chapter 01- manufacturing methods

8/11/2019 Chapter 01- Manufacturing Methods

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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

chapter 01- manufacturing methods

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