PRODUCTION SYSTEM
DEFINITION OF PRODUCTION SYSTEM
Production is the process by which goods and services are created. Production system is basically set of activities by which resources flowing within a defined system are combined and transformed in a controlled manner to add value in acccordance with the policies of the management.
CHARACTRISTICS OF PRODUCTION SYSTEM
It has an objective It has organised activities. It tranforms the various inputs into useful outputs. It acts in combination with other organisation system. There exists a feedback about the activities which is essential to control and improve system performance.
CLASSIFICATION OF PRODUCTION SYSTEM
Job shop Batch production system Continuous production system Cellular production system
JOB SHOP PRODUCTION SYSTEM
Job shop production are characterized by manufacturing of one or few quantity of products designed and produced as per the specification of customers within prefixed time and cost. Each job demands unique technological requirements, demands processing on a certain sequence.
Characteristics
High variety of products and low volume Use of general purpose machines and facilities Highly skilled operators Large inventory of materials, tools, parts. Detailed planning for sequencing the requirements of each product, capacities for each work centre and order priorities.
Advantages
Variety of products can be produced Operators bound to become more skilled and competent as each job gives them learning opportunities. Full potential of operators can be utilised
Limitations
Higher cost due to frequent set up changes Higher level of inventory at all the levels and hence higher inventory cost. Production planning is complicated Large space requirement
Batch production system
It is defined as a form of manufacturing in which the job passes through functional departments in lots or batches and each lot may have a different routing. It is characterized by the manufacture of limited number of products produced at regular intervals and stocked awaiting sales
Characteristics
Shorter production runs Plants and machinery are flexible Plant and machinery set up is used for production of item in a batch and change of set up is required for processing the next batch. When manufacturing lead time and cost are lower as compared to job order production.
Advantages
Better utilisation of plant and machinery Promotes functional specialisation Cost per unit is lower as compared to job order production. Lower investment in plant and machinery Flexibility to accommodate and process number of products. Job satisfaction exists for operators.
Limitations
Material handling is complex because of irregular and longer flows. Production planning and control is complex.
Continuous production
It is also termed as mass production system. In it the manufacture of discrete parts or assemblies is through a continuous process.
Characteristics
Standardisation of products and process sequence. High degree of automation. Large volume of products. Short cycle time of production. Lower in process inventory. Flow of material is continuous and without any back tracking. Production planning and control is easy. Material handling can be completely automatic.
Advantages
High rate of production with reduced cycle time. Higher capacity utilisation due to line balancing. Less skilled workers are required. Low process inventory Manufacturing cost per unit is low.
Limitations
Breakdown of one machine will stop an entire production line. Line layout needs major changes with change in the product design. High investment in production facilities. The cycle time is determined by the slowest operation
Cellular production system
It is also termed as group technology system It is used to describe the operations of a group technology machine cell. It takes full advantage of the similarity between parts through standarisation and common processing. Similar machines are placed together.
Advantages
Improvement in material flow which reduces the distance travelled by the materials. Reduction in set up time. Reduction in the lead time. Gives the tools to the worker to be multi process and multi functional. Waste reduction and simple machine maintenance
limitations
Rearrangement of the entire factory floor and modification of equipment. Different cells may require the same machine and tools resulting in duplication causing higher investment. High resources in training the workers as each operator is responsible for a large number of assembled parts and operations.
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