Continuous Flow Process Example

Read this page to learn the difference between a continuous flow process and batch
manufacturing. Scroll down for a diagram of both types of processes provided by
Lucidchart.

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Understanding a continuous flow process

A continuous flow process is a method of manufacturing that aims to move a single unit
in each step of a process, rather than treating units as batches for each step. The
diagram below helps illustrate how this works. In the left column, you can see a
standard batch process. Each step is completed for several units at once, which
comprises a batch. In the right column we see a single unit go through the flow, and the
process is repeated as many times as necessary. This may seem to take longer, but it
can actually be much more time efficient, as long as the next unit is introduced to the
process as soon as the first unit has completed step one.

The process is called continuous flow because you are continuously producing new
products. Its advantageous in many industries, such as vehicle manufacturing, where
you need to keep up with high demand from consumers. Batch production is useful in
other scenarios as well, such as completing one-time work for a client.

Continuous flow process

More lean manufacturing diagrams

Continuous flow is one aspect of lean manufacturing, which is a method used to

improve production efficiency
Production process

The production process is concerned with transforming a range of inputs into those
outputs that are required by the market.

This involves two main sets of resources - the transforming resources, and the
transformed resources.

The transforming resources include the buildings, machinery, computers, and people
that carry out the transforming processes. The transformed resources are the raw
materials and components that are transformed into end products.

Any production process involves a series of links in a production chain. At each stage
value is added in the course of production. Adding value involves making a product
more desirable to a consumer so that they will pay more for it. Adding value therefore is
not just about manufacturing, but includes the marketing process including advertising,
promotion and distribution that make the final product more desirable.

It is very important for businesses to identify the processes that add value, so that they
can enhance these processes to the ongoing benefit of the business.

There are three main types of process:job, batch and flow production.

Job production

Job or 'make complete' production is the creation of single items by either one operative
or a team of operative's e.g. the Humber Bridge or a frigate for the navy.

It is possible for a number of identical units to be produced in parallel under job

production, e.g. several frigates of a similar type. Smaller projects can also be seen as a
form of job production, e.g. hand knitting a sweater, writing a book, rewiring a house,
etc.

Job production is unique in the fact that the project is considered to be a single
operation, which requires the complete attention of the operative before he or she
passes on to the next job. A good example of job production is the work carried out by
Portakabin in creating modular buildings such as offices, which it designs, assembles
and maintains for clients. Examples from the service industries include cutting hair, and
processing a customers' order in a store like Argos.

The benefits of job production are:

1. The job is a unique product, which exactly matches the requirements of the customer,
often from as early as the design stage. It will therefore tend to be specific to a
customer's order and not in anticipation of a sale. For example, someone doing a
customised spray paint job on a motorcycle will first discuss with a customer the sort of
design he would like. A detailed sketch would then be produced on a piece of paper.
Once the sketch has been approved the back of the sketch will be chalked over and
traced on to the relevant piece of the motorbike. The background work is then sprayed
on with an airbrush before the fine detail is painted on. The finished work is then
inspected by the customer who will pay for a unique product.

2. As the work is concentrated on a specific unit, supervision and inspection of work are
relatively simple.

3. Specifications for the job can change during the course of production depending upon
the customer's inspection to meet his or her changing needs. For example, when a
printing firm like Polestar is asked to produce a catalogue for a grocery chain it is
relatively simple to change the prices of some of the goods listed in the catalogue.

4. Working on a single unit job, coping with a variety of tasks and being part of a small
team working towards the same aim would provide employees with a greater level of
satisfaction. For example, aircrews working for United Airways would treat each flight as
a specific job, with passengers requiring individual attention to their specific needs - e.g.
for vegetarian dishes, wheelchair access to the flight, etc.

Batch production

The term batch refers to a specific group of components, which go through a production
process together. As one batch finishes, the next one starts.

For example on Monday, Machine A produces a type 1 engine part, on Tuesday it

produces a type 2 engine part, on Wednesday a type 3 and so on. All engine parts will
then go forward to the final assembly of different categories of engine parts.

Batches are continually processed through each machine before moving on to the next
operation. This method is sometimes referred to as 'intermittent' production as different
job types are held as work-in-progress between the various stages of production.

The benefits of batch production are:

1. It is particularly suitable for a wide range of almost similar goods, which can use
the same machinery on different settings. For example batches of letters can be
sent out to customers of an insurance company.
2. It economises upon the range of machinery needed and reduces the need for a
flexible workforce.
3. Units can respond quickly to customer orders by moving buffer stocks of work-in-
progress or partly completed products through the final production stages.
4. It makes possible economies of scale in techniques of production, bulk
purchasing and areas of organisation.
 5. It makes costing easy and provides a better information service for management.

Flow production

Batch production is described as 'intermittent' production and is characterised by

irregularity. If the rest period in batch production disappeared it would then become flow
production. Flow production is therefore a continuous process of parts and sub-
assemblies passing on from one stage to another until completion.

Units are worked upon in each operation and then passed straight on to the next work
stage without waiting for the batch to be completed. To make sure that the production
line can work smoothly each operation must be of standard lengths and there should be
no movements or leakages from the line, i.e. hold-ups to work-in-progress.

For flow production to be successful there needs to be a continuity of demand. If

demand varied, this could lead to a constant overstocking of finished goods.

Although with modern robotics it is possible to create variations in products being

produced through continuous flow techniques, typically such products will be relatively
standardised.

Achieving a smooth flow of production requires considerable pre-production planning to

make sure that raw materials are purchased and delivered just-in-time, that sufficient
labour is employed and that there is continuous attention to quality throughout the
production process.

The benefits of flow production are:

ease of using just-in-time techniques to eliminate waste and minimise costs

labour and other production costs will be reduced through detailed planning and
the use of robotics and automation
deviations in the line can be quickly spotted through ongoing quality control
techniques
as there is no rest between operations, work-in-progress levels can be kept low
the need for storage space is minimal
the physical handling of items is minimal
investment in raw materials and parts are quickly converted into sales
control is easy.