APPC

Manufacturing systems.

NIFT, Navi Mumbai,

Presentation by Ranjan Kumar Saha, Associate
Professor for classroom discussion
 Productive system types
• Process-Focused systems– The nature of the
demand on the productive system results in
intermittent demand for the system’s facilities, and
each component flows from one process to the next
intermittently. Thus, the process-focused system
with intermittent demand on process types must be
flexible as required by the custom product, and each
generic department and it’s facilities are used
intermittently as needed by the custom orders.
 Productive system types
• Process-Focused systems– for e.g. in a
machine shop we might expect to find milling
machine departments, lathe departments,
drill departments and so on. The flow of the
items being processed in such productive
system is dictated by individual product
requirements, so the routes through the
system are variable.
 Productive system types
• Product-Focused systems: The nature of the demand
on the productive system that produces high volume,
standardized products results in continuous use of
the facilities. Processing is adapted completely to the
product. Individual processes are physically arranged
in the sequence required, and the entire system is
integrated for a single purpose. Thus continuous
system have a product focus.
 Types of Production Systems
1) Intermittent Production system-
(For custom order manufacturing)
a) Project Production
b) Jobbing Production
c) Batch Production(can be production for stock)
2) Continuous system- (Production for stock)-
a)Mass Production.
b) Process production.
 Intermittent System
• These are those where the prod’n facilities are
flexible enough to handle a wide variety of products
and sizes.
1. Most products are produced in small qty’s.
2. Machines and equipments are laid out by process.
3. Workloads are generally unbalanced.
4. Highly skilled operators are reqd. for efficient use of
machines and equipments.
5. In-process inventory is large.
6. Flexible to suit prod’n varieties.
 Features of Intermittent system
1. Demand can be discontinuous .
2. All operational stages may not be balanced.
3. Elaborate sequencing and scheduling is required.
4. Needs high inventory.
5. Storage is necessary at each stage of production
process.
6. Can adjust to new situation and specification.
7. Items are manufactured according to order.
 Types of Intermittent Systems
• A) Project production: Project production is
characterized by complex sets of activities that must
be performed in a particular order within the given
period and within the estimated expenditure. Where
output of a project is a product, such products are
generally characterized by immobility during
transformation. Operations of such products are
carried out in fixed position assembly type of layout.
e.g. production of ships, locomotive and aircraft,
construction of roads, buildings.
 Project production system
• Characteristics of project production:
• A)Definite beginning and definite end.
• B)Non-uniform requirement or resources.
• C) Involvement of different agencies.
• D)Fixed position Layout.
• E)High cost overruns.
 Job production
• Job production/Jobbing production : - Job or
‘make complete’ is the Production charactersed by
the manufacturing of one or few numbers of a single
product designed and manufactured strictly to
customer’s specifications, within the given period
and within the price fixed prior to the contract.e.g.
general repair shops, special purpose machine tool
manufacturers, tailoring shops manufacturing made-
to-measure suite of clothes.
• Characteristics of job/jobbing production:
• A) In this system the goods are produced to definite
customer’s orders. There is no assurance of
continuous demand for specific items.
• B)small production runs.
• C) Discontinuous flow of materials
• E) Disproportionate manufacturing cycle time.
• F)General purpose machines and process layout.
• G)high skilled labour.
 Batch production
• Batch production is characterised by the
manufacture of a limited mumber of a product( but
many such quantities of different products) produced
at regular intervals and stocked in warehouses as
finished goods(or finished parts) awaiting sales (or
withdrawal for assembly).
• E.g. Process industry such as pharmaceuticals, paints,
chemicals, manufactures of readymade garments,
etc.
 Batch production
• Characteristics of Batch production:
• a) short production runs.
• B) skilled labour in specific trade.
• C) General purpose machines and process type of layout.
• D) large work in progress.
• F) Flexibility of production schedules.
• G) Need to have production planning and control.
• H) Limited function of production planning and control.
 Continuous system
• In this the items are produced for the stocks
and not for specific orders. Before planning
mfg to stock, sales forecast is made to
estimate likely demand of product and master
schedule is prepared to adjust the sales
forecast according to past orders and level of
inventory. After setting master production
schedule, detailed planning is carried on.
• In continuous manufacturing systems each
production run manufactures in large lot sizes
and the production process is carried on in a
definite sequence of operations in a pre-
determined order. FIFO priority rules are
followed in the system. In short, here input-
output characteristics are standardized
allowing for standardization of operations and
their sequence.
 Features of continuous system
1. There must be continuity of demand.
2. The product must be standardized .
3. Material should be per specifications and delivered
