DTE - scales of production

What is batch production?

A specific quantity (a batch) of identical products is made. After one batch is finished, the equipment can be changed to make a different batch.

Why is batch production used?

-Allows some variety in products.

-Good for medium demand items.

-Machines can be reused for different products.

-Cheaper than one-off production, but more flexible than mass production.

-Templates or moulds can ensure consistency of production

Examples of batch production?

-A bakery making a batch of 200 muffins, then cleaning equipment to make a batch of bread rolls.

-A clothing company making T-shirts in different colours.

Advantages of batch production?

-More efficient than one-off production

-Variety - can change batches to meet different customer demands

-Less waste as materials can be ordered for batches

Disadvantages of batch production?

Downtime when switching between batches

Storage needed for completed batches

If one batch has a fault, it can affect many products

Why is one-off production used?

-When customers want something personalised or custom-made.

-High quality and craftsmanship are needed.

-Expensive because it takes a lot of time and skill

Examples of one-off production?

-A wedding dress made to fit one person.

-A custom-built house designed by an architect.

-A prototype of a new product.

Advantages of one-off production?

-Product is customised to suit the customer exactly

-High quality and craftsmanship

-Workers often have high skill levels and job satisfaction

Disadvantages of one-off production?

-Expensive - high labour costs and specialised materials

-Takes a long time to produce

-Difficult to repeat, as each product is different

What is mass production?

Large quantities of identical products are made using an assembly line and automation.

Why is mass production used?

-High demand for standardised products.

-Low cost per item because of economies of scale.

-Requires expensive machinery, but very efficient once set up.

Examples of mass production?

-Coca-Cola bottles made on an automated line.

-Cars are made in factories such as Ford or Toyota.

-Smartphones like the iPhone.

Advantages of mass production?

-Low unit cost (cheap per product) due to economies of scale

-Automated assembly line requires fewer workers

-Fast and efficient

-Consistent quality because of standardised processes

Disadvantages of mass production?

-High setup costs (machines and equipment are expensive)

-Little flexibility - can't easily change design

-Workers may get bored with repetitive tasks

What is one-off production?

A single, unique product is made to meet a specific customer's requirements.

What is continuous production?

The production process runs 24 hours a day, 7 days a week, making a product that is constantly in demand.

Why is continuous production used?

-For products needed in very large quantities.

-Stops and starts are costly, so production runs non-stop.

-Highly automated with little human input.

Examples of continuous production?

-Oil refining in a petroleum plant.

-Electricity generation in power stations.

-Steel production in large factories.

Advantages of continuous production?

-Very efficient - no time wasted starting and stopping

-Low labour costs (mostly automated)

-Consistent product quality

Disadvantages of continuous production?

-Extremely expensive to set up and maintain

-Difficult to stop the process - repairs can be disruptive

-Little flexibility to change the product

What is a prototype?

a test model of a product. it helps to evaluate and test a design, and confirm design methods and cost

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