batches. Flow production allows individual products to move continuously through standardized production stages. Mass customization combines customized products with low unit costs by allowing some product components to vary while keeping others the same. The choice of production method depends on factors like market size, available capital and resources, and customer demand.
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0% found this document useful (0 votes)
58 views2 pages

Overview of Production Methods

There are four main production methods: job production, batch production, flow production, and mass customization. Job production involves producing one-off customized products while batch production produces a limited number of identical products in batches. Flow production allows individual products to move continuously through standardized production stages. Mass customization combines customized products with low unit costs by allowing some product components to vary while keeping others the same. The choice of production method depends on factors like market size, available capital and resources, and customer demand.
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© All Rights Reserved
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Production methods

Introduction:
 There are several different ways in which goods and services can be produced
 They usually classified into
o Job production
o Batch production
o Flow production
o Mass customization

Job production:
 Producing a one-off item specially designed for the customer
 These products can be small (specially designed wedding ring) or large (a custom made
food truck)
 In order to be called job production, each individual product has to be completed before
the next product is started. Thus, at any one time there is only one product being made.
 Job production involves labour intensive production method, producing specialised
products.
 Job production is motivating to the workers because they produce the whole product
and can take pride in it
 However, job productions
o Needs highly skilled labour force, which is not abundant and thus expensive
o Takes long time to complete a product (although rewarding for workers)

Batch production:
 Producing a limited number of identical products, (in batches)
 The production process involves a number of distinct stages
 Every unit in batch must go through an individual production stage before the batch as a
whole moves on to the next stage.
 Usually used in industries where there are demand for batches of identical products.
 It also allows each individual batch to be specifically matched to the demand that is
altering the design and composition of the batches.
 Batch production allows firms to use division of labour in their production process and it
enables some gain from economies of scale if the batch is large enough.
 However,
o Batch production tends to have high levels of work-in-progress stocks at each
stage of the production process.
o The work may well be boring and demotivating for the workers
o If batches are small, then economies of scale cannot be achieved and unit costs
will be high
o There is often a need to clean and adjust machinery after each batch has passed
through

Flow production:
 In this process individual products move from stage to stage of the production process
as soon as they are ready, without having to wait for any other products.
 Flow production systems are capable of producing large quantities of output in a
relatively short time.
 It suits the industries where the demand for the product in question is high and
consistent
 It also suits production of large numbers of standardized item that only requires
minimal alterations (that’s why also known as mass production)
 Flow production has the following advantages
o Lower labour costs as most of the process is mechanized.
o Quality tends to be consistent and high and easy to check at various points
throughout the process.
o Also the constant output rates will make the planning of input simple.
o Unit cost is reduced, as there is ability to gain economies of scale.
 However, the flow production requires high initial set up cost. In addition the work
involved tends to be boring, demotivating and repetitive.

Mass customization:
 This production technique tends to provide the flexibility and worker satisfaction of job
production along with the gains of low unit costs of flow production.
 This process combines the latest technology with multi skilled labour forces to use
production line to make a range of varied products
 This allows the business to move away from mass marketing approach with high output
of identical products
 Instead, focused or differentiated marketing can be used which allows for higher added
value.
 So products can be customized to suit customers’ need in a matter of hour, by changing
just a few of the key component but keeping the rest the same
 Thus low unit costs are maintained with greater product choice
 However, both multi skilled labour force and latest flexible machineries are expensive

Production method making the choice:


 Factors that will influence which production methods will be adopted by a business
o Size of the market
 Job production- very small market
 Batch production – if the market demands for large number of units, but
at different times of year
 Flow production- when there is a large and consistent market for
similar or identical products throughout the year.
o The amount of capital available
o Availability of other resources
 E.g. unskilled labour for flow production
 Skilled labour for job production
o Market demand exists for products adapted to specific customer requirements
 Cost advantage of high volumes combined with ability to make slightly
different products for different markets then mass customization is
appropriate.

Problems of changing production methods:


 Job to batch
o Cost of equipment
o Additional working capital to finance stocks and work in progress
o Staff demotivation as less individual craft
 Job or batch to flow:
o Cost of capital equipment
o Staff training to be flexible and multi skilled so that boredom can be reduced by
moving workers to different tasks
o Accurate estimates of future demand to ensure that output matches demand.
Evaluation:
 The traditional difference between the three basic production methods are becoming
less obvious
 Many complex products are now easily being produced as per consumer requirements
due to modern technology
 The flexibility that technology offers large firms can risk the survival of small business
 However, there is always likely to be demand for original specialist products and thus
small firms with non mass production method will still thrive in these markets.

Common questions

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Job production is more motivating for workers because it involves producing an entire product, allowing workers to take pride in their work and see the final outcome of their efforts, which enhances job satisfaction . In contrast, flow production involves repetitive and mechanized tasks that can lead to boredom and demotivation . The implications for labor costs are significant: job production requires a highly skilled labor force, which is more expensive due to the specialized and varied nature of the work . Conversely, flow production benefits from lower labor costs due to its mechanization and reduced need for skilled labor .

