Explain Intermittent And Continuous Operations. Under What Type Of Situation It Would Be Used In Automobile Industry 353p69

PRODUCTION TYPES

MEANING AND DEFINITION OF PRODUCT/PRODUCTION Production is the creation of goods and services Production refers to a sequence of operations that transforms material from a given to a desired form in a minimum possible cost. According to E.S.BUFFA. “PRODUCTION IS A PROCESS BY WHICH GOODS AND SERVICES ARE CREATED” MEANING OF PRODUCTION SYSTEM A system in an assemblage of objects united by some form of regular interaction. Production system constitutes a number of activities and operations. There are three components of production system namely, inputs transformation process and output. Inputs in the production system are in the form of material, men and equipment. Output is in the form of goods and services while trans formation process involves many operations necessary to change inputs into output. Definition of production system According to buffa and sarin, production system may be defined as “the means by which we transform resource inputs to create useful goods and services as outputs.

MATERIALS LABOUR MACHINES FACILITIES ENERGY

Transformation or conversion process Operation management System design Operation planning and Control

INFORMATION & TECHNOLOGY

Information concerning outputs for process control

Outputs Product & services

PRODUCTION SYSTEMS

Intermittentn production system

Continuous production system

Job production

Mass production

Analytical

Process production

Assembly production

Synthetic

Batch production

Continuous/Flow Production System

Meaning of Continuous/Flow Production System Production process in which the processing of the product is continuous and progressive Broken operations Large production Single product or less variety Eg: Automobile plants, chemical plants, oil mills, sugar mills and steel mills.

Definition of Continuous/Flow Production system: According to Buffa, “continuous flow production situation are those where the facilities are standardized as to routings and flow since inputs are Standardized. Therefore, a standard set of process and sequences of processes of processes can be adopted”. Flow production can also be defined as production during which the work content of the product continually increases.

Features of Continuous/Flow Production System  Product flows unit by unit through the plant.  Large production in anticipation of demand.  The plant layout is of product type, and machines are arranged according to product layout pattern.  Specialized machine tools and equipment.  Well balanced capacities of machines.  Heavy expenditure on tools and plants.  Conveyor system for handling production materials.  Production control system is as per the rate of flow of each piece of production material.  Slightest block in flow of production material is overcome by “crash measures”  Supervision on the production system is in the hands of personnel well trained.  Machine set-ups remain unchanged for a considerably long period.

Advantages/Merits of Continuous/ Flow Production System Accuracy of the product design. Product quality is superior Direct labour cost is reduced Work-in-progress is at the lowest cost. Limited material handling Weakness in materials or methods is quickly highlighted. Planning of requirements. Transformation of investment in materials into income is relatively rapid. Delay in the production process is automatically detected Control over costs, materials and output is simplified. Overhead cost per unit is reduced considerably.

Limitations of Continuous/Flow Production Method It is a rigid method of production. It is always necessary to avoid piling up of work

Requirements of Continuous/Flow production System  Regular and continuous demand.  Standardized product.  Availability of materials.  Effective prevention maintains.  Proper balanced stages of production system.  Well defined operation.  Effective in-line inspection of the plant  Work as per quality standards laid down.

Suitability of Continuous/Flow Production System Limited variety of products on large-scale in a continuous manner. Flow production method can be applied to the following conditions: Regular and uniformed demand for the products. High volume of production required to meet market demand. Product to be marketed is standardized. Well balanced production process which avoids any disturbance in the process.

Mass production system • A large quantity of one or two standard products follows the system called mass production system. • The demand for the products is large and continuous. • Flow of material is in straight line • Standardization is the key note of mass production • The degree of mechanization and automation is high the production process is also continuous • A product wise layout and balanced production line are two significant features of mass production system Example:Premier Pi automobile assembly, Onida TV assembly and so on.

The assembly line of mass production system is as give below:-

WORK STATION

WORK STATION

K

A Inputs

Assembled products

WORK STATION B

Note: - The assembly line of operations of material can be manual or through conveyor belts. Mass production system is generally employed in industries where the production is carried on without interruption. The quality of production is superior and uniform due to standardization and mechanization.

Merits of mass production system: • There is smooth flow of material for production purpose. • Less storage space is adequate for temporary storage and WIP (work in progress). There are small WIP inventories as output of one • process becomes input of the next process Production planning and control PPC is simple and • easy. No expertise is required to operate the system. • Demerits of mass production: • One machine failure results in whole stoppage of the whole production line. Assembly lines are not flexible. • Production speed is determined by the slowest • machine. Capital intensive system due to the duplication of the • machines along the production line.

