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Production methods depend upon the nature of the products and the
requirements of the customers.
What are needed to create and distribute a product?
type of process used normally rely on the size/volume of
products.
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Input
Raw materials
Process
Manufacturingprocesses
Output
Finishedproducts
Four basic
production
methods
Job Production
Batch
Production
Mass
Production
Just in Time
(JIT) Production
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Complete one job at a time
Usually for unique products or produced small scale
e.g. make-to-order die or mould/a special musicinstrument
made to client/customers specification
Very costly and requires highly skilled worker andexpensive materials.
Also known as one-off production, and craftproduction
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Advantages
High quality products
Possible for high level of customization and flexible
Greater job satisfaction
Disadvantages
Very expensive
Do not apply economies requirement Requires specialist worker
Slow production process
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Completion based on number ofproduct units
Product is produced in blocks or batchesand could happen on small or large scale
Using general-purpose equipments andcommon methods
Only for sale at a limited time e.g. automotive industrymodel after
model, foods & beverages industry
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Advantages
Lower unit cost
Workers can specialize
Variety in production
Needs less skilled workers
Disadvantages
Repetitive works and less motivation to workers Cost increases due to requirement of storage place
Problem to manage stages of batches
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Mass - Large quantity of product made at highspeed
Using computer controlled robotics system Machines run 24 hours each day
e.g. Production of television set, cloth, toys, canned food etc.
Flow - Continuous process, very high volume ofstandardized output.
Applies production line method
e.g. petrochemical refineries, electricity utilities, sugar/flourmaking etc.
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Advantages
Low unit cost due to large output
Specialization of workers Less skilled workers
Quality can be maintained and standardized
Disadvantages
Repetitiveness can lead to unmotivated workers
High overhead cost
Breakdown of machine can cause trouble
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Producing the right part in the right
place at the right time Stocks of raw materials are kept to a minimum
Strives to eliminate manufacturing waste suchas moving and storing raw materials
Also known as lean production or stocklessproduction
Improve profits and return on investment
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Advantages
Stock of raw material are kept as low as possible
Improve profits and return on investment
Improving product quality
Disadvantages
Delays could happen if stock is not available on time
Requires highly organized management system forordering raw materials
Shortage of stock could lead to serious productiondelay
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Producing moderate to high volume of
output with more variety Emphasizes on quality, flexibility, time reduction and
team work
Less space, less inventory, and small group of
workers Use highly skilled workerforce and flexibleequipments
Product similar to mass production
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Advantages
flexibility
variety High quality goods/products
Disadvantages
No safety nets in the case of system breakdown
Less opportunities for career advancement
Stress workers
Need more skilled worker than mass production
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1. Explain what the advantages that mass production has
over one-off production or batch production?
2. Explain or discuss the disadvantages of mass production
with regards to the quality of the product and the effect
that it may have upon the workers?3. What positive and negative effects can mass production
have upon a community?
4. Why would certain people be prepared to pay more
money for a product which has been made by a lessefficient system of manufacturing e.g. one-off production?
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Market
Production System
Production Floor
Suppliers
Customers
Raw
Material
Inventory
Finished
Goods
Inventory
Work in Process
Cost
Production
System Value
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Job Lot Production
(Unit/Piece
Production)
Moderate Production
(Batch Production)
Mass Production
Pro
ductionQua
ntity
Production Variety
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Continuous
flow process
Pr
oductionQu
antity
Production Variety
Automation
Mechanizatio
n
Flexible
Workstation
Cell
Workstation
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High
Volume
Stand Alone NC
Equipment
Flexible
Manufacturing
System (FMS)
Transfer Line
Low
Volume
High VarietyLow Variety
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Costper
piece
No. of parts per hour
Mass
Production
Batch
Production
Piece Part
Production
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Transfer
Lines
Volume
productionper
partno.
VarietyPart numbers per system High
Dedicated
system
Flexible
system
Automatic
cells
Job shops
High
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Flow shop
Job shop
Cellular
Fixed
Continuous flow
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D GML
M GLPart B
Part A
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D GML
M GLPart B
Part A
M GMPart C
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D
L
M
L
G
D
D
CellPart C & D
Part A & B
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Product APeople Machinery
Product A Product B
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Source: Prof. Madya Mohd Yusuff Mohd,
Manufacturing Processes Course Manual 1A, 2009