Production methods

depend upon the nature of the products and the

requirements of the customers.
What are needed to create and distribute a product?
type of process used normally rely on the size/volume of
products.
Input
Raw materials
Process
Manufacturing
processes
Output
Finished
products
Four basic
production
methods
Job Production
Batch
Production
Mass
Production
Just in Time
(JIT) Production
Complete one job at a time
Usually for unique products or produced small scale
e.g. make-to-order die or mould/a special music
instrument
made to client/customers specification
Very costly and requires highly skilled worker and
expensive materials.
Also known as one-off production, and craft
production

Advantages
High quality products
Possible for high level of customization and flexible
Greater job satisfaction
Disadvantages
Very expensive
Do not apply economies requirement
Requires specialist worker
Slow production process

Completion based on number of
product units
Product is produced in blocks or batches
and could happen on small or large scale
Using general-purpose equipments and
common methods
Only for sale at a limited time
e.g. automotive industry model after
model, foods & beverages industry
Advantages
Lower unit cost
Workers can specialize
Variety in production
Needs less skilled workers
Disadvantages
Repetitive works and less motivation to workers
Cost increases due to requirement of storage place
Problem to manage stages of batches

Mass - Large quantity of product made at high
speed
Using computer controlled robotics system
Machines run 24 hours each day
e.g. Production of television set, cloth, toys, canned food etc.
Flow - Continuous process, very high volume of
standardized output.
Applies production line method
e.g. petrochemical refineries, electricity utilities, sugar/flour
making etc.

Advantages
Low unit cost due to large output
Specialization of workers
Less skilled workers
Quality can be maintained and standardized
Disadvantages
Repetitiveness can lead to unmotivated workers
High overhead cost
Breakdown of machine can cause trouble

Producing the right part in the right
place at the right time
Stocks of raw materials are kept to a minimum
Strives to eliminate manufacturing waste such
as moving and storing raw materials
Also known as lean production or stockless
production
Improve profits and return on investment
Advantages
Stock of raw material are kept as low as possible
Improve profits and return on investment
Improving product quality
Disadvantages
Delays could happen if stock is not available on time
Requires highly organized management system for
ordering raw materials
Shortage of stock could lead to serious production
delay

Producing moderate to high volume of
output with more variety
Emphasizes on quality, flexibility, time reduction and
team work
Less space, less inventory, and small group of
workers
Use highly skilled workerforce and flexible
equipments
Product similar to mass production
Advantages
flexibility
variety
High quality goods/products
Disadvantages
No safety nets in the case of system breakdown
Less opportunities for career advancement
Stress workers
Need more skilled worker than mass production

1. Explain what the advantages that mass production has
over one-off production or batch production?
2. Explain or discuss the disadvantages of mass production
with regards to the quality of the product and the effect
that it may have upon the workers?
3. What positive and negative effects can mass production
have upon a community?
4. Why would certain people be prepared to pay more
money for a product which has been made by a less
efficient system of manufacturing e.g. one-off production?
Market
Production System
Production Floor
S
u
p
p
l
i
e
r
s

C
u
s
t
o
m
e
r
s

Raw
Material
Inventory
Finished
Goods
Inventory
Work in Process
Cost
Production
System
Value
Job Lot Production
(Unit/Piece
Production)
Moderate Production
(Batch Production)
Mass Production
P
r
o
d
u
c
t
i
o
n

Q
u
a
n
t
i
t
y

Production Variety
Continuous
flow process
P
r
o
d
u
c
t
i
o
n

Q
u
a
n
t
i
t
y

Production Variety
Automation
Mechanizatio
n
Flexible
Workstation
Cell
Workstation
High
Volume
Stand Alone NC
Equipment
Flexible
Manufacturing
System (FMS)
Transfer Line
Low
Volume
High Variety
Low Variety
Cost
per
piece
No. of parts per hour
Mass
Production
Batch
Production
Piece Part
Production
Transfer
Lines
V
o
l
u
m
e

p
r
o
d
u
c
t
i
o
n

p
e
r

p
a
r
t

n
o
.

Variety Part numbers per system High
Dedicated
system
Flexible
system
Automatic
cells
Job shops
High
Flow shop
Job shop
Cellular
Fixed
Continuous flow
D G M L
M G L
Part B
Part A
D G M L
M G L
Part B
Part A
M G M
Part C
D
L
M
L
G
D
D
Cell
Part C & D
Part A & B
Product A People Machinery
Product A Product B
Source: Prof. Madya Mohd Yusuff Mohd,
Manufacturing Processes Course Manual 1A, 2009