Continuous vs. Intermittent Production Systems: Key Differences
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Continuous vs. Intermittent Production Systems
The degree of continuity of material flow categorizes production systems into two main types: Continuous Production and Intermittent Production. Here's a breakdown of their key differences:
Characteristics of Each Production System
| Feature | Continuous Production | Intermittent Production |
|---|---|---|
| Products | Standardized products for customers | Defined products |
| Production Trigger | Inventory-based | Order-based |
| Production Flow | Constant flux lines | Batch or prolonged runs |
| Setup Time | Short setup times; low setup cost (seldom done) | High setup cost (frequently done) |
| Capital Intensity | Capital intensive | Labor intensive |
| Production Stoppages | Major problems and losses | Less serious impact |
| Equipment Layout | Specialized equipment by product (machines follow the manufacturing course) | Universal equipment by process or functional layout (similar machines grouped) |
| Material Management | Materials are carried from one place to another depending on the stage | Materials are carried from one place to another depending on the stage |
| Inventory | Low in-process inventory, high finished product inventory | High in-process inventory, low finished product inventory |
| Personnel | Mostly unskilled personnel | Skilled operators, more difficult monitoring, detailed instructions needed |
| Decision Flexibility | Difficult or uneconomical to modify product-process-plant equipment | More complex programming operation, but the structure is not irreversible |
| Control and Costing | Quantitative control and costing of production processes | Quantitative control and costing of production work orders (controlled individually) |
| Quality Control | Statistical methods used | Statistical methods not typically used |
| Requirements for Rational Use | Stable demand, standardized products, interchangeable parts, uninterrupted material supply | - |
Process Design
Process design involves choosing inputs, transactions, flows, and methods for producing goods and services, along with their detailed specifications. It may be initiated due to:
- Starting new productive activities
- Developing a new product
- Significant changes in demand
- Competitive pressure
Decisions involve:
- Choice of technology
- Division of labor
- Operation sequence
- Materials to use
- Make-or-buy decisions
- Type of layout
- Total production time
Process Design Methodology
- Problem Statement: Define objectives, restrictions, relevant variables, time, and resources.
- Information Gathering: Analyze the current process, and research other technologies.
- Analysis and Alternative Generation: This phase ends when the cost of upgrading equals the value of likely improvements.
- Evaluation of Alternatives: Choose the most convenient option.
- Detailed Design: Specify the chosen alternative.
- Implementation: Procure equipment, train staff, and purchase machines and tools.
- Monitoring: Follow up until the new process is settled.
Standard Time
Standard Time is the time required to complete an operation when executed according to a specified method, assuming a reasonable work rate for a typical worker.
Modern Design Approach (Post-1980)
The current design approach emphasizes:
- Production aligned with demand, achieving process flexibility.
- Just-in-Time (JIT): Producing and delivering only the quantities required by customers or subsequent process stages.
- Reduced or eliminated inventories of finished goods and in-process materials (aiming for zero stock).
- Mobile containers accompanied by Kanban cards in assembly plants.
Just-In-Time Production Goals
- Zero stock
- Zero defects
- Zero failures
- Zero paperwork
Kanban System
Kanban cards are used at each workstation to request necessary inputs from preceding stations, specifying only the amount needed for current production. There are two main types of Kanban cards:
- Production Kanban: Indicates the item and quantity to be produced.
- Transport Kanban: Indicates the item and quantity required by the station.
- Supplier Kanban
Efficiency and Productivity
Efficiency refers to implementing a standard set.
Productivity is the ratio of how effectively a resource is used.