When deciding between batch production and mass customization, a business must consider market demand for product variety and the desired level of customization versus standardization. Batch production allows for varied product designs for different batches, suited for markets demanding limited quantities at different times, but lacks high customization . Mass customization, however, enables the combination of low unit costs from flow production with flexibility in product variation, making it ideal for businesses targeting differentiated marketing . The choice also depends on the availability of capital for investing in advanced technology and skilled labor needed for mass customization . Additionally, businesses must consider logistical factors such as setup times and production line adjustments required for mass customization versus batch production .

Increasing flexibility provided by modern technology can significantly affect competition between large and small firms in the production industry. For large firms, technology facilitates the production of complex, customized products at scale, enhancing their ability to cater to niche markets while maintaining efficiency and cost-effectiveness, thus threatening small businesses that traditionally excelled in specialized, bespoke products . However, by leveraging modern technology, small firms can also gain the ability to produce complex and customized products efficiently, preserving their competitive edge in markets that demand original specialist products . Nonetheless, the high cost of adopting these technological solutions can be prohibitive for small businesses, thus maintaining a competitive advantage for larger firms with more capital resources . This shifting dynamic underscores the role of technology as both an equalizer and a barrier, potentially widening the gap between resource-rich and resource-limited companies.

Implementing mass customization comes with several challenges despite its advantages of flexibility and low unit costs. Businesses face the high costs associated with acquiring the latest flexible machinery and maintaining a multi-skilled labor force capable of adapting to varying production demands quickly . Additionally, the complexity of balancing customization with efficient production line operations requires sophisticated IT systems and inventory management strategies to handle varying inputs and outputs efficiently . There is also the challenge of maintaining quality and consistency when altering products to meet specific customer needs rapidly . These logistical and technical challenges require significant investment and strategic planning to overcome effectively.

The availability of skilled and unskilled labor significantly affects the choice between job production and flow production methods. Job production requires a highly skilled labor force to produce specialized, customized items, making it more suitable for businesses that have access to skilled workers and can afford higher labor costs . In contrast, flow production benefits from a labor force that is predominantly unskilled, as the process is highly mechanized and tasks are repetitive, leading to lower labor costs . Therefore, businesses' access to different types of labor directly influences which production method is feasible and economically viable based on local labor market conditions.

Changing from one production method to another can have significant effects on a company’s operations and workforce. Transitioning from job production to batch production involves costs associated with new equipment and the management of increased inventory levels, which requires additional working capital . For the workforce, there can be demotivation due to the decreased individual craftsmanship required in batch production . Shifting from job or batch to flow production entails substantial capital investment in equipment and requires staff training to ensure they are multi-skilled and can be rotated across tasks to prevent monotony . Accurate demand forecasting becomes crucial to avoid overproduction, and the efficiency of operations must increase to manage the larger scale of production . These changes demand careful planning and strategic resource allocation to maintain productivity and employee satisfaction.

Technology significantly influences the differences between traditional and modern production methods by enhancing flexibility, efficiency, and customization capabilities. Modern production methods like mass customization and advanced flow production leverage technology to seamlessly adapt production lines to create varied products without sacrificing the efficiency of large-scale production . This flexibility allows companies to move away from mass marketing identical products to a broader, more targeted approach using advanced machinery and IT systems . Traditional methods, such as basic job and batch production, relied more heavily on manual labor and were less adaptable to quick product changes, emphasizing lower flexibility in customization and scale . Overall, technology reduces the distinctions between traditional methods by facilitating complex product adaptations while maintaining low costs and high productivity levels.

The choice of production method in response to market demands and resource availability is determined by several key factors. The size of the market influences the method: job production is suitable for very small markets, batch production for markets that demand large numbers of units at certain times, and flow production for large, consistent markets . Available capital and the type of labor force available also play critical roles; for example, skilled labor is essential for job production, while unskilled labor suffices for flow production . Additionally, market demand for customized products may make mass customization a viable option, particularly when there are cost advantages in high volumes combined with the ability to tailor products slightly for different markets . Overall, the intersection of market characteristics and available resources guides the production method choice.

In batch production, economies of scale are achieved when the batch is large enough to allow for a division of labor and reduced per-unit costs. However, if batches are small, economies of scale cannot be achieved, leading to high unit costs . In contrast, flow production inherently benefits from economies of scale by producing large quantities of standardized items, which consistently leads to lower unit costs due to mechanization and consistent output rates . Therefore, while batch production can achieve economies of scale under certain conditions, flow production typically maintains lower unit costs as standard.

Mass customization balances the flexibility and worker satisfaction of job production with the low unit costs typical of flow production by integrating advanced technology and a multi-skilled labor force to produce varied products efficiently . It allows businesses to maintain low unit costs due to the mechanization and economies of scale of flow production, while also providing product variety for differentiated market needs . However, the cost implications include higher expenses for flexible machinery and skilled labor, which are essential to facilitate quick switches in production requirements and customization . Despite these additional costs, the ability to offer customized products at competitive prices can lead to higher added value and customer satisfaction, potentially offsetting these expenses .

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