By Anuradha Gaikwad

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Ê 6roduction 6rocess

Ê An Activity whereby raw material is converted into

semi finished products and

Ê thereby adds to the value of utility of products,

Ê which can be measured as the difference between

the value of inputs and value of outputs. 2

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Ê 6roduction function
Ê Encompasses the activities of procurement,
allocation and utilization of resources.
Ê The main objective of production function is to
produce the goods and services demanded by
the customers in the most efficient and
economical way.
Ê Therefore efficient management of the
production function is of utmost importance in
order to achieve this objective.
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Ê is a system whose function is to convert a set
of inputs into a set of desired outputs.
Conversion
Inputs Outputs
6rocess

Land
Building Goods
Machines and
Labour capital Services
Management
Material Control
Others
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½. Job 6roduction System.

2. Batch or Intermittent 6roduction.

3. Continuous 6roduction.

4. Mass 6roduction

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Ê erein one or few units of the products are

produced as per the requirement and

specification of the customer.

Ê 6roduction is to meet the delivery schedule

and costs are fixed prior to the contract.

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½. Space vehicles 8. Custom clothing

2. Aircraft 9. 6rototype
3. Machine tools ½ . Large turbo generators
4. Special purpose ½½. Material handling
machines machines
5. Tooling ½2. Construction equipment
6. Jigs
7. Fixtures

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Ê Irregular
Ê Small lots

Ê Flexible machines

Ê Skilled workers

Ê Very small quantities

Ê Specially made

Ê igh variety low repetition

Ê Skills required are very broad

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Ê Skilled jobber or team of jobbers complete the
entire product
Ê Fixed position or process layout

Ê Multi-skilled operatives

Ê One part of the task is completed before next

starts
Ê A project with a team which combines to complete
the whole is more complex
Ê 6roduct routings vary widely

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Ê Job is a unique product

Ê Work is concentrated on a specific unit

supervision and inspection relatively simple

Ê Specifications can change depending on the

customer demand

Ê Operators become more skilled & competent as

each job gives them learning opportunity.
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Ê [tilisation of full potential of operators.

Ê Opportunity to use innovative ideas and creative
methods.
Ê Working on a single unit, coping with a variety of
tasks gives more satisfaction.
Ê General purpose machines help in variety
production.
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Ê [nder this system the goods are produced
partly for inventory and partly for customer's
orders.
Ê E.g. components are made for inventory but
they are combined differently for different
customers.
Ê Automobile plants, printing presses, electrical
goods plant are examples of this type of
manufacturing
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Ê In this, limited quantities of each of the

different types of products are manufactured
on same set of machines.

Ê Different products are produced separately

one after the other.

Ê E.g., automobile parts, electrical goods, etc.

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½. Shorter production runs.
2. 6lant and machinery set up is is changed as per
requirements of the batch of items.
3. More number of set ups and hence high cost.
4. Amount of supervision is less compared to job
order.
5. 6lant and machinery are flexible.
6. Manufacturing lead time and cost are lower as
compared to job order production.
7. igher level of work in process inventory.
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½. Better utilisation of plant and machinery.

2. 6romotes functional specialisation.
3. Cost per unit is lower as compared to job order
production.
4. Lower investment in plant and macinery.
5. Flexibility to accommodate and process
number of products.
6. Job satisfaction exists for operators.
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½. Material handling is complex because of
irregular and longer flows.
2. 6roduction planning and control is complex.
3. Work in process inventory is higher compared
to continuous production.
4. Longer production times.
5. igher set up costs due to frequent changes in
set up.
6. Lower utilisation of production facilities
compared to mass production.
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Ê It refers to the production of standardized
products with a standard set of process and
operation sequence in anticipation of demand.
Ê It is also known as mass flow production or
assembly line production.
Ê Associated with continuous production and high
demand.
Ê The system is suitable for oil refineries, cement
manufacturing etc.
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½. Steel 6. Chemicals

2. Ores 7. 6etroleum products

3. Cloth 8. Cement

4. 6harmacy products 9. Rubber

5. gases. ½ . 6aint

½½. 6aper processing

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½. Dedicated plant and equipment with zero
flexibility.
2. Material handling is fully automated.
3. Wet or dry product flow measurable by weight
or volume.
4. Shorter lead-times.
5. Component materials cannot be readily
identified with final product and the product
cannot be disassembled.
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6. The end product is not naturally divisible and

hence n additional step such as bottling or
canning is needed to get the product into
saleable units.
7. Larger investment and usually capital intensive
units.
8. 6rocess follows a predetermined sequence of
operations.

