Page 100 - DMGT501_OPERATIONS_MANAGEMENT

Operations Management

Notes 3. Batch Production (Disconnected Line): Production is in discrete parts that are repeated at
regular intervals. Essentially, it is somewhat like a standardized job shop. Such a structure
is generally employed for relatively stable line of products, each of which is produced in
medium volume, either to customer order or for inventory. The process has the ability to
switch over from one product to another with relative ease. Though mostly general-
purpose machine are used, they are supported with specially designed jigs and fixtures.
The skill level of labour is high but not critical.

Example: Equipment like X-ray machines, earth moving and material handling
equipment, electronic devices, etc. Wipro GE manufactures medical equipment and ECIL
manufactures mainframe computers using batch production.

This is also applicable to many small-scale enterprises or many chemical processes, etc.,
e.g., Oracle or People Soft produce CDs with standard software in batch productions
depending on the demand.
4. Assembly Line: An assembly line is a mass production process. On assembly line, production
follows in a predetermined sequence of steps, which are continuous rather than discrete.
The product moves from workstation to workstation at a controlled rate, following the
sequence needed to build the product. The product variety is low and special purpose
tools and equipment is normally employed. When other processes are employed in a line
fashion along with assembly, it is commonly referred to as a production line.

Example: Automobiles, appliances like washing machines, televisions, etc. Maruti makes
cars on an assembly production line; ECIL makes electronic components and McDonald's its
burgers using the same concept.

5. Continuous Flow: Continuous production is common in the food processing industry,
and in industries involving undifferentiated materials such as petroleum and chemicals.
Most bulk products are manufactured using continuous flow production. Generally, online
control and continuous system monitoring is needed. Such processes are usually highly
automated and, in effect, constitute one integrated machine. Shutdowns and start-ups are
very expensive in this production mode, and need to be avoided.

Example: The Reliance Petrochemical complex at Patalganga and the Thermal Power
Plants operated by NTPC.
6. Cell Manufacturing (Group Technology): A cell is a self-sufficient unit, in which all
operations required to make components or complete products can be carried out. It is
like a mini-factory within the factory, which is managed by a cell team. TI Cycles
reorganized its manufacturing into cells to serve other operations. Thus cell manufacturing
creates a client-server relationship between the different components of the production
system. Cell layouts can be U-shaped or a segment of a line (a product or sub-assembly
stage) allowing a self-organizing, multi-skilled group of fewer people to manage the
operation. Shorter processing times, better team attention to quality problems, reduction
of work in progress, lower handling costs and simpler scheduling can be achieved. Built in
spare plant capacity (redundancy) or providing additional machines to a cell can
accommodate small changes or fluctuations in demand and bring benefits.
7. Flexible Manufacturing Systems (FMS): A flexible manufacturing system generally consists
of a number of CNC machine tools and a materials handling system that is controlled by
one or more dedicated computers. A typical flexible manufacturing system can completely
process the members of one or more part families on a continuing basis without human

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