Production rhythm
Production rhythm involves balanced, consistent with the schedule, manufacture and transfer of products and equally repetitive, and coordinated work stations in the company. This means that at any time during the period of repetition, particular workplace or specific production cell produces the same output.
Rhythmic production is one in which there are strict binding machine centres, the allocation of specific operations to the relevant working positions, the length of the production of the same product (details) is standardized.
Rhythmic production requires both precision and a clear division of tasks and resources to the various units as well as the quick and systematic correction of possible deviations. Work performed rhythmically is characterized by the same intensity and coordination of tasks.
Rhythmic production include pipelined production, constants, variable or complex production lines. During rhythmic production cells and units carry out production processes of serial and mass production type. It runs in accordance with specified cycle repeating itself. Master schedule for the production is constantly updated. A period of repetition is the most important parameter of organizational production and rhythm of production.
Other features of rhythmic production are:
- immutability of adopted technology, production volumes and assortment of manufactured products
- breakdown of long-term manufacturing jobs into smaller units in shorter intervals
- allocation of production tasks to the corresponding machine centres:
- standard production schedule
Examples of Production rhythm
- Lean Manufacturing: Lean manufacturing is a production rhythm used to create more value for customers by reducing waste and improving efficiency. It relies on creating synchronized production cells that are designed to produce a specific set of products. Each production cell is equipped with the necessary tools and equipment to complete the assigned production task. The production cells are designed to reduce the cycle time needed to produce a product, while maximizing the value that is produced by each cell.
- Just-in-time Manufacturing: Just-in-time manufacturing is another production rhythm that relies on having the right items in the right place at the right time. This production rhythm involves having a continuous flow of parts and materials so that when it is time to produce a product, all the necessary components are already in place. This production rhythm helps to reduce waste and improve efficiency, as well as reduce inventory costs.
- Kanban Manufacturing: Kanban manufacturing is a production rhythm that uses visual cues to signal when a product is needed. This production rhythm relies on a series of cards, or kanbans, that are placed at strategic locations throughout the production process. When a product is needed, the kanban is moved from one location to the next, signaling to the production team that it is time to produce the product. This production rhythm helps to improve efficiency and reduce waste by ensuring that the right products are produced at the right time.
Advantages of Production rhythm
Production rhythm has a number of advantages for a business, such as:
- Increased productivity: Production rhythm ensures that the production process is consistent and efficient, which leads to increased productivity. This is because the same tasks are repeated in the same order, reducing the amount of time spent on each task and increasing the speed of production.
- Reduced waste: As production is done in an orderly and consistent fashion, there is less waste of materials. This means that the output is higher and the cost of production is lower.
- Improved quality: As the same tasks are done in the same order, the quality of the product is improved. This is because the same procedures are followed and mistakes are less likely to be made.
- Improved morale: When production is done on a regular basis and to a high standard, it improves the morale of the workforce. This helps to create a more productive and positive environment.
Limitations of Production rhythm
Production rhythm has its own limitations:
- It is not suitable for businesses that require variety and flexibility in production. Companies that manufacture different products or services, or produce at different times of the year need to be able to adjust their production processes to accommodate the changing demand.
- If production is interrupted or changes, the rhythm can be disrupted and it can take some time to restore the balance.
- Production rhythm can be costly as it requires a large amount of equipment and personnel to maintain consistency and high output.
- Production rhythm can limit creativity and innovation as it relies on a specific set of processes and operations to be repeated.
- It can be difficult to manage production rhythm when there are multiple production lines that need to be coordinated. This is especially true when production is happening in different locations.
Production rhythm is often associated with other approaches, all with the aim of increasing production efficiency and improving product quality. Those approaches are:
- Just-in-Time (JIT): a system that works to reduce the amount of inventory stored in the facility by arranging for the materials to arrive at the production line at the exact time they are needed, thus eliminating the need to store them in the facility.
- Lean Manufacturing: a system of production focused on eliminating waste and inefficiency, increasing production speed, and improving product quality.
- Kanban: a system of parts replenishment and production control, where visual cards and signals are used to direct the production process.
- Continuous Flow Manufacturing: a system of production where the production process is broken down into steps and each step is completed in a continuous, uninterrupted flow.
Overall, these approaches are all aimed at improving production efficiency and product quality, while reducing inventory and waste.
| Production rhythm — recommended articles |
| Production line — Forms of production — Serial production — Group technology — Mass production — Unitary production — Continuous process — Job shop — Work cycle |
References
- Guide, V. D. R. (2000). Production planning and control for remanufacturing: industry practice and research needs. Journal of Operations Management, 18(4), 467-483.
