Every product we use such as bread, a car, or even a bridge is created through a process known as a production system. A production system is the organized way in which a company converts raw materials into finished products. It includes people, machines, materials, and methods that work together to achieve efficiency and quality.
In Operations Management, the study of production systems helps businesses choose the best way to produce goods efficiently. Depending on the type of product, the quantity required, and customer needs, companies use different production systems.
There are three types production systems:
- Intermittent Production
- Continuous Production
- Project or Static-Position Production
Let us now understand each of these systems in detail.
Table of Contents
1. Intermittent Production
An intermittent production system produces goods only when required. The production does not run all the time but stops and starts depending on demand. This system focuses on flexibility and product variety instead of large quantities.
There are two types of intermittent production systems: Job or Unit Production and Batch Production.
a) Job or Unit Production
Definition:
Job production is used when items are made one at a time based on specific customer orders. Each product is unique and follows its own process.
Characteristics and Explanation:
- Low volume but high variety: Only a few units are made at a time, but each one is different. For example, a goldsmith makes a custom-designed necklace for each client.
- Use of general-purpose machines: Machines are flexible and can perform different tasks. A carpenter uses the same tools for making chairs, tables, and cupboards.
- Highly skilled labor: Workers must be experts because they make different products each time. For instance, an artist painting portraits needs creativity and precision.
- Unique routing and scheduling: Each order follows a different route through the factory and has its own time schedule.
Examples:
Custom furniture, wedding invitation designs, and special-purpose machinery.
Explanation:
Job production gives maximum flexibility and customization. It is perfect for products that are made once or that need individual attention. However, it takes more time and costs more money compared to other methods.
b) Batch Production
Definition:
Batch production involves making a specific number of identical items in one go, called a batch. After completing one batch, the same machines can be used to make another type of product.
Characteristics and Explanation:
- Moderate volume and variety: Production happens in medium quantities. For example, a bakery may make 500 vanilla cakes and then switch to 500 chocolate cakes.
- Changeover between batches: After completing a batch, machines are cleaned and reset for the next one. This takes time but allows flexibility.
- Planning for batch sizes: Managers decide the number of items in each batch to meet demand without wasting resources.
- Consistency in quality: Products made in the same batch look and perform the same because they are produced under similar conditions.
Examples:
Bakery products, seasonal garments, and pharmaceutical tablets.
Explanation:
Batch production offers a good balance between efficiency and flexibility. It allows companies to meet different customer needs while controlling production costs.
2. Continuous Production
Definition:
Continuous production is used when a company needs to produce large volumes of standardized products. The process runs continuously, and materials flow through machines without stopping. It focuses on high efficiency and low cost per unit.
Continuous production is divided into two types: Mass Production and Process Production.
a) Mass or Flow or Line Production
Definition:
Mass production means making large quantities of the same product using specialized machines arranged in a sequence or line.
Characteristics and Explanation:
- High volume, low variety: The same product is produced in large numbers, such as cars or televisions. The design does not change frequently.
- Fixed routing and sequence: Machines are arranged according to the order of operations. The product moves from one station to another until it is finished.
- Specialized machinery: Each machine performs one specific task. This speeds up production but reduces flexibility.
- Low cost per unit: Since large quantities are made, the cost of each item becomes very low due to economies of scale.
Examples:
Automobile manufacturing, refrigerator assembly, and bottled drink production.
Explanation:
Mass production is best for large companies that make identical products in bulk. It increases speed and reduces cost but does not allow for customization.
b) Process or Continuous Process Production
Definition:
Process production involves a continuous flow of materials through machines or chemical processes. The output is uniform, and production rarely stops.
Characteristics and Explanation:
- Continuous material flow: Materials move automatically from one process to the next without interruptions. For example, crude oil continuously moves through refining units to produce petrol.
- High capital investment: This system uses expensive equipment and automation technology that requires large initial investment.
- Highly automated and controlled: Computers and sensors monitor the process to maintain quality and efficiency.
- Homogeneous products: The final product is the same in every unit produced, such as cement, oil, or steel.
Examples:
Oil refining, cement manufacturing, and chemical production.
Explanation:
Process production is suitable for industries that produce large quantities of identical products. It gives high efficiency but requires heavy investment and continuous supervision.
3. Project or Static-Position Production
Definition:
Project production is used for large, unique, and complex projects. The product remains in one location, and workers, materials, and equipment move to that site.
Characteristics and Explanation:
- Unique and one-time products: Each project is different from others. For example, constructing a bridge or ship is a one-time task that cannot be repeated exactly the same way.
- Fixed location: The work happens at a specific site. Instead of moving the product, the people and equipment come to it.
- Long duration and high investment: Projects take a long time and require a large budget. This includes construction costs, labor, materials, and technology.
- Intensive planning and coordination: Because several teams work together, managers must carefully plan each stage to finish on time and within budget.
Examples:
Shipbuilding, bridge construction, and power plant installation.
Explanation:
Project production is best suited for large projects that need detailed planning and close coordination between teams. Every project is different, so strong management skills are essential.
Comparison of Production Systems
| Type | Production Volume | Product Variety | Typical Examples |
|---|---|---|---|
| Job Production | Low | High | Custom furniture, artwork |
| Batch Production | Medium | Moderate | Bakery, garments, pharmaceuticals |
| Mass Production | High | Low | Cars, refrigerators |
| Process Production | Very High | Very Low | Oil refining, cement production |
| Project Production | One-time | Unique | Shipbuilding, bridge construction |
Conclusion
Production systems are at the heart of every business that manufactures goods. Each system is designed for a different purpose:
- Intermittent production is ideal for custom and flexible work.
- Continuous production is best for large-scale, standardized products.
- Project production is used for unique and complex tasks at fixed sites.
By understanding these systems, anyone can learn how companies plan and organize production to deliver quality products efficiently. Whether it is a bakery, a car factory, or a bridge construction site, each uses the type of production system that suits its goals and resources.
