Manufacturers employ various production methodologies to enhance their production process. Each manufacturing business has unique equipment needs, production workflows, and customization requirements tailored to its specific goals and industry demands. In this blog post, we will explore the following topics:
What is Batch Production?
Batch production is a production method in which manufacturers produce identical products in one production run and is generally associated with process manufacturers. The products are manufactured in multiple process steps within a specific timeframe. After each process step, manufacturers perform quality control checks and set up the machine and equipment with the required configurations, such as the speed and time of the machine run. Quality checks at each stage help to ensure the product, process, equipment, and machine meet the quality standards and SOPs are followed.
Manufacturers decide the volume and quantity of batches. In some cases, each production line has a queue time. Items wait in line to begin the next manufacturing process step. Production is done in a series of process steps, allowing quality control at all production stages.
Key Characteristics of Batch Production
- Products are manufactured with a defined quantity
- Production is done in one go before switching to another step
- Production of items with varying specifications are produced using the same machinery and labor
- Equipment and machinery are reconfigured, and quality checks are done after each process step, resulting in downtime
- Manufacturers maintain inventory to manage overstocking and material shortages during production
- Ideal for SMEs (Small-Medium Enterprises)
Example of Batch Production
A bakery manufacturing company using the batch production method produces 500 loaves of bread in one batch. It then pauses the batch to adjust and reconfigure the same equipment and machine to produce 1000 cookies in another batch.
Different Types of Production Methods
Many manufacturing companies use batch production methods. Let’s explore other common production methods with examples that manufacturing companies use:
What is Continuous Production?
Continuous production, also known as flow production, is a method to that continuously manufacture goods in high volume. In this method, items flow from one machine to the next to complete the production without interruption.
Example of Continuous Production
SweetLife Manufacturing company produces orange juice, and the production process flow is as follows:
- Manpower assigned to the sorting work center loads the raw materials on a conveyor belt that goes through the sorting stage, where the oranges that meet quality standards are kept.
- After sorting, the materials then go to the mixing and blending production stage, and labor assigned at the mixing workstation sets the machines and equipment.
- With the blend of orange juice, an intermediate goes to the bottling and filling work center, where the intermediate is converted into a finished good.
- After filling the orange juice bottles, it moves to the packaging stage, where all the bottles are assembled and palletized.
Manufacturers can perform quality control operations at multiple stages to ensure the product meets the quality and compliance requirements. Process manufacturing companies usually use this method.
What is Job Shop Production?
Job shop production is when items are manufactured with different specifications. In job shop production, custom or specialized products are produced in small batches in varying units and quantities. Instead of creating standardized products, it allows for more flexibility to create a product with custom and personalized customer requirements.
Example of Job Shop Production
An automotive manufacturing company receives a custom order from a customer to manufacture an exhaust system made up of stainless steel for a specific vehicle model. The manufacturing process will begin with fabricating the exhaust system in small batches to fulfill quantity requirements. Each exhaust system will go through the process of cutting, bending, and welding, and the work center will be tailored to fit the exact vehicle model. After the completion, the exhaust system will go through a quality control process, and then the shipment is delivered to the customer.
What is Assembly Line Production?
Assembly line production is a manufacturing process in which production takes place in a pre-defined sequence. Each employee works on a specific task of product assembly sequentially until it reaches the completion stage. The product moves along the conveyor belt in the assembly line, where workers and machines are used to add a new component. Manufacturers use assembly line production methods to do mass production of standardized products.
Example of Assembly Line Production
Automobile companies mass-produce cars in a sequential manner. The product moves along the assembly line in a sequence of chassis assembly, body assembly, engine installation, painting, interior, and quality testing. Workers add and assemble the component parts at each workstation to create a final product.
Key Considerations of Production Methods
Each manufacturing production method has its unique advantages and challenges. Some key considerations for choosing the right production method that fits industry-specific needs:
- Product Variety – When manufacturers want to create product variants and switch between batches after each batch completion, the batch production method is suitable.
- Similar Products – Continuous production is ideal for manufacturers requiring the production of similar products in high volume with consistency and minimal downtime.
- Product Customization – If production with varying product specifications and customization is required, then job shop production is a suitable method.
- Product Assembly – Assembly line production is ideal for industries that require the assembly of different component parts to create a final product in high volume.
What Are the Advantages of Batch Production?
1. Improve Product Flexibility
The batch production method caters to ever-changing market demand. It allows manufacturers to produce multiple products using the same machine and equipment. Manufacturers can flexibly produce a broad range of products or seasonal products using this method.
2. Cost Efficiency for Batch Runs
It is an efficient and cost-effective method for SMEs. This method helps to save costs as instead of operating the machine all the time, the machine runs only when the batch is produced. Cost per unit decreases as larger production of items distributes the fixed cost of production line setup and operation to larger units.
3. Enhance Maintenance With Quality Control
Batch production allows manufacturers to plan for regular maintenance activities and quality control checks between batch runs. It enhances the machine’s performance and reduces machine breakdowns and production delays, ensuring quality and safety standards.
What Are the Disadvantages of Batch Production?
1. Increase Downtime
In batch production, machine setup time and adjustments are done between batches. It consumes a lot of time to configure and set up the machine or equipment to prepare them for the next batch. It increases downtime and impacts overall production efficiency.
2. High Wastage Risk
Higher wastage risk is associated with batch production method as defects in one batch can cause failure of the entire batch leading to wastage. It may require rework and batch creation from scratch.
3. Complex Planning and Scheduling
The batch production method can sometimes be complex when planning and scheduling activities due to multiple batch creations. Managing resource allocation across multiple products and batches can be challenging in quickly meeting changing market demand.
Optimize Batch Production With Modern Tools and Technology
Manufacturing companies are turning to ERP systems like Acumatica to optimize production processes. ERP systems help manufacturers to optimize production schedules based on inventory availability, machine capacity, and demand forecasts. It allows manufacturers to gain real-time visibility into inventory levels, avoiding overstocking and material shortages. Manufacturers can utilize ERP systems for end-to-end traceability. Traceability is vital in manufacturing industries to trace raw materials and finished products throughout all the production stages.
ERP system with an integrated quality management system enables manufacturers to automate their quality control process at every manufacturing stage. It helps to ensure that products meet the quality, regulatory, and compliance requirements. Integrate Quality Management Suite with robust cloud ERP and Acumatica to streamline batch production in manufacturing.
Contact us or an Acumatica partner to learn about eWorkplace Apps solutions developed for manufacturers and distributors.
