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Production System Facilities

The document describes three levels of production systems - job shop, batch production, and mass production - based on annual production quantity. It provides details on their typical facilities layouts and manufacturing approaches. Job shops support very low volumes of customized products. Batch production involves making batches of different products on shared equipment. Mass production dedicates facilities entirely to high volume production, using either dedicated machines or flow line processes.

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Ruby Smith
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176 views

Production System Facilities

The document describes three levels of production systems - job shop, batch production, and mass production - based on annual production quantity. It provides details on their typical facilities layouts and manufacturing approaches. Job shops support very low volumes of customized products. Batch production involves making batches of different products on shared equipment. Mass production dedicates facilities entirely to high volume production, using either dedicated machines or flow line processes.

Uploaded by

Ruby Smith
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Production System - Categories/Levels

1. Support system (design & other business functions) [Professional staff] Set of procedures used by company to manage production and solve technical & logistics problems encountered in ordering materials, moving work through the factory and ensuring that products meet quality standards.

2. Facilities (Direct labour) Machines, tooling, material handling equipment, inspection equipment, computer systems that control manufacturing operations.

PRODUCTION SYSTEM FACILITIES


Facilities also include the plant layout, which is the way the equipment is physically arranged in the factory. The equipment is usually organized into logical groupings, and we refer to these equipment arrangements and the workers who operate them as the manufacturing systems in the factory. Manufacturing systems can be individuals work cells (single production m/c and worker assigned to that machine). We more commonly think of manufacturing systems as groups of machines and workers, for example, a production line. If we limit our discussion to discrete products, the quantity produced by a factory has a very significant influence on its facilities and the way manufacturing is organized. Production quantity refers to the number of units of a given part or product produced annually by the plant. 1) 2) 3) Low production: Quantities in the range of 1 to 100 units per year. Medium production: Quantities in the range of 100 to 10,000 units annually. High production: Production Quantities are 10,000 to million units annually.

It is instructive to identify product variety as a parameter distinct from production quantity. There is an inverse correlation between product variety and production quantity in terms of factory operations. When product variety is high, production quantity tends to be low and vice versa. Manufacturing plants tend to specialize in a combination of production quantity and product variety that lies somewhere inside the diagonal band in figure.

(Figure)Relationship between product variety and production quantity in discrete product manufacturing.

1. Jobshop
Production facility usually associated with the quantity range of 1 to 100 units per year. Makes low quantities of specialized and customized products. Typically complex such as space capsules, aircraft and special machinery. Repeat orders may never occur. Equipment is general purpose and the labour force is highly skilled. A jobshop must be designed for maximum flexibility to deal with the wide part and product variations encountered (hard product variety). If the product is large and heavy and therefore difficult to move in the factory, it typically remains in a single location, at least during final assembly. Workers and the processing equipment are brought to the product (FIXED POSITION LAYOUT). Egs. Ships, aircraft, railway locomotives and heavy machineries. In actual practice, these items are usually built in large modules at single locations, and then the completed modules are brought together to final assembly using large capacity cranes. o Individual parts of these large products are made using PROCESS LAYOUT (in which the equipment is arranged according to the function or type. Lathes in one dept, milling machines in another). o Parts are routed through the depts. o In the needed order usually in batches. Process layout is flexible; it can accommodate a great variety of alternative operation sequences for different part configurations. Disadvantages: 1. machinery and methods to produce a part are not designed for high efficiency. 2. Much material handling is required to move parts between depts., so in process inventory can be high. (Diagrams of product and process layouts can be drawn manually)

2. Batch production:
Quantities in range of 100 to 10,000 units annually. When product variety is hard a batch of one product is made, after which the facility is changed over to produce a batch of next product. The production rate of the equipment is greater than the demand rate for any single product so the same equipment can be shared among the multiple products. Disadvantage: Setup or changeover time (time to change tool, reprogram machinery etc) is time lost. Batch production commonly used in make to stock (MTS) situations-items made to replenish inventory that gradually depletes by demand. Usually PROCESS LAYOUT is used. If product variety is soft, no extensive changeovers. It is possible to configure the equipment so that groups of similar parts or products can be made on the same equipment without significant loss of time in the changeovers. The processing or assemblies of different parts or products are accomplished in cells consisting of several workstations or machines (CELLULAR MANUFACTURING/LAYOUT). Each cell is designed to produce a limited variety of part configurations; that is, the cell specializes in the production of a given set of similar parts or products, according to the principles of GT.

3. Mass production:
Production Quantities are 10,000 to million units annually. When high demand rate for product and the facility is dedicated for production of that product. Type1: quantity production: Type2. Flow line production

Quantity production
Mass production of single parts on single pieces of equipment. The method of production quantity typically involves std mchines such as stamping presses equipped with special tooling (eg. Dies and material handling devices) in effect dedicating the equipment to the production of one part type.

Flow line production


Multiple workstations arranged in sequence, and the parts or assemblies are physically moved through the sequence to complete the product. The workstations consist of production machines and /or workers equipped with specialized tools. The collection of stations is designed specifically for the product to maximize the efficiency (PRODUCT LAYOUT-workstations arranged into one long line). The work is usually moved between stations by powered conveyer. At each station, a small amount of the total work is completed on each unit of product.

Eg. Assembly line associated with products such as cars and household appliances. 1. Single model production line-pure case of flow line production where there is no variation in the products made on the line. Every product is identical. 2. Mixed model production line-to successfully market a given product, it is often necessary to introduce model variations so that individual customers can choose the exact style and options that appeal to them. This model differences represent soft product variety. Eg. Cars coming off the assembly line have variations in options and trim representing models of the same basic car design.

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