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9. Maintenance is an important aspect.

½ . [nit coat is lower due to high volume.

½½. 6lanning and scheduling is a routine action.

½2. 6ersons with (semi-skilled) limited skills, can

be used on production line.

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½. Variations in raw materials quality due to
different sources of supply.
2. 6rocessing technology variations.
3. Variations in yields of output.
4. Demand for by-products and joint products.
5. Shelf life of raw materials.
6. 6roduct differentiation is limited.
7. 6lant availability depends on preventive
maintenance system.
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Ê [nder this, the production run is conducted on
a set of machines arranged according to the
sequence of operations.
Ê A huge quantity of same product is
manufactured at a time and is stocked for sale.
Ê Different products will require different
manufacturing lines.
Ê Since one line can produce only one type of
product, this process is also called as line flow.

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½. Standardisation of product & process

sequence and hence product (line) layout is
recommended.
2. Dedicated special purpose machines having
higher production capabilities & output rates.
3. Large volume of products.
4. Shorter cycle time of production.
5. Lower in process inventory.
6. 6erfectly balanced production lines.
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7. Flow of materials, components and parts is

continuous & without any backtracking.

8. 6roduction planning and control is easy.

9. Extent of supervision required is less.

½ . Material handling can be fully automated.

½½. [nit per cost is low due to high volume.

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½. igher rate of production with reduced cycle

time.
2. igher capacity utilisation due to line
balancing.
3. Less skilled operator can man the process.
4. Low in process inventory.
5. 6roduction cost per unit will come down due to
economies of scale.

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½. Breakdown of one machine will stop an entire
production line.
2. Line layout needs major adjustment / changes
with the changes in the product design.
3. igh investment in production facilities.
4. Supervision is general rather than specific.
5. Work for operators is monotonous without much
challenge.
6. The cycle time is determined by slowest
operation.
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Ê [nder this, the production run is conducted for

an run is conducted for an indefinite period.
Ê Identical products are produced in large
numbers.

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Ê igh volumes and low variety
Ê Standard repeat products
Ê ighly capital intensive and automated
Ê Few changeovers
Ê Difficult and expensive to start and stop
Ê 6roduct layout usually along conveyors or pipes
Ê No idle time
Ê Operators at work stations perform tasks as it passes
through the workstation
Ê Line is dedicated to one product only
Ê Flexible continuous flow line may be capable of
switching over to a model or product variant
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Ê Ease of using just in time technique
Ê Labour and production costs reduced due to
detailed planning
Ê Deviants in the line are spotted through quality
control techniques
Ê No rest between operators so work-in-progress
levels can be kept low
Ê Space storage is minimum
Ê 6hysical handling is minimum
Ê Investment is quickly converted into sales
Ê Control is easy 3
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Ê Assembly line is industrial arrangement of

machines, equipment, and workers for
continuous flow of work pieces in mass-
production operations

Ê First assembly line was introduced by enry Ford

in ½9 8

Ê Consists of sequence of work stations

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Ê It is the issue of assigning tasks to the work station

Ê Tasks may require different times

Ê Assignment of tasks times to work stations are

unequal

Ê This leads to idle time

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Ê Assignment of tasks depends on demand rate
Ê Depending on demand rate lines might be
duplicated
Ê Requires logical planning

Ê Distribute total job among the work station so

that all stations can complete their designed
tasks at approximately same time
Ê Split total assembly procedure into sub
assemblies
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Ê Demand is high duplicate entire line

Ê Shortens the assembly line

Ê May require more equipment and tooling

Ê More tasks are assigned to a work station

Ê Enriches work content

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