Types of Production Systems

There are six types of production systems:

 

1.      Job shop

2.      Batch production

3.      Assembly line

4.      Continuous flow

5.      Cell manufacturing

6.      Flexible manufacturing systems

Job shop

Job shop is a type of production system, it process small batches of large no. of product varieties. It requires different set of processing steps. Production equipment involve in varies production activities. Highly skilled man-power is required.   

Number of machines         -           one/two

Volume                              -           Low to Moderate

Skilled labour                    -           High

Variety                               -           High

Customization                   -           High (catering to clients requirements)

Example

A printing machine shop comprises only one or two machines but it offer different services like printing invitation cards, different types of binding, pamphlets, etc.,

Batch Production Systems

In Batch Production, production is repeated frequently. We call it as standardized job shop. High skill labour required, but not critical. Production depends on demand.

Variety                                          -           Moderate

Volume                                         -           Moderate to High

Skill                                               -           combination of both High and Moderate

Technology                                   -           High to Moderate

Number of Human Resources      -           Moderate to High

Example

1. Pharmaceutical Industries

a)      Crocin

b)      Crocin-Plus

c)      Crocin-cold & flue

d)      Crocin Pain relief

The above all are variants of Crocin, which has standardized process compared to a job shop.

2. Standard software – Anti verses, OS (Windows - 10)

Assembly Line Manufacturing

Assembly line production system is for mass production. A set of steps can be followed in a sequential order in production system. Tools and equipment’s are specially design for the production, low skilled labour/man-power requirement. 

a)      It follows Product layout

b)      They has a dedicated line volume

Variety                    -           Less

Skill                        -           Less

Technology            -           Less

Human Resource  -           Low to Moderate

Example

1. Manufacturing of FMCG goods, they follow assembly line and standardization further increases.

2. Automobile manufacturing   

Continuous Flow Production Systems

Continuous flow involve high automation. It required control through online and continuous monitoring system. Involving high expenses in Shut down and Start-up. High skill level manpower required.

Variety                               -           No variety (Negligible)

Skill                                    -           High

Technology                        -           Moderate to High

Human Resource              -           Low to Moderate

Example

Oil refinery, it has only extraction of oil. The process is highly standardized.

·         Chemical Industry

·         Power generation

Cell Manufacturing

A cell manufacturing/production system is an independent unit. It is like a mini factory within the factory, in which all processes required to make components/complete products can be carried out.

Variety                               -           High

Technology                        -           Moderate to High

Example

A process for a product requires cutting, followed by drilling and finishing, the cell/mini factory would include the equipment/machine for performing those steps, arranged in that order. High variety of production.

Flexible Manufacturing System

Flexible Manufacturing/production system consists of no. of CNC (Computer Numeric Control is the automation of machine tools) machine tools and equipment’s. It brings flexibility to manufacturing. Computer control machines, they can respond to pre-programmed instructions.

a)      It is an extension of batch manufacturing system

b)      Variety- High

c)      Suitable where changes to reactions are unpredictable.

d)      Automation- High

Example

Maruti can switch from producing large batches of one model of car to another model with a different shape and arrangements of sub- assemblies within minutes and multi skilled workers can reconfigure their work stations with required material

Statistical Tools (Theory)

1.      Time series

Time series is the most important statistical tool which ensure business success. Mainly time series is used for prediction and forecasting, deals with time (minutes, hours, days, years) based data, which will help to take decision. Time series method is very useful models when you have in sequence correlated data. Most of business decision taken on the basis of time series data to analyze sales number for the next year, website traffic, competition position etc.

2.      Z-Test

A z-test is a statistical test used to test the hypothesis two population means are different when the variances is known and the sample size is large (n>30).

3.      T-Test

It is used to test hypothesis of two populations whether they are significantly different (or) it is a common method for comparing the mean of one group to a value / the mean of one group to another.

4.      Chi Square Test

It is used to compare observed data with data that we would like to expect to obtain according to a specific hypothesis.

5.      ANOVA (Analysis Of Variance)

·         Determine whether two or more groups are different

·         Determine if any groups are the best

One way ANOVA

One-way analysis of variance is the distinctive method for comparing three or more group means. The usual goal is to determine if at least one grouped mean/median is different from the others.

6. Co-Relation

     It represents the degree of association or statistical relationship among two variables.ie.

      Degree of linear relationship. It value lies from -1 to +1

      If value close to -1, it is negative co-relation.

      If value close to +1, it is positive co-relation.

7. Regression analysis

Regression analysis is a statistical process for calculating the relationships among variables, which includes many techniques for modeling and analyzing several variables. The attention is on the relationship between a dependent variable and one or more independent variables.

8. Multivariate analysis

Multivariate analysis is basically the statistical process of simultaneously analyzing. Multiple independent variables with multiple dependent variables.

9.  Control chart

Control chart is a graph representation used to study how the process changes over a period of time.  Collected data are plotted in time order. A control chart has a central line (control limit) for the average/mean, an upper line for the upper control limit (UCL) and a lower line for lower control limit (LCL).