PPC in Mass and Flow Production System
Continuous production is the specialized manufacturing of identical articles on which the equipment is fully engaged. Continuous is normally associated with large quantities and high rate of demand. Since identical articles are produced the operations are repetitive production auxiliary aids such as special tools jigs and fixtures material handling system, inspection devices can be used advantageously.
Continuous production can be classified into two types:
- Mass Production
- Flow Production
In mass production a large number of identical articles are production but inspite of advanced mechanization and tooling the equipment need not be specially designed for this type of article only. Both plant and equipment are flexible enough to produce other products involving same production processes.
If the management decides that a certain line should be discontinued the machinery can be switched over to produce another article. Such change in policy usually does not involve major modifications in plant layout but change in tooling may be quite possible.
A shop of automatics is an example associated with mass production. Although the automatics may be continuously engaged on the production of say a certain type of opinions they can be switched over to production of screw or similar machine elements when the need arises. Another example is a highly mechanized press shop that can be utilized for the production of different components or production made of sheet metal without having to introduce major changes in the shop layout.
In flow production the plant it s equipment and layout are primarily designed to manufacturing the product in question. Flexibility in selection of products for manufacturing is confined to minor modifications in layout or design of models. Notable example are automobiles engines house hold machinery chemical plants etc. A decision to switch to a different over to a different kind of product may not only result in extensive tooling ( this is often needed even when only the model is changed) but also in basic changes in layout and equipment policy especially when special purpose machines and complex materials handling systems are involved.
Production planning and control in continuous production is usually far simpler than in job or batch production. Extensive effort is required for detailed planning before production starts, but both scheduling and control need not usually by very elaborate.