Serial production

Serial production is one of the main types of organization of mass production. It is a technique used in the manufacture of products in series made in the same way. As in mass production, products during the manufacturing process are in constant motion between each production positions.

The main difference between mass production and serial production is the continuity of the work. In the case of mass production manufacturing of products is carried out on a continuous basis, there is no production breaks.

Serial production, however, is characterized by the production of a batch of products after which, production is stopped. It this time it is possible to adapt the manufacturing machines for the production of a new type of product. Also stopping of production in anticipation of another order is commonly used.

Fig. 1. Production process

Application of serial production

Serial production is used mainly by: footwear and paints producers, in the production of drugs and their ingredients, in bakeries, etc. Bakeries deliver products according only to the ordered quantity, and set up manufacturing process in advance. This allows for more efficient use of working time and equipment needed. After preparing the whole batch ovens are switches off which translates to savings of money.

In the manufacture of paints and inks, managers start the production of colours from bright (e.g. yellow) and next each successive batch of colours are slightly darker (from orange to black). Production carried out in such a way allows to decrease costs.

Examples of Serial production

• Automobiles: Automobiles are one of the most common examples of serial production. Many automobile companies, such as Ford, use serial production to manufacture thousands of cars every year. During the manufacturing process, each car goes through a series of production positions, such as welding, painting, and assembly. The parts are all the same, and the cars are all created in the same way, allowing for efficient production.
• Electronics: Many electronics, such as smartphones and tablets, are produced using serial production. During the manufacturing process, these devices go through a series of production positions, such as soldering, testing, and assembly. The parts are all the same, and the devices are all created in the same way, allowing for efficient production.
• Packaged Foods: Packaged foods, such as chips and cookies, are produced through serial production. During the manufacturing process, these foods go through a series of production positions, such as mixing, baking, and packaging. The ingredients are all the same, and the foods are all created in the same way, allowing for efficient production.

Advantages of Serial production

Serial production offers several advantages in manufacturing, including:

• Cost savings: This type of production allows for the most efficient use of materials and labor, resulting in cost savings. Additionally, as products are made in the same way, there is less time spent on changing machinery and learning new processes, making the production process more efficient.
• Standardization: Serial production allows for a high level of standardization, ensuring that all products are made to the same specifications and that they meet quality control standards. This reduces the risk of defects and ensures consistency in the end product.
• Scalability: Serial production is highly scalable, meaning that it can be easily adapted to meet changing demands in the market. This allows for quick responses to customer needs and also allows for the production of larger numbers of products in a shorter amount of time.
• Automation: Serial production typically involves the use of automated machines, which can reduce the amount of labor needed and the time required to produce the same number of products. This allows for a more efficient and cost-effective production process.

Limitations of Serial production

Serial production has its own limitations, including:

• High capital costs: Since serial production involves dedicated, specialized machinery to produce the same product, it requires a significant amount of capital to acquire and maintain the necessary equipment.
• Limited flexibility: Serial production can produce products quickly, but it is not as flexible as other production methods. If a product design changes or a new product needs to be manufactured, the machinery must be modified or replaced, increasing costs and taking more time.
• High dependence on suppliers: As the process is highly dependent on the availability of the raw materials and parts, any disruption in the supply chain can lead to significant downtime and loss of production.
• Low product variety: Serial production can produce large quantities of a single product quickly, but cannot accommodate different product designs and variations.

Other approaches related to Serial production

Other approaches related to Serial production include:

• Just-in-time manufacturing: Just-in-time (JIT) is a production system that delivers materials and components in the exact amount and at the exact moment they are needed in the production process. This helps to reduce costs, as raw materials and components do not have to be stored and reordered.
• Kaizen: Kaizen is a process of continuous improvement in the manufacturing process. It is an ongoing effort to achieve higher efficiency and quality by making small, incremental changes.
• Lean manufacturing: Lean manufacturing is a system of production that focuses on eliminating waste and maximizing efficiency. It is based on the notion that all steps in the production process should be necessary and add value to the product.
• Automation: Automation is a process of employing automated machines and processes in the manufacturing process. This can help reduce costs, increase productivity, and improve product quality.

In summary, Serial production is a type of mass production that relies on a continuous flow of products between each production position. Other approaches related to Serial production include Just-in-time manufacturing, Kaizen, Lean manufacturing, and Automation. These approaches help to reduce costs, maximize efficiency, and improve product quality.

Serial production — recommended articles

Mass production — Group technology — Unitary production — Production line — Just in time — Production rhythm — Continuous process — Pull system — Single minute exchange of die

References

• Boyaci, T., & Gallego, G. (2001). Serial production/distribution systems under service constraints. Manufacturing & Service Operations Management, 3(1), 43-50.
• Bracht van, E. (1995, October). Performance analysis of a serial production line with machine breakdowns. In Emerging Technologies and Factory Automation, 1995. ETFA'95, Proceedings., 1995 INRIA/IEEE Symposium on (Vol. 3, p. 417-424). IEEE.
• Gong, L., de Kok, T., & Ding, J. (1994). Optimal leadtimes planning in a serial production system. Management Science, 40(5), 629-632.
• Yano, C. A. (1987). Setting planned leadtimes in serial production systems with tardiness costs. Management science, 33(1), 95-106.
• Mass Production @ Wikipedia.