UNIT- 4 PRODUCTION SYSTEM 5.

Determining the production capacity: The production capacity of the

system is determined by analyzing the demand for the product or service
Production system and the availability of resources. This involves determining the number
 A production system is a process that produces goods or services. of products that can be produced within a given time frame and the
 It involves the conversion of raw materials into finished products
resources required to achieve this level of production.
through a series of operations or activities.
 The production system can be designed in various ways depending on Types of production system
the nature of the product, volume of production, resources available, and
The two main types of production systems are:
other factors.
 Intermittent Production System:
 The main goal of a production system is to produce high-quality
1. Project production flows
products efficiently and effectively while minimizing costs and
maximizing profits. 2. Jobbing production flows
3. Batch production flows
Design of production system  Continuous Production System:

The design of a production system refers to the process of planning and 1. Mass production flows
developing an efficient and effective method of producing goods or services. 2. Process production flows
It involves the analysis of the production process, identification of the
required resources, and determination of the best way to organize these
resources to ensure that the production process is efficient and cost- Intermittent Production System
effective, which in turn leads to increased profitability and customer  Intermittent production system refers to a manufacturing system in which
satisfaction. It involves several key steps including: the production of goods is based on customer orders and the flow of
1. Determining the product or service to be produced: The first step in production is not continuous, but rather occurs in irregular intervals. This
designing a production system is to identify the product or service that system is characterized by the production of a wide variety of products
the organization intends to produce. This involves analyzing the market on a small scale. The design of these products keeps changing according
demand, identifying the customer requirements, and determining the to the customer's orders, making the system very flexible.
desired output.  Some examples of intermittent production system are the work of a
2. Analyzing the production process: The next step is to analyze the goldsmith, who produces ornaments on a small scale basis as per the
production process and identify the various activities involved in customer's requirements, and a tailor, who stitches clothes for each
producing the product or service. This involves determining the customer independently as per one's measurement and size. In this
sequence of activities, the time required for each activity, and the system, general- purpose machines are used, and the sequence of
resources required. operation keeps changing as per the design of the product.
3. Identifying the required resources: Once the production process has  The characteristics or features of intermittent production system
been analyzed, the next step is to identify the resources required to carry are:
out the process. This includes identifying the materials, labor, equipment,  Production flow is not continuous but intermittent
and other resources required.  Wide variety of products are produced
4. Determining the layout of the production system: The layout of the
 Small volume of production
production system is important for ensuring that the resources are
organized in the most effective way possible. This involves determining  General-purpose machines are used
the location of the resources, the sequence in which they will be used,  Sequence of operation changes as per the design of the product
and the flow of materials and goods through the production process.  The quantity, size, shape, design, etc. of the product depends on the
customer's orders.
The three main types of intermittent production systems are:  The two main types of continuous production systems are:
1. Project Production Flow: This type of production system is used to 1. Mass Production Flows: Mass production flows involve the
manufacture products that are unique and are only produced once. It production of a large quantity of a standardized product. The
involves a large amount of planning and coordination, as every project production process is continuous, and the products are produced in
is different. Examples include constructing a building, designing a large volumes using specialized machinery. For example, producing
new car model, or producing a one-time special event. thousands of cars, manufacturing a large quantity of pharmaceutical
products, or producing thousands of packaged food items.
2. Jobbing Production Flow: In this type of production system, small
quantities of products are produced according to the customer's 2. Process Production Flows: Process production flows involve the
requirements. This production system is characterized by a high level production of a continuous flow of a standardized product. The
of customization and flexibility. For example, a carpenter who makes production process is divided into a sequence of steps, and each step
custom furniture would use jobbing production flow to produce is performed by specialized machinery. For example, refining crude
unique pieces of furniture for each customer. oil into petroleum products, producing chemicals, or producing
electricity.
3. Batch Production Flow: This type of production system is used to
manufacture products in small batches. It involves producing a
limited quantity of products that are made to a specific design. Production Planning & Control (PPC)
Examples include producing a limited quantity of t-shirts with a
 PPC, or Production Planning and Control, is a process used in
specific design, or manufacturing a batch of cookies with a particular
manufacturing to ensure that products are produced efficiently, on time,
recipe.
and at the desired quality level. It involves the coordination of resources,
including people, machines, and materials, to meet production goals while
Continuous Production System minimizing waste and maximizing efficiency.
 A continuous production system is a type of manufacturing system that  Production planning is the process of determining what products to
operates constantly without any interruptions or frequent halts. In this produce, how much to produce, and when to produce them. It involves
system, goods are produced on a large scale for stocking and selling, creating a production schedule, identifying necessary resources, and
based on demand forecasts rather than individual customer orders. The setting production targets.
inputs and outputs are standardized, and the production process and  Production control, on the other hand, is the process of monitoring and
sequence are predetermined. controlling the production process to ensure that it runs smoothly and
 Examples of continuous production systems include the food industry,
according to plan. This involves tracking production progress,
where large-scale production of food takes place based on demand identifying and resolving issues that arise, and adjusting production plans
forecasts, and the fuel industry, where crude oil and other raw sources as necessary.
are processed continuously on a large scale to yield usable forms of fuel  Together, production planning and control helps manufacturers to
and meet global energy demands. optimize their resources, minimize waste, and increase productivity,
 The characteristics or features of continuous which ultimately leads to higher profits.
production system are:  The main objectives of PPC are:
 Production is continuous, without any interruptions  Meeting production targets
 Products are always the same, following a standard format  Optimizing utilization of resources
 Quality is pre-determined and maintained throughout production  Ensuring timely delivery of products
 Products are made in advance, based on forecasted demand  Reducing production costs
 Standardized schedules and instructions are used for the production  Ensuring quality control
process.  Minimizing production downtime
  Enhancing customer satisfaction
 Improving production efficiency
 Facilitating continuous improvement in production
processes.

Steps of PPC
The following are the six steps involved in the PPC process:
1. Planning: The first step in PPC is planning, where the production plan
is formulated based on the sales forecast and market demand. The
production plan is a document that outlines the quantity and type of
products that need to be produced within a specific period. The plan
takes into consideration the production capacity, availability of
resources, and other factors that could impact production.
2. Routing: After the production plan is formulated, the next step is
routing. Routing involves determining the sequence of operations that
need to be performed to produce a product. It also involves determining
the machines, tools, and equipment required for each operation.
3. Scheduling: The third step is scheduling, which involves creating a
timetable for production. The timetable outlines the start and end times
for each operation, taking into account the availability of resources and
the lead time required for each operation.
4. Loading: After scheduling, the next step is loading. Loading involves
assigning the work to machines and operators based on the production
schedule. The goal of loading is to ensure that the machines and
operators are utilized to their maximum capacity while meeting the
production targets.
5. Dispatching: The next step is dispatching, which involves releasing the
work orders to the shop floor. The dispatching process involves
providing the necessary instructions to the operators, such as the
materials required, the sequence of operations, and the production
targets.
6. Follow up: Inspection and Correction: The final step in the PPC
process is follow up, which involves monitoring the production process
and making corrections where necessary. Follow up involves inspection
of the work in progress to ensure that it meets the quality standards,
identifying any deviations from the production plan, and taking
corrective actions to ensure that the production targets are met.