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BATCH PROCESS
Jens Thomas
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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.
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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
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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.
Introduction Contd.
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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.
Layout and material flow
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Batch process layout[2]
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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 of batch process
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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.
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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.
Characteristics contd.
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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 CJC [5]
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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.
Case Study contd.
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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[6]
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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
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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
Advantages and disadvantages
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References
[1] unknown, http://www.thetimes100.co.uk/theory/theory--production-process--254.php, Retrieved on16thjanuary2010
[2] unknown http://www.mbaknol.com/operations-
management/batch-production-and-its-key-
characteristics,Retrieved on16thjanuary2010
[3] John Miltenburg, Manufacturing Strategy, Productivity press,1995
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References
[4] unknown http://www.technologystudent.com/joints/bat1.htm,
Retrieved on16thjanuary2010
[5] unknown http://tutor2u.net/business/gcse/production_batch.htm,
Retrieved on 16 thjanuary2010
[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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