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Classification of Production Systems

Overview of Job Shop, Batch, Mass, and Continuous Production Systems
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Introduction to Production Systems
What are Production Systems?
A production system refers to the method and organization used to manufacture
goods and services. It involves the planning, designing, and managing of resources
(labor, machinery, materials) to produce desired outputs efficiently. Production
systems can be classified into Job Shop, Batch, Mass, and Continuous Production,
each catering to specific production needs.
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1. Job Shop Production
It is a method where small quantities of customized products are manufactured to
meet specific customer requirements. It is characterized by low volume and high
variety, with products made to order.
Characteristics
 High variety and low volume of products.
 Use of general-purpose machines organized into departments.
 Highly skilled operators handle unique technological requirements.
 Requires detailed planning for sequencing work and resource allocation.
Advantages
 Flexibility in producing a variety of products.
 Skilled workers gain diverse experience and learning opportunities.
 Operators can showcase creativity and innovation.
 General-purpose machines accommodate varying product requirements.
Limitations
 Higher production costs due to frequent setup changes.
 Complex production planning and scheduling.
 Large space requirements and high inventory costs.
 Slower production rates due to customized setups.

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2. Batch Production
It involves manufacturing products in specified quantities (batches) at regular
intervals. Products in a batch undergo the same sequence of operations before the
setup is changed for the next batch.
Characteristics
 Suitable for shorter production runs.
 Flexible machinery adapts to different batches.
 Requires setup adjustments between batches.
 Lower lead time and cost compared to job shop production.
Advantages
  Better utilization of machines and resources.
 Flexibility to accommodate diverse products.
 Lower cost per unit compared to job shop production.
 Promotes functional specialization and job satisfaction.
Limitations
 Material handling and workflow are more complex.
 Higher inventory of work-in-process materials.
 Increased setup costs due to frequent changes.
 Complicated production planning and control.

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3. Mass Production
It refers to the large-scale manufacture of standardized goods using continuous
processes. It involves a product layout where machines and workers are arranged
sequentially to optimize output.
Characteristics
 Standardized products with uniform quality.
 Machines are specialized and dedicated to high production rates.
 Materials flow continuously without backtracking.
 Lower inventory levels and shorter cycle times.
Advantages
 High production efficiency and reduced cycle times.
 Low unit cost due to economies of scale.
  Requires less-skilled operators.
 Simplified production planning and control.
Limitations
 Inflexible to product design changes.
 High initial investment in specialized equipment.
 Production is disrupted by machine breakdowns.
 Slowest operation determines the overall cycle time.

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4. Continuous Production
It is a highly automated production system where raw materials are transformed
into finished goods without interruption. It is used for high-demand, standardized
products.
Characteristics
 Dedicated equipment with no flexibility.
 Fully automated material handling systems.
 Process follows a pre-defined sequence of operations.
 Minimal manual intervention and high consistency in outputs.
Advantages
 Highest efficiency and output rates.
 Standardized products with uniform quality.
  Low unit cost due to high-volume production.
 Fully automated material handling reduces labor costs.
Limitations
 Very high initial investment.
 No flexibility for product customization.
 Limited ability to differentiate products.
 Requires regular maintenance of machinery to prevent downtime.
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SUMMARY

Aspect Job Shop Batch Production Mass Continuous

Production Production Production

Volume Low Medium High Very High

Product High Medium Low Very Low

Variety

Flexibility Very High High Low None

Machinery General-purpose Flexible Specialized Dedicated,

automated

Operator Highly skilled Moderately skilled Low skill required Minimal skill
Skills required

Setup Time High (unique Moderate Low None

setups per (adjustments
product) between batches)

Material Manual, labor- Partially manual Partially Fully automated

Handling intensive automated
 Planning Very complex Complex Simple Routine
Complexity

Cost per High Medium Low Lowest

Unit

Examples Custom Seasonal clothing, Consumer goods Petroleum

furniture, electronics assembly (e.g., cars, refining, power
prototypes phones) generation