3. Continuous Process
Its name derives from how materials move
through the process. Usually one primary
material, such as a liquid, gas, wood fibers, or
powder, moves without stopping through the
facility.
Example: Oil refinery
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4-3
4. Product-Flow Characteristics
Continuous Process
Process industries (beer, paper, oil, etc.)
Highly standardized and automated
High volumes of production
Flexibility limited
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4-4
5. Assembly Line Flow
Materials move linearly from one operation to
the next according to a fixed sequence, with
little inventory held between operations.
Each operation performs the same process
over and over with little variability in the
products or services provided. Production
orders aren't directly linked to customer
orders, as is the case with project and job
processes.
Example: Automobile production line 4-5
4-5
6. Assembly Line Flow
Manufacturers with line flow processes often
follow a make-to-stock strategy, with standard
products held in inventory so that they are
ready when a customer places an order. This
use of a line flow process is sometimes called
mass production.
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4-6
7. Product-Flow Characteristics
Assembly Line Flow
Linear sequence of operations
Discrete products (autos, appliances, etc.)
High-volume, standardized products
Inflexibility in product and volume
Very efficient
Large capital investment
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4-7
8. Assembly Line Flow
(metal bracket, see fig. 4.1)
cut drill bend paint
Task or work station
Product flow
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4-8
9. Batch Process
A batch process is similar to a job shop,
except that the sequence of activities tends to
be in a line and is less flexible.
Products are produced in batches, for example,
to fill specific customer orders.
Example: Bakery
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4-9
10. Batch Process
A batch of one product or customer group is
processed, and then production is switched to
the next one.
Eventually, the first product or service is
produced again.
A batch process is similar to a job shop,
except that the sequence of activities tends to
be in a line and is less flexible. The activities,
while in-line, are disconnected from one
another. 4-10
4-10
11. Product-Flow Characteristics
Batch Flow
Production of batches or lots
Batches flow from one work center to another
Low volume products
Many different types of products
Flow is jumbled and intermittent
Flexible labor and equipment
4-11
4-11
12. Batch Flow
(three metal brackets, see fig. 4.2)
Bend
Batch A
Cut Paint Batch B
Batch C
Drill
Task or work station Product flows
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4-12
13. Job Shop
A job shop is a flexible operation that has
several activities through which work can
pass. In a job shop, it is not necessary for all
activities to be performed on all products, and
their sequence may be different for different
products.
Example: Printing and Machine shop
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4-13
14. Job Shop, continued
To illustrate the concept of a job shop,
consider the case of a machine shop. In a
machine shop, a variety of equipment such as
drill presses, lathes, and milling machines is
arranged in stations. Work is passed only to
those machines required by it, and in the
sequence required by it. This is a very flexible
arrangement that can be used for wide variety
of products.
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4-14
15. Job Shop, continued
Companies choosing a job process often bid
for work. Typically, they make products to
order and don't produce them ahead of time.
The specific needs of the next customer are
unknown, and the timing of repeat orders from
the same customer is unpredictable. Each new
order is handled as a single unit--as a job.
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4-15
16. Project
In a project, the inputs are brought to the
project location as they are needed; there is no
flow in the process.
The firm brings together the resources as
needed, coordinating them using project
management techniques.
Since there is no flow of product - the quantity
produced usually is equal to one.
Example: building construction
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4-16
17. Factors Affecting Process Choice
Market conditions and competition
Capital requirements
Labor supply and cost
State of technology
4-17
4-17
18. PRODUCT-PROCESS MATRIX (Figure
4.5)
Low volume,
Unique, one of Low volume, Higher volume High volume, high
Multiple
a kind low few major standardization,
products
product standardization products commodity
Project
Building NONE
Job Shop
Printing
Heavy
Batch
Equipment
Auto
Assembly assembly
line
Sugar
Continuous NONE Refinery
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4-18
