How it works
With flow or mass production, the line is stopped to
change products or models. Continuous production
uses the same concept, but it runs throughout the year
so output is nonstop. This method is used for identical
commodities with high, consistent demand, including
paper, cardboard, packaging, laundry detergent,
Continuous production
During continuous production, a product is made 24 hours a day,
seven days a week. The production line runs continuously to cope
with demand, and staff work around the clock in shifts.
Papermaking
In this continuous process,
automated machinery runs
24 hours a day, 365 days a year.
The paper trail
Paper is used throughout the world, and factories operate 365 days a year to
satisfy constant demand. Lumber is the raw material for papermaking. Once the
lumber has been debarked, chipped, and pulped, the fibers are washed and dyed.
At the end of its life cycle, some paper is recycled.
electronic components, and oil products. As with mass
production, processes are automated, staffing levels
are kept to a minimum, and quality control is essential.
There is high competition in industries using
continuous production. Margins may be low, but
demand is often relatively stable, encouraging
investment in capital equipment.
headbox
Fiber and water are fed
onto a moving wire mesh.
wire section
Some of the water is
sucked away to leave wet
fibers that form paper.
Wood
Lumber is a renewable
resource and logs are
stockpiled. Trucks make
constant deliveries to
processors for pulping.
Paper recycling
Recycled paper is
an important resource
for the paper industry.
US_280-281_Continuous_Production.indd 280 21/11/2014 16:28
280 281
How operations and production work
Manufacturing and production
4 billion
trees are cut down every
year to make paper
typical uses
Continuous production is used for undifferentiated
commodities required in large and constant amounts.
O
I
L
R
E
F
I
N
E
R
I
E
S
A
N
D
C
H
E
M
I
C
A
L
P
L
A
N
T
S
P
A
P
E
R
P
R
O
D
U
C
T
I
O
N
G
L
A
S
S
P
R
O
D
U
C
T
I
O
N
E
N
E
R
G
Y
:
E
L
E
C
T
R
I
C
I
T
Y
A
N
D
G
A
S
PRESS SECTION
More water is
squeezed out of
the wet sheets.
DRYING
The paper is dried off.
COATING AND
CALENDERING
The paper is coated,
compressed, and
smoothed.
FINISHING
AND SUPPLY
The finished paper is
constantly supplied
to printers, packers,
and newspapers.
US_280-281_Continuous_Production.indd 281 21/11/2014 16:28
280 281
How operations and production work
Manufacturing and production
4 billion
trees are cut down every
year to make paper
typical uses
Continuous production is used for undifferentiated
commodities required in large and constant amounts.
O
I
L
R
E
F
I
N
E
R
I
E
S
A
N
D
C
H
E
M
I
C
A
L
P
L
A
N
T
S
P
A
P
E
R
P
R
O
D
U
C
T
I
O
N
G
L
A
S
S
P
R
O
D
U
C
T
I
O
N
E
N
E
R
G
Y
:
E
L
E
C
T
R
I
C
I
T
Y
A
N
D
G
A
S
PRESS SECTION
More water is
squeezed out of
the wet sheets.
DRYING
The paper is dried off.
COATING AND
CALENDERING
The paper is coated,
compressed, and
smoothed.
FINISHING
AND SUPPLY
The finished paper is
constantly supplied
to printers, packers,
and newspapers.
US_280-281_Continuous_Production.indd 281 21/11/2014 16:28
Combining
methods
On the classic assembly
line, each worker is skilled
at producing one type
or part of an item. At the
other end of the scale,
one person completes all
stages, creating the finished
product from beginning to
end. Cell manufacturing
combines flow production
with job production to
create autonomous units.
A number of workers are
dedicated to production,
or part-production, of a
set of goods.
Hybrid processes
Flow production
One process is handled by one or more workers and that job
is completed before the product or part moves on to the next
workstation. Worker 1 uses only one set of tools for the process,
before the product moves on to Worker 2, and so on down the line.
(See pp.276–277.)
How it works
There are many examples of hybrid
processes. One is linked batch flow
production, where only two or three
pieces of equipment are required
and a batch flows from one process
to another. This is common in the
chemicals and pharmaceuticals
industries. For instance, a company
may make headache medication
and a hay fever remedy in tablet,
capsule, and liquid form, and
in varying doses; each batch
flows through a series of steps,
depending on composition
and form, from bulk processing
to packaging. Another example
is cell manufacturing, which
combines job production with
flow (mass) production.
Manufacturing firms may adapt existing processes or combine two
production methods for optimal performance, particularly if they make
a wide range of products.
Increments Small steps of
gradual improvement over a period
of time, rather than breakthrough
or transformational change
Hybridization Replacing several
separate processes with one single
hybrid process
NEED TO KNOW
PRODUCTION LINE
INPUT
OUTPUT
WORKER 1 WORKER 2
WORKER 3 WORKER 4
US_282-283_Hybrid_processes.indd 282 21/11/2014 14:25
282 283
how operations and production work
Manufacturing and production
Job production
One worker creates
a one-of-a-kind product,
such as a custom kitchen,
from start to finish. This
way of working can be
more rewarding for the
worker, who uses a range
of skills, but it tends to be
costly for the customer.
See pp.272–273.
Cell manufacturing
Combining the best of flow and job production, here a group of products
or parts is produced in separate small units (cells) made up of a number of
workers in the factory. Workers are trained to produce all the items in the set.
Dissimilar items can be produced without slowing the production line. The
idea is to improve performance by giving each cell a degree of autonomy.
PRODUCTION LINE
INPUT
OUTPUT
By combining manufacturing
processes, companies can create
products with new and original
qualities. For instance, a food
company that makes bread
and french fries may speed up
production of the fries by baking
them in the bread oven first. This
has the unintended but beneficial
consequence of making the fries
healthier. A new product is created,
which may now be marketed as
a new proposition to a different
set of consumers.
potatoes
dough
french fries
lighter fries
bread
CELL 1 CELL 2
CELL 3 CELL 4
HYBRID PROCESSES FOR INNOVATION
WORKER
US_282-283_Hybrid_processes.indd 283 15/12/2014 13:54
282 283
how operations and production work
Manufacturing and production
Job production
One worker creates
a one-of-a-kind product,
such as a custom kitchen,
from start to finish. This
way of working can be
more rewarding for the
worker, who uses a range
of skills, but it tends to be
costly for the customer.
See pp.272–273.
Cell manufacturing
Combining the best of flow and job production, here a group of products
or parts is produced in separate small units (cells) made up of a number of
workers in the factory. Workers are trained to produce all the items in the set.
Dissimilar items can be produced without slowing the production line. The
idea is to improve performance by giving each cell a degree of autonomy.
PRODUCTION LINE
INPUT
OUTPUT
By combining manufacturing
processes, companies can create
products with new and original
qualities. For instance, a food
company that makes bread
and french fries may speed up
production of the fries by baking
them in the bread oven first. This
has the unintended but beneficial
consequence of making the fries
healthier. A new product is created,
which may now be marketed as
a new proposition to a different
set of consumers.
potatoes
dough
french fries
lighter fries
bread
CELL 1 CELL 2
CELL 3 CELL 4
HYBRID PROCESSES FOR INNOVATION
WORKER
US_282-283_Hybrid_processes.indd 283 15/12/2014 13:54
..................Content has been hidden....................

You can't read the all page of ebook, please click here login for view all page.
Reset