Process Selection - A Review of Continuous Flow, Assembly Line, Batch Flow and Job Shop

Summary

This video explains the process selection for manufacturing products, focusing on the key factors of volume and product variation. It covers four types of process selections: continuous flow, assembly line, batch flow, and job shop. Continuous flow is ideal for high-volume, low-variation products, while assembly line is for slightly varied products. Batch flow is used for moderate volume and variation, requiring equipment changeovers, and job shop is suited for low-volume, highly customized products. The video emphasizes the importance of matching the process selection to the production volume and product variability for optimal efficiency.

Takeaways

• 😀 Process selection depends on two main factors: volume (how much is produced) and variety (how differentiated the products are).
• 😀 Continuous flow is suitable for high-volume, low-variation production of the same product repeatedly.
• 😀 An example of continuous flow includes manufacturing identical cars with no variations in design or features.
• 😀 Refining oil is also an example of continuous flow, though there might be multiple end-products due to temperature variations.
• 😀 Assembly line processes are for high-volume production with minimal product variation (e.g., cars with slight upgrades or premium features).
• 😀 Batch flow involves high to moderate-volume production with more product variation, requiring equipment changeovers between batches.
• 😀 A batch flow process means stopping production to reconfigure equipment when variations in the product require it.
• 😀 Job shops are used for producing highly customized products in low volumes, such as custom-made cars or jewelry.
• 😀 Job shop production is more expensive because of the customization and unique modifications required for each order.
• 😀 The layout of your production facility (product-oriented or process-oriented) helps determine the appropriate process selection for manufacturing.
• 😀 The key takeaway for process selection is to match the production volume and product variation to the right process: continuous flow, assembly line, batch flow, or job shop.

Q & A

What are the two key factors to consider when selecting a process for product manufacturing?

The two key factors to consider are the volume of production (high, moderate, or low) and the variety of products (degree of variation or differentiation).

What type of process selection should be used when producing high volumes of identical products?

A continuous flow process selection should be used when producing high volumes of identical products, as there is no variation in the product.

Can you give an example of continuous flow in manufacturing?

An example of continuous flow in manufacturing is the production of cars with no variation, where the same car is produced repeatedly without change in the process.

What makes oil refining an example of continuous flow despite having some variation in its products?

Oil refining is an example of continuous flow because the process itself does not stop and keeps flowing, even though different products may be produced due to temperature variations during the refining process.

How does assembly line production differ from continuous flow?

Assembly line production also involves high volume, but unlike continuous flow, it allows for minimal variation, such as producing the same car model with slight modifications, like upgraded features.

What is the key characteristic of batch flow production?

Batch flow production involves producing products in batches, with a stop in the process to change equipment before starting a new batch. This is typically used when there is more variation in the product.

Why is the changeover in equipment a drawback in batch flow production?

The changeover in equipment is a drawback because it requires time to stop production and modify the equipment to accommodate the next batch, leading to potential downtime and inefficiency.

What is a job shop, and when would it be used in production?

A job shop is used for producing customized or unique products in low volumes. It is typically used when there is a high degree of variation in the products, and the production process needs to be more flexible.

How does the cost of producing in a job shop compare to other process types?

Producing in a job shop is usually more expensive because the products are customized, requiring special modifications to the production process for each unique order.

How do process-oriented layouts differ from product-oriented layouts?

Process-oriented layouts are typically used in job shops, where the focus is on flexibility and customization, while product-oriented layouts are used in continuous flow, assembly line, and batch flow, where the focus is on efficiency and high-volume production.