Production process

Production process
See also
Total quality control Quality loss function Pull system Business process mapping Controlling Uniformity of production Planning and control Dependent demand ABC method

Production process is a complex of phenomena and activities that involve materials and goods gradually undergoing changes. They cause successive development of features of products, directed by its intended use. The end of the production process occurs when all the necessary features of given product have been achieved.

Types of production processes

There are different types of production processes:

• Job-Order Production: This production process is used for making custom products. It involves producing a single unit or a small batch of items according to a specific customer order. It is suitable for making unique items that cannot be mass-produced.
• Batch Production: This production process is used for making products in small batches. It involves producing a specific number of items in a single operation. It is suitable for producing items with similar characteristics and components.
• Mass Production: This production process is used for making a large number of identical products in a short period of time. It involves producing items in continuous batches. It is suitable for making items with standard components and characteristics.
• Continuous Production: This production process is used for producing a continuous stream of items. It involves producing an uninterrupted flow of items with minimal intervention. It is suitable for items that require a long production cycle.

Example of production process

One example of a production processes is the manufacturing of automobiles. This megaprocess typically involves several processes, including:

Design and development: The automaker designs and develops the car, including the exterior and interior design, as well as the powertrain and other components.
Tooling and prototyping: The automaker creates the tools and machinery needed to manufacture the car, and builds prototypes for testing.
Parts sourcing and assembly: The automaker sources all the necessary parts for the car, such as the engine, transmission, and body panels. These parts are then assembled into the finished car at the assembly plant.
Quality control and testing: The finished cars undergo a variety of tests to ensure they meet safety and performance standards before they are released to dealerships.
Shipping and distribution: The cars are shipped to dealerships, where they are available for purchase by customers.

Classification of production processes

The classification of the production processes depend on the nature of the activities. There are:

• technological processes,
• transport processes,
• storage processes.

Technological process

Technological processes in production involve the use of machines, computers, and other equipment to create products. This includes the use of robotics and automation to speed up production and increase efficiency. There are many different types of technological processes used in production, such as CNC machining, 3D printing, and additive manufacturing. Other processes include injection molding, die-casting, and fabricating. These processes are used to create products from raw materials, such as metals, plastics, and composites. The use of technology in production helps companies to produce higher quality products in less time and with less cost.

Internal transport processes

Internal transport processes in production involve the movement of materials within a factory or warehouse. This includes the movement of raw materials, intermediate products, and finished products between different production stages. Companies use a variety of different methods for internal transport, such as forklifts, conveyor belts, and automated guided vehicles (AGVs). Internal transport processes are essential for ensuring that materials are moved efficiently and accurately between different production stages. They also help to reduce production costs by minimizing the need for manual labor.

The example of production process

Storage processes

Storage processes in production involve the safe and secure storage of materials, intermediate products, and finished products. This includes storing products in warehouses, factories, and other storage facilities. Companies use a variety of different storage processes, such as racking systems, palletizing, and automated storage systems. Storage processes are essential for ensuring that materials and products are safely stored and can be easily retrieved when needed. They also help to reduce production costs by minimizing the need for manual labor.

Functions of production processes

Another type of production processes classification is division depending on the way in which they are associated with the product development. There are:

• Core production processes: are the activities that are directly related to the creation of the product. These activities include material acquisition, material processing, assembly, and testing. Material acquisition involves obtaining the necessary materials and components needed to create the product. Material processing includes activities such as cutting, drilling, and welding. Assembly involves putting the components together to create the finished product. Finally, testing ensures that the product meets the required specifications and quality standards.
• Support production processes: are activities that are not directly related to the product, but are necessary for the production process. These include activities such as procurement, inventory management, and quality control. Procurement involves obtaining the necessary materials and components needed to create the product. Inventory management involves keeping track of the materials, components, and products that are in stock. Quality control involves ensuring that the products meet the required specifications and quality standards.
• Management production processes: are activities that are related to the management of the production process. These activities include planning, scheduling, and controlling. Planning involves determining the most efficient way to produce the product. Scheduling involves organizing the production process in an efficient manner. Controlling involves monitoring the production process and making adjustments as necessary. Management production processes are essential for ensuring that the production process runs smoothly and efficiently.

Concepts that help achieve organization of processes

• Lean Manufacturing: Lean manufacturing is a method of organizing production processes that focuses on eliminating waste and increasing efficiency. It involves streamlining processes and eliminating activities that do not add value to the production process.
• Just In Time (JIT) Manufacturing: JIT manufacturing is a method of organizing production processes that focuses on reducing inventory and increasing efficiency. It involves scheduling production activities just in time for when they are needed and reducing inventory levels.
• Kaizen: Kaizen is a method of organizing production processes that focuses on continuous improvement. It involves making small, incremental changes to the production process and continually monitoring and improving the process.
• Total Quality Management (TQM): TQM is a method of organizing production processes that focuses on quality control. It involves implementing quality control processes and procedures to ensure that products meet the required specifications and quality standards.
• Six Sigma: Six Sigma is a method of organizing production processes that focuses on reducing defects and increasing efficiency. It involves implementing processes and procedures to reduce defects and improve efficiency.
• Reengineering: Reengineering is a method of organizing production processes that focuses on streamlining processes and eliminating activities that do not add value. It involves rethinking and redesigning existing processes to eliminate waste and improve efficiency.
• Industry 4.0: Industry 4.0 is a method of organizing production processes that incorporates the use of advanced technologies such as robotics, artificial intelligence, and the Internet of Things. It involves using these technologies to automate and improve production processes.

Stock compensation for optimal production flow

Compensating stocks are created for processes with small share in the value of production to prevent any production disturbances. Managers strive to minimize the cost of production in the course of the process but in the same time, maintaining undisturbed production cycle. For about 10% of total production, managers go in the other direction to compensate for the disturbances, namely, they apply greater detail of planning and regulation.

The accuracy of the control can be directed on all items, selected number of them, or on some workstations. Selection of items that require an accurate control is made using Pareto curve analysis. The flow of the selected items should be controlled by all positions in the production process. The remaining groups of items can be controlled only on few key positions.

The next factor in the accuracy of the control is the level of stability. At this stage managers need to confine themselves to qualitative assessment, because the stability of production is difficult to determine in a more measurable way.

Frequency of control is another way of reducing possibility and impact of disturbances in production processes. This analysis can be carried out from the point of view of efficiency of management of the production process.

See also:

• Serial production
• Mass production
• Operational controlling

References

• Bardhan, I., Whitaker, J., & Mithas, S. (2006). Information technology, production process outsourcing, and manufacturing plant performance. Journal of Management Information Systems, 23(2), 13-40.
• Lee, H. L., & Rosenblatt, M. J. (1987). Simultaneous determination of production cycle and inspection schedules in a production system. Management science, 33(9), 1125-1136.
• Levy, F. K. (1965). Adaptation in the production process. Management Science, 11(6), B-136.
• Morroni, M. (2009). Production process and technical change. Cambridge university press.
• Schonberger, R. J. (2007). Japanese production management: an evolution—with mixed success. Journal of Operations Management, 25(2), 403-419.