Chapter 23 - Scales of Production

What is the definition of 'one-off production'?

The manufacture of a single, unique product, often custom-made to a client's specific requirements.

What is the definition of 'batch production'?

The manufacture of a set number of identical products made at the same time, before re-setting equipment for a different run.

What is the definition of 'mass production'?

The manufacture of large numbers of identical products made on a production or assembly line.

What is the definition of 'continuous production'?

A non-stop, high-volume production method, often running 24/7 and fully automated.

What is the principle of 'economies of scale'?

As production volume increases, the fixed costs are spread over more units, causing the cost per unit to decrease.

What does the 'scale of production' in manufacturing refer to?

The number of products made, which is determined by factors like demand, cost, and available resources.

What are the two types of small to medium-scale production?

One-off production and batch production.

What are the two types of large-scale production?

Mass production and continuous production.

What is another term for a product that is custom-made to a client's specific requirements in one-off production?

Bespoke.

What is a typical example of a one-off product in jewellery?

Handcrafted or custom jewellery.

What is an example of a one-off product used for design testing and evaluation?

A prototype.

What is an example of a one-off product in the clothing industry?

Tailored clothing or a bespoke wedding dress.

Why are products made via one-off production typically expensive?

The high labour and material costs are spread over only one product.

What is the typical skill level of workers involved in one-off production?

Very high, often craftspeople or specialists.

How is the production speed of one-off production generally characterised?

Very slow, as each part is individually designed and made.

How is the production flexibility of one-off production characterised?

Very high, allowing for complete customisation.

What is a key benefit of one-off production related to the client?

It allows for high levels of personalisation and unique designs.

What is a major limitation of one-off production regarding cost?

It has a very high cost per unit.

One-off production is highly dependent on what type of resource?

Highly skilled labour.

Quantities in batch production typically range from tens to _________ _________ of units.

Several thousand.

What is an example of batch production in the food industry?

Baked goods, like a batch of 50 loaves of bread.

What is an example of batch production in the fashion industry?

Seasonal fashion items or clothing ranges in different sizes.

What is an example of batch production in the furniture industry?

Flat-pack furniture or a set of dining chairs.

Why is batch production more efficient than one-off production?

Processes are repeated for several items, and jigs or templates can be used to ensure consistency.

What feature of batch production allows for seasonal variations and limited editions to be made quickly?

High flexibility, as machinery can be reset for a new batch.

How does the unit cost of batch-produced products compare to one-off products?

It is lower because production costs are spread over more units.

What is the typical skill level of workers in batch production?

Semi-skilled to skilled, or moderate.

A tool used to aid repetition and hold work in place, common in batch production, is called a ___.

Jig.

What is a key benefit of batch production regarding quality?

It allows for consistent quality across the batch.

What is a limitation of batch production related to equipment setup?

Tooling costs for items like moulds and jigs are involved, and time is lost when retooling.

Large-scale production involves making products in very high volumes, often using what type of machinery?

Automated machinery.

Mass production often uses ________ _____ techniques, where each worker or machine performs a specialised task.

Assembly line.

What is an example of a product made using mass production from the automotive industry?

Cars.

What is an example of a product made using mass production from the electronics industry?

Smartphones, radios, or remote controls.

How does mass production affect the design of products?

It makes them standardised, with little variation in size and parts.

What is the typical skill level of workers on a mass production assembly line?

Low, as tasks are repetitive and specialised.

How is the production speed of mass production characterised?

Fast.

How is the production flexibility of mass production characterised?

Low, as the setup is designed for one specific product.

What is a major limitation of mass production related to its setup?

It requires a large initial investment and has a high setup cost.

A key benefit of mass production is its ability to produce consistent quality at a very low ______ ______.

Unit cost.

Continuous production is often used for very high-demand products where _________ is critical.

Efficiency.

What is an example of a product made using continuous production?

Drink cans, paper pulp, steel sheets, or petrochemicals.

How much human intervention is typically involved in continuous production?

Very little, other than to maintain machinery.

Why does continuous production have extremely low unit costs?

It achieves maximum efficiency and benefits greatly from economies of scale.

What is the typical skill level of workers in continuous production?

Very low, as the process is almost fully automated.

How is the production speed of continuous production characterised?

Very fast.

How is the production flexibility of continuous production characterised?

Very low or inflexible, as it's designed for one standardised product.

What is a major limitation of continuous production related to its machinery?

Machinery maintenance can affect the entire output, and the initial cost of machinery is very high.

What is a 'prototype'?

The first working model of a design used for testing, development, and evaluation.

The process of setting up a production line with different tools for a new task is called ________.

Retooling.

What type of manufacturing builds up a form in layers, such as 3D printing?

Additive manufacturing.

What type of manufacturing shapes a form by removing material from a larger piece?

Subtractive manufacturing.

What scale of production would be used for promotional books for a one-time sports event?

Batch production.

The production of raw paper stock is an example of what scale of production?

Continuous production.

What scale of production is typically used for children's plastic building blocks made via injection moulding?

Continuous production.

What scale of production would be used for mass-market textiles like plain T-shirts and socks?

Mass production.

What scale of production is most suitable for bespoke, made-to-measure garments like couture outfits?

One-off production.

A carpenter making a set of identical dining chairs would be an example of what scale of production?

Batch production.

For which production scale is the use of CAD/CAM particularly common for ensuring accuracy and efficiency?

Batch production.

Which scale of production requires shift work to facilitate 24/7 operation?

Continuous production (and sometimes mass production).

How are fixed costs like machinery and buildings managed to reduce unit costs in large-scale production?

They are spread over thousands or millions of units.

What term describes a series of workers and machines in a factory by which an item is progressively assembled?

Assembly line.

Why would an architectural firm use foam-core board to create a model?

It is a low-cost and easily manipulated material suitable for making one-off prototypes.

What is a limitation shared by both mass and continuous production regarding design?

They are inflexible and typically limited to standard designs with little to no variation.

What is a key difference in efficiency between batch and one-off production?

Batch production is more efficient because processes are repeated for multiple identical items.

What production scale would be appropriate for a limited edition doll?

Batch production.

What production scale would be appropriate for newspapers?

Mass production (or batch, if for a specific event).

In what production scale are templates, moulds, and formers used to ensure consistency?

Batch production.

Which production method is characterised by being 'tailor made' to specific user needs?

One-off or bespoke production.

Which scale of production has the lowest unit cost?

Continuous production.

Which scale of production has the highest unit cost?

One-off production.

Why is batch production considered highly flexible?

Machinery can be reconfigured or retooled between batches to produce different product variations.

What is a limitation of batch production related to market demand?

It can be challenging to keep up with changing trends.

In large-scale production, what is the primary benefit of using automated machinery?

It allows manufacturers to produce items efficiently, consistently, and at a lower cost per unit.