Design of Production

System

A production process consists of

activities that are required in
transforming an input set (human
resources, raw materials, energy,
money,information,
etc.)
to
valuable outputs with the help of
processors.

A production system converts inputs into

outputs with the help of processors

A generalised production system

can
be represented as:-

INPU
T

OUTPU
T
(goods/services
)

PROCESSOR

Classification on the basis of output

Three bases considered1. Variety
2. Uniformity
3. Volume per output
type
o Two types a)continuous

LOW

HIGH

CONTINUOUS
FLOW
PRODUCTION

VARIET
Y

MASS
PRODUCTION

BATCH
PRODUCTION

HIG
H
HIG
H

INTERMITTENT
JOB
ORDER

PROJECTS

LOW
UNIFORMITY
LOW
VPO
T

ON THE BASIS OF MACHINERY

CONTINUOUS

INTERMITTENT

1.SPECIFIC MACHINERY

1.GENERALISED MACHINERY

2.PERMANENT MACHINE
SETUP

2.FREQUENT CHANGES IN
MACHINE SETUP

3.DUPLICATION OF
MACHINES

3.LESS MACHINES REQUIRED

ON THE BASIS OF MATERIAL

HANDLING AND LABOUR USE
CONTINUOUS

INTERMITTENT

1.UNSKILLED AS WELL AS
SMALL TEAM OF
SPECIALISED LABOUR
FORCE
2.MECHANIZED MATERIAL
HANDLING
3.MATERIAL HANDLING
COST IS LESS
4.INVESTMENT IN
INVENTORY IS HIGHER

1.HIGHLY SKILLED LABOUR

FORCE
2.NOT FEASIBLE TO EMPLOY
MECHANIZED HANDLING
3.MATERIAL HANDLING
COST IS HIGHER
4.NEED FOR INVENTORY
IS MINIMISED

ON THE BASIS OF OUTPUT

PRODUCED-

CONTINUOUS

INTERMITTENT

1.FEW STANDARD
PRODUCTS IN LARGE
QUANTITIES

1.WIDE RANGE OF
PRODUCTS IN SMALL
QUANTITIES

2.OUTPUT ON THE BASIS

OF ANTICIPATION OF
DEMAND

2.OUTPUT ACCORDING
TO ORDER RECEIVED

DIFFERENCES ON THE BASIS OF

MAINTENANCE AND CONTROL
EMPLOYED

CONTINUOUS

INTERMITTENT

1.ABSENCE OF
MAINTENNCE MAY
INTERRUPT WHOLE
PROCESS

1.NO DANGER OF
STOPPAGE OF WHOLE LINE

2.CONTROLLING IS SIMPLER

2.CONTROLLING IS COMPLEX

1.FLOW TYPE

Output cannot be segregated into

different
units
High degree of uniformity
Output cannot be measured directly
Example-power plant

2.MASS PRODUCTION
Straight line flow of materials
Output of one stage normally
becomes input for another
Output visible in form of
identical units
Standardised output produced
in large quantities
PROBLEMS

1.
2.
3.

Balancing of production lines

Machine maintenance
Raw materials supply

1.BATCH PRODUCTION SYSTEM Variety of products are made in small quantities

Various products compete for share of machines
Outputs are aggregated in form of batches
Batches may comprise of similar or dissimilar
outputs
PROBLEMS
1. Machine-job allocation problem
2. Determination of economic batch quantity
3. Scheduling and sequencing of operations
. Example electrical goods

2.JOB-ORDER PRODUCTION
SYSTEM
Does not has its own
standard product but
accepts whatever customer
orders come in
Output identifiable in terms of
specific job order
Material flow is very complex
PROBLEMS
1. Determination of the sequence of
processing

3.PROJECT PRODUCTION SYSTEM

Project is a temporary endeavour
having a defined beginning and end
;undertaken to meet unique goals
and objectives
Project is non repetitive
This type of production system uses
resources on different projects
Product remains fixed and
manpower and facilities put work
on it
PERT/CPM can be used for
planning and control in this case