on time.
4. All operation stages in the process must be
balanced.
5. Work must conform to quality standard.
6. Inspection must be in line with production.
 Types of continuous system
• Mass production (Mass & flow Prod.)
• Process production
 Mass & Flow production
• Mass as well as flow production are
characterized by the manufacturer of a several
number of a standard product produced and
stocked in the warehouses as finished goods
awaiting for sales.
• Mass production E.g. plastic goods.
• Flow production e.g. assembly shops of
automobiles, refrigerators, radios, television
sets, electric fans,etc.
 Mass & Flow production
• Characteristics of Mass & Flow production.
• A)continuous flow of material
• B)special purpose machines and product type layout.
• C)low skilled labour.
• D)Easy supervision
• E)limited work in progress
• F)Less flexibility in production schedule.
 Process production
• Process production is characterised by the
manufacture of a single product produced and
stocked in the warehouses awaiting sales. The
flexibility of such product is almost zero as only one
type of product can be produced in such plants.
• Typical E.g. of such plants are
sugar,steel,cement,coke,refineries,etc.
 Process production
• Characteristics of process production:
• A)Special purpose machines with built-in controls.
• B)Highly mechanized material handling.
• C)low skilled labour.
• D) negligible work in progress
• E) limited production planning and control function.
 Classification of Production System
• Production systems can be classified as Job Shop, Batch, Mass and
Continuous Production systems.
 Manufacturing systems in Apparel
Industry
• Make through system
• Conventional bundle system
• Clump system
• Progressive bundle system
• Flexible flow system
• Straight lien system
• Synchro flow system
• UPS
• Modular
 Conventional bundle system
• Sewing MC arranged in lines
• Central storage / dispatch area
• Worker 1 collects bundle from distributor, sew,
back to distributor
• Distributor passes the bundle to worker 2
Conventional bundle system
 The Clump system
• Variation of conventional bundle system
• Operators collects a clump rather than bundle
 Conventional bundle adv. & Dis adv.
• Flexible. Copes with • Excessive material
frequent style changes handling
• Less impact of • Difficult to control
absenteeism as inventory
distributors can control • WIP cannot be monitored
the amount of work • Work place engineering is
received & dispatched difficult
• Easy to operate & easy to • High WIP
supervise
• Large storage required
• Uniform level of quality.
Controller checks quality
 Progressive bundle system
• Sewing operations laid out in sequence
• Each operator receives bundle, untie, work, tie
and pass to operator no 2
• Need storage as rack/bin/table for storing WIP
Progressive bundle system
 Progressive bundle system adv & dis
adv
• High productivity
• High level of labor utilization
• A Uniformly high standard of
work can be achieved
• Training time and costs can be
reduced
• Semi skilled labor can be used
• Individual performance can be
monitored and incentives
offered
• M/C investment cost is high
• Not adaptable for short run
production & frequent style
changes, as it require
arrangement of workstations.
• High handling costs for bundle
handling & transportation
• High WIP , so it involves high
capital commitment and can
block the cash flow of the
factory
• High management skill require
to arrange the work flow and
decide the no. of operator for
each operation
 Flexible Flow system
• Similar to progressive
• Workers work at engineered work place
• Work supplied thru rack @ side
• Flow is flexible
Flexible Flow system
 Straight line system
• Manufacturing process broken down into
several operations which take the same time
to complete
• Groups of operators
• Handle only individual garments
• Work passed by tray
• Conveyor belt for distribution can be used and
its speed will be set to suit the cycle time
Straight line system
Straight line system
 Synchro flow system
• Similar to straight line
• Garment parts of same size & color are
processed separately
• I.e. they flow in synchronize manner
Synchro flow system adv & dis adv
• Fast throughput time • Absenteeism can causes
• Low work in progress problems, as the system
• Less material handling is based on workers
time working within a time
limit.
• Does not require a great • MC break down & worker
deal of technical absenteeism may disrupt
supervision work flow
• High std of work
measurement necessary
and high pre production
skills needed.
 UPS
• Unit production system
• Computer controlled prod line
• Overhead conveyor system to move individual units
• All parts of a single garment are carried by means of
hanging carrier
• No need to remove parts from carrier
• Automated material handling
• Electronic data collected
• Payroll & inventory data
• Immediate tracking of styles
UPS
UPS
 UPS
Advantage
• Very flexible and complied
with work measurement
• Little WIP
• Fast throughput time can be
achieved because of the lower
WIP in the system.
• Low WIP and over head
transport system leads to
better space utilization.
• Less handling time
• High quality of garments.
Dis Advantage
• Investment cost of this
system is high.
• A central place needed for
quality control
• Suitable for large orders for
a particular style, as high
preparation works are
needed for plant layout and
line balancing
 Modular Manufacturing
• Groups operators into teams / modules
• Team works on one / few garment at a time
instead of bundles
• Operators sit/stand
• Rotate workstations
• Self inspect
Modular Manufacturing
Modular Manufacturing