Process production system:-

Process production system is an extended form of mass production. • Goods with continuous and high demand are suitable to be produced through process product system e.g., medicines, plastic goods, petroleum products, chemicals and so on. • A single raw material is transformed into different products at different stage of production process e.g., crude petroleum is processed into petroleum, kerosene, diesel oil and gasoline. • The flow of production under process system may be classified into analytical production process and synthetic production process.

Assembly production system:• Assembly production system developed in the automobile industry in the USA. • It is convenient when a limited variety of similar products is to be manufactured on a mass scale or in large batches on a continuous basis.

Intermittent production system:The goods are manufactured specially to fulfill orders made • by customers rather than for stock. Here, the flow of material is intermittent. Under intermittent production system, the basic product design changes from time to time. Features of intermittent production system:• The flow is not continuous but intermittent • A wide variety of products are manufactured The volume of production is small • General purpose machines are used • One specific sequence of operation is not used in the • production process • The components are produced and assembled as per customer orders • Functional or process layout is used Intermittent production system is more complicated as compared to continuous production system as different products are to be manufactured by using the available production facilities.

Continuous v/s intermittent production:Continuous production

Intermittent production

1 product:

same product is produced continuously.

The product design changes as per batch/job. Same product is not produced continuously

2 production process:

lacks flexibility

Production process is flexible.

3 nature of production: large scale production of standardized products

Small scale production of wide scaled goods

4 capital investment:

it is substantial

It is limited/low

5 standardization:

product and process are standardized

Product and process are not standardized

6 storage requirement:

only at limited locations

Storage is required at each operation.

7 use of equipments:

regularly

Equipments are used for limited time

8 production cost :

: per unit cost is low

Per unit production cost is high

Job production method/system (job shop):_ Job order production means manufacture of products to meet specific customer requirements of special order. It is always non-standardized. Examples: - Bridge building, dam construction and ship building are common examples of job order production industries. Features of job production method:-

The plant layout of the factory / production unit is of process type. Varieties of general purpose machines and equipment are installed Large quantity of inventories Large storage space and adequate extra machines The flow of material is complex A permanent staff of highly skilled employees Specialized labor A sales organization with competent and technically qualified persons  Accurate store keeping        

Merits of job production method:Limited investment in machinery Flexible organization Production process is not disturbed

Demerits of job production method:Most complex system of production Inventories are high Material handling costs are high Speed of work is slow Work loads are unbalanced Inefficient utilization of labor

Batch production method:-

Definition: - The manufacture of product in batches (small or large) or lots by a series operations, each operation being carried out on the whole batch before any subsequent operation is undertaken. Meaning of batch production method: Batch production is the production of a number of identical articles, either to meet a specific order or to satisfy continuous demand.  The whole production system is flexible  The production takes place periodically  A batch consisting of a certain quantity is made on a machine  In batch production limited quantity of one type of product is manufactured at a time  Batch production method is used extensively  Production problems are complex in the batch production method  Scheduling of production becomes more complex.

Features of batch production method: The manufacturing plant should be well equipped with machines and equipment with capacity to undertake production of wide variety.  The general purpose machines and special purpose machine are used in the production process  The machines and equipment are arranged according to the sequence of operations i.e. process layout is used  Tooling arrangement are comparatively extensive as provision needs to be made for interchangeability of each part produced from the same drawing  A large variety of products are manufactured in lots or batches  There is absence of proper balance in the work load of different departments  Stock of work in progress is high and the product design department is comparatively large

Merits of batch production method:  The features of flow production and job production are combined in batch production method.  Capital investment is comparatively low  There is job satisfaction to operatives  Specialized supervision is possible  Flexibility with respect to personnel and equipment  Breakdown of single process does not affect complete production activity.

Demerits of batch production method:  Work-in-progress inventory is high  Standard sequence of operation is absent  Machine and tooling arrangements need frequent changes.

Job production

Batch production

Meaning

Manufacture of goods as per specifications given by the customer. It is special order production.

Production of no of identical articles either to meet a specific order or to satisfy continuous market demand.

Examples

Bridge building, dam construction and ship building.

Manufacturing of switch gears, heavy motor vehicle and electric motor.

Method of production

Manufacture of single complete unit by an operator or a group of operators.

The work content of each unit is broken into a number of operations and the operators are divided into groups for the completion of workgroup wise.