1. PRODUCTION TYPES

2. 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.

3. Transformation or conversion process Operation planning and
Operation management
System design
Operation planning and
Control
MATERIALS
LABOUR
MACHINES
FACILITIES
ENERGY
INFORMATION & TECHNOLOGY
Information feedback concerning outputs for process control
Outputs
Product & services

4. PRODUCTION SYSTEMS Intermittentn production system Job production
Continuous production system
Job production
Batch production
Mass production
Process production
Assembly production
Analytical
Synthetic

5. Continuous/Flow Production System

6. 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.

7. 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.

8. 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.

9. 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.

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

11. 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.

12. 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.

13. 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 Padmini automobile assembly, Onida TV assembly and so on.

14. The assembly line of mass production system is as give below:-
WORK STATION A
WORK STATION K
Assembled products
Inputs
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.

15. 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.

16. 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.

17. 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.

18. 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.

19. 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

20. The plant layout of the factory / production unit is of process type.
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

21. 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

22. 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.

23. 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

24. 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.

25. 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 work-group wise.