Determining the length of the production cycle

Determining the length of the production cycle (i.e. period from the start of the production process to its completion) involves identification of particular product material and process requirements. Production cycle depends on such factors as: specification of the product, technological sophistication, organization of the production process, qualifications of the employees and available resources.

Calculation of the length of the production cycle is important in the planning of the production, supply and waste disposal processes. For this purpose managers can use methods that have varied character (i.e. analytical, graphics and mixed). Duration of the operations of the production process and time gaps in the basic production process can be determined using statistical analysis, experimental design, estimation methods. The most common methods are: estimation and statistical-empirical method. These methods are not very accurate, and sometimes cannot be applied, in particular in case of new products or new equipment. In such case managers could apply analytical or heuristic methods.

Knowledge of the length of the production cycle is a very important economic aspect in the production management. Production requires material resources, employees and equipment from the beginning to the end of its duration. By this, significant financial costs are incurred while financial results (income) appear after some time. For this reason, each enterprise is committed to reduction of the length of the production cycle, which also reduces costs of production and gives more opportunity to sell products faster.

Examples of the length of the production cycle

• For a high-volume production of simple parts such as screws and nuts, the production cycle can be as short as a few minutes. It includes the processes of stamping, plating and packaging, which can be automated and completed in a matter of minutes.
• For complex products such as cars and aircraft, the production cycle is much longer, as it involves a wide range of processes such as design, manufacturing, assembly, testing and delivery. This process could take months or even years to complete.
• For sophisticated products such as medical devices and electronics, the production cycle can be even longer. It includes processes such as research and development, prototyping, production, quality assurance and regulatory approvals. This process could take several years to complete.

Advantages of determining the length of the production cycle

Determining the length of the production cycle can be beneficial in many ways. These advantages include:

• Improved efficiency - Knowing the length of the production cycle can help to identify any inefficiencies in the process and develop strategies to reduce them. This can lead to a more streamlined production process, resulting in cost savings.
• More accurate forecasts - Having an accurate timeline for the production cycle can enable better forecasting of market demand and help to ensure that there is enough capacity to meet demand.
• Improved quality control - Knowing the length of the production cycle allows for better planning of quality control processes. This can help to reduce defects and ensure the product meets quality standards.
• Reduced lead times - Understanding the production cycle can help to reduce lead times and increase customer satisfaction. This can also reduce cost and time to market, which can be advantageous for businesses.

Limitations of determining the length of the production cycle

The length of the production cycle can be determined by various factors, such as the specification of the product, technological sophistication, organization of the production process, qualifications of the employees and available resources. However, there are certain limitations to accurately determine the length of this cycle:

• The complexity and scope of the product can significantly affect the production cycle, and it may be difficult to accurately predict how long it will take to produce.
• The availability of resources, including materials, machinery, and labor, can also limit the length of the production cycle. If resources are scarce, the production cycle may be longer than expected.
• Unforeseen events, such as an unexpected problem with machinery or an unexpected delay in the delivery of materials, can also limit the length of the production cycle.
• The complexity of the production process can also limit the length of the production cycle. If the process is complicated, it may take longer to complete.
• The qualifications of the employees involved in the production cycle can also limit its length. If the employees are not qualified or experienced enough, the production cycle may take longer.

Other approaches related to the length of the production cycle

One possible approach to determining the length of the production cycle is to consider the following elements:

• Specifications of the product - the complexity of the product and its components, as well as the number of stages in production, will determine the amount of time it takes to complete the cycle.
• Technological sophistication - the more advanced the technology employed in production, the more efficient the process and the shorter the production cycle.
• Organization of the production process - a cohesive, well-structured plan will reduce the time taken to complete the production cycle.
• Qualifications of the employees - experienced, highly-skilled employees can operate machinery more efficiently and effectively, leading to a shorter production cycle.
• Available resources - the availability of certain materials or machines can significantly reduce the length of the production cycle.

In conclusion, the length of a production cycle is determined by the product specifications, technological sophistication, organization of the production process, qualifications of the employees and available resources.

Determining the length of the production cycle — recommended articles

Designed quality — Line balancing — Production reserve — Optimization of the production run-length — Continuous process — Master production schedule — Cycle time — Non recurring cost — Tooling costs

References

• Herrmann, J. W., & Chincholkar, M. M. (2000, September). Design for production: a tool for reducing manufacturing cycle time. In Proc. of the 2000 ASME Design Engineering Technical Conference (p. 10-13).
• Rahim, M. A., & Lashkari, R. S. (1985). Optimal decision rules for determining the length of the production run. Computers & industrial engineering, 9(2), 195-202.
• Rahim, M. A., & Raouf, A. (1988). Optimal production run for a process having multilevel tool wear. International journal of systems science, 19(1), 139-149.