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Batch Process Presentation)

Batch production involves grouping components together that will undergo the same production process. In batch production, a definite group of components is processed together through each machine before moving to the next operation. Batch production is commonly used when customers place small, one-time orders or prefer to place small repeat orders. It allows for the accumulation of similar customer orders into a single batch for production. Batch production is characterized by short runs on equipment, skilled labor for specific processes, and potential queues between machines due to differing cycle times. While it requires careful planning, batch production can provide flexibility and efficient machine utilization.

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660 views17 pages

Batch Process Presentation)

Batch production involves grouping components together that will undergo the same production process. In batch production, a definite group of components is processed together through each machine before moving to the next operation. Batch production is commonly used when customers place small, one-time orders or prefer to place small repeat orders. It allows for the accumulation of similar customer orders into a single batch for production. Batch production is characterized by short runs on equipment, skilled labor for specific processes, and potential queues between machines due to differing cycle times. While it requires careful planning, batch production can provide flexibility and efficient machine utilization.

Uploaded by

Telse Simon
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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BATCH PROCESS

Jens Thomas

Aim and Objective


Aim : To explain about the batch production system followed in Manufacturing industry. Objective : To understand the characteristics of batch production To know about the implementation of batch production in industries To understand the advantages and disadvantages of batch production.

Introduction
Term batch refers to a definite group of components, which go through a production process together. As one batch finishes, the next one starts. Production of different type of engine parts can be taken as an example. Batches are continually processed through each machine before moving into the next operation.

Introduction Contd.
In other words, the batch flow production system produces low volumes of many different products for one of the three reasons -Customers place one time orders for small quantities. -Customers prefer to place small repeat orders from time to time.

-The organisation prefer to accumulate orders from different customers for the same or similar products into a batch and produce them together.

Layout and material flow


Functional and cellular layouts are used in the batch flow production system[3]. Flow of material in functional layout is irregular and considerable material handling is needed for moving the batches from department to department. In the case of cellular layout, the material flow is less varied.

Batch process layout[2]

Characteristics of batch process


Short Runs The equipments and assembly setup are used for a limited number of assemblies or parts and are then changes to make a different product[4]. Skilled labor in specific trades The labors are expected to possess skill in their related specific manufacturing process. Supervisor to possess knowledge of a specific process The supervisors should have considerable knowledge of each specific process.

Characteristics contd.
Limited span of control The amount of supervision required in batch production is lower. The ratio of direct workmen to supervisors changes depends on the batch size. General-purpose machines and process type of layout Plant and equipments are procured and arranged to obtain maximum flexibility. Less Manual materials handling Materials handling in batch production is minimum.

Characteristics contd.
Manufacturing cycle time affected due to queues. The batches of work tends to queue up at different machines due to batch sizes, differing cycle times etc. Large work-in-progress. WIP is large due to varying work content of different components, and formation of queues b/n machines. Flexibility of production schedules. Disruptions due to absenteeism or machine breakdowns do not seriously affect production as job can be shifted to another operator or another machine.

Case Study CJC [5]


CJC is a Denmark based manufacturing firm producing plow, seed drills, spreaders etc. Plant fabricates 6000 different parts.

Almost all the parts were required in low volume. Low volumes of different parts required resulted in frequent changeovers. Frequent changeovers contributed to frequent machine down time. To compensate this, products were manufactured in small batches.

Case Study contd.


Key findings When a machine takes long conversion time , it saves time to just run a whole bunch of pieces once the settings are completed. By using batch production fewer defects are there. Better levels of cost and quality were the prime results. Better utilisation of machines.

Advantages and disadvantages[6]


Advantages It is cheaper to produce a whole batch instead of single line production. This system is not very capital intensive. Less investment is required in machines A single production line can be used to produce several products. Machines can be used more efficiently.

Advantages and disadvantages


The number of machines required is lesser because they are utilized for multiple lines of the same product Specialized supervision is possible in such a system It provides for greater flexibility with respect to labour and equipment

Advantages and disadvantages


Disadvantages Batch production requires very careful planning to decide what batch will be produced and when. Batch production can result in the build up of significant work in progress. Work in progress requires large workspace and capital. More skilled workers are required to produce different lines of the same product

References
[1] unknown, http://www.thetimes100.co.uk/theory/theory-production-process--254.php, Retrieved on16th january2010 [2] unknown http://www.mbaknol.com/operations-

management/batch-production-and-its-keycharacteristics, Retrieved on16th january2010


[3] John Miltenburg, Manufacturing Strategy, Productivity press,1995

References
[4] unknown http://www.technologystudent.com/joints/bat1.htm, Retrieved on16th january2010 [5] unknown http://tutor2u.net/business/gcse/production_batch.htm, Retrieved on 16 th january2010 [6]Unknown,http:// http://www.tutorsonnet.com/operations_managem ent_homework_help/production_planning/planning_and_control_of_b atch_production_assignment_help_tutoring.htm, , Retrieved on16th january2010

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