Introduction

• Any mfg org. can be termed as a

prod’n system to produce goods &
services. There are three main
components of this system namely
inputs, transformation process and
output. Combination of all activities
and operations to produce some
goods and services is known as mfg
system.
 Manufacturing systems
• Prod’n is the process by which goods
and services are created. The inputs
can be raw materials, components,
paperwork, etc. whereas o/p are
completed parts, products, paper
work o/p services and scrap. The
conversion process can be
characterized as Receipt and
storage of raw materials. These are
drawn by the prod’n deptt. acc. To
• The mfg system nay therefore be
viewed as an interdependent gyps.
Of sub systems, each related to its
successor, each performing a
different function through yet united
with other for achievement of overall
system objectives. It interacts with
both internal and external
environment. The internal
environment can be a combination of
mktg, a/c’s, personnel and finance
activities. The external envir. Can be
combined effect of customers,
competitors, suppliers etc.
 Types of Mfg Systems
• Intermittent system
• Continuous system
 Intermittent System
• These are those where the prod’n
facilities are flexible enough to handle a
wide variety of products and sizes.
• Most products are produced in small
qty’s.
• Machines and equipments are laid out by
process.
• Workloads are generally unbalanced.
• Highly skilled operators are reqd. for
efficient use of machines and
equipments.
• In-process inventory is large.
• Planning and ctrl mechanism for
intermittent systems is such that
here the customers provides the blue
print and other specification
regarding the product to be mfg’d
Then the org. Formulates their
prod’n strategy to suit the needs of
the customer
 Types of Intermittent
Systems
• Job Prod’n:- Job or ‘make complete’
prod’n is the prod'n of single complete unit
by one operator or gp. Of operators e.g.
bridge buid’g, dam construction etc. Here
whole project is considered as one
operation and work is completed on each
product before passing on to next. Each
product is a class by itself and requires a
distinct and separate job for prod’n
purposes. The system requires versatile
and highly skilled Labour wit high capital
invt’s. Ctrl of operations is relatively
• In this system the goods are produced to
definite customer’s orders. There is no
assurance of continuous demand for
specific items and the mfg depends on
the receipt of orders from customers.
2. Whole project is taken as single
operation.
3. Work is to be completed on each product
before processing the next item.
4. Versatile and skilled Labour is needed .
5. High capital invt.
6. Ctrl operations are relatively simple.
7. High unit cost of prod’n.
Any org mfg heavy and special purpose
 Batch Prod’n.
• In the system of batch prod’n any product
is divided into parts or operations and that
each operation is to be completed
throughout the whole batch before the
next operation is undertaken. The best
example of batch prod’n system is of
chemical industry, where different
medicines are mfg'd in batches.
• In this system a batch is not passed to
next operation until the work on the
previous operation is complete for the
whole batch and no new batch enters the
prod’n line, till all the operations for mfg
any product are completed. This results in
considerable idle time for various
Features of Intermittent
system
1. Demand can be discontinuous .
2. All operational stages may not be
balanced.
3. Elaborate sequencing and scheduling is
required.
4. Needs high invt.
5. Planning, routing and scheduling changes
with fresh orders.
6. Storage is necessary at each stage of
prod’n process.
7. Can adjust to new situation and
specification.
 Continuous system
• In this the items are produced for the
stocks and not for specific orders.
Before planning mfg to stock, sales
forecast is made to estimate likely
demand of product and master
schedule is prepared to adjust the
sales forecast according to past
orders and level of inventory. After
setting master prod’n schedule,
detailed planning is carried on.
• In continuous mfg systems each
prod’n run manufactures in large lot
sizes and the prod’n process is
carried on in a definite sequence of
operations in a pre-determined order.
FIFO priority rules are followed in the
system. In short, her input-output
characteristics are standardized
allowing for standardization of
operations and their sequence.
 Features of continuous
system
1. There must be continuity of demand.
2. The product must be standardized .
3. Material shd. Be per specifications and
delivered on time.
4. All operations stages in the process must
be balanced.
5. Work must conform to quality standards.
6. Appropriate plant and equipment must be
provided.
7. Maintenance must be by anticipation and
not by default.
8. Inspection must be in line with prod’n
 Types of continuous
system
• Mass prod’n
• Process prod’n
 Mass prod’n.
• Standardization is the fundamental
characteristic of this system. Here
items are produced in large qty’ies
and much emphasis is given to
consumers orders. In fact the prod’n
is to stock and not to order. Uniform
and uninterrupted flow of material is
maintained through the pre-
determined sequence of operations
reqd. to produce the product. The
 Process prod’n
• This method is used for mfg those items
whose demand is continuous and high e.g.
petroleum products, particular brand of
medicines, heavy chemical industries etc.
Here single raw material can be
transformed into different kinds of product
at different stages of the prod’n process
e.g. in processing of crude oil in refinery
one gets kerosene, gasoline etc. at
different stages of prod’n.
• In mass and processing systems planning
and scheduling for materials and finished
products is done well in advance.