4.3

Production Systems

Craft production

A small-scale production process centred on manual skills.

Production Systems

Mechanized production

A volume production process involving machines controlled by  humans.

Production Systems

Automated Production

A volume production process involving machines controlled by production computers

Production Systems

One-off production

*Is an individual product or a prototype for larger-scale production.*

One-off production adv/dv

Advantages

• Highly customisable to consumers needs.

• Flexibility for the designer and consumer.

• Allow for testing of prototypes before continuous flow production.

Disadvantages

• Can be expensive as any tools or machinery needed are included in the final cost.

• Time consuming if craft manufacturing techniques are used

• May be that the product is not designed for disassembly (DfD) there are no interchangeable parts.

Production Systems

Batch Production

* Batch production is a manufacturing method used to produce or process any product in batches, as opposed to a continuous production process, or an one-off production.

Batch Production Adv/Dv

Advantages

• Cheaper than one-off production (economies of scale).

• Customisable products but not as highly as one-off production.

• Easily adjust to market demands or seasonal  items

• Greater consumer choice (e.g. Swatch watches).

• For smaller or upstart companies that can’t afford continuous flow production.

• It can reduce initial capital outlay because a single production line can be used to produce several products.

Disadvantages

• Down time between productions runs when retooling.

• Products have to be stored raising the costs per item.

Production Systems

Mass Production

* *The production of large amounts of standardized products on production lines, permitting very high rates of production per worker.*

Production Systems

Continuous Flow Production

* *Continuous flow is a production method used to manufacture, produce or process materials without interruption.*

Continuous Flow Production adv/dv

Advantages

• Cheaper than other production methods (economies of scale).

• If a part or product needs replacing consumer is assured that it still exists (e.g. bic pens).

• Lack of inventory which reduces storage costs.

Disadvantages

• Standard products so less choice for the consumer.

• Automated production is high in initial costs

• Training of staff to run machines and CIM

Mass customization

*  *A  CIM system that manufactures products to individual customer needs or wants.*

Mass Cutomization adv/dv

Advantages

• Economies of scale are achieved even for small orders

• Highly customisable to consumer needs or likes

Disadvantages

• Long layover time from with product is customised to reaching the consumer.

• Very high initial capital costs

• Special training for employees

**Selecting an appropriate scale of production**

Product characteristics

 Complexity, features, design, product family, etc

**Selecting an appropriate scale of production**

Staff skills

High tech skills for automation.

**Selecting an appropriate scale of production**

Financial Considerations

Is it cost effective to produce, profits, etc

**Selecting an appropriate scale of production**

Material characteristics

Plastics are suited to continuos flow production more than say certain metals or other materials.

**Selecting an appropriate scale of production**

Size of market

Mont Blanc pens are geared to a market segment which is small whereas Bic pens target are wider market for cheap disposable pens.

**Selecting an appropriate scale of production**

Nature of market

Such as the variety of products expected by the consumer such as Swatch watches.

**Selecting an appropriate scale of production**

Desired manufacturing processes 

Injection moulding is suited to  continuos flow production because it an be fully automated and use cheap thermoplastics

**Selecting an appropriate scale of production**

Desired production scale 

 Such as one-off, batch or continuos.