Intermitted Manufacturing Systems

Intermittent Manufacturing Systems

Intermittent Manufacturing Systems, also known as batch production systems, produce goods in small to medium-sized batches. They provide flexibility to handle various products with different specifications, making them ideal for industries with variable demand and diverse products.

Features

• Flexibility
  • Adaptability: Easily adjusts to changes in product design, volume, and mix.
  • Reconfiguration: Machines and equipment can be quickly reconfigured for different production needs.
• Batch Production
  • Discrete Groups: Goods are produced in distinct batches, not continuously.
  • Variety: Each batch can have different specifications, catering to small to medium quantities.
• Varied Production Processes
  • Functional Layout: Similar processes are grouped together, enabling diverse operations (machining, assembly, packaging).
• Skilled Workforce
  • Versatility: Workers must perform multiple tasks and operate various machines.
  • Adaptability: Essential for handling new production requirements efficiently.
• Complex Scheduling
  • Coordination: Timing of different batches and resource allocation is complex.
  • Planning: Requires sophisticated planning to minimize delays and ensure timely completion.
• Inventory Management
  • Optimization: Maintaining optimal levels of raw materials, work-in-progress, and finished goods.
  • Just-in-Time (JIT): Techniques to ensure materials are available when needed without excessive holding costs.

Scope

• Customization and Small Batch Production
  • Bespoke Items: Ideal for producing tailored products, such as custom furniture and specialized machinery.
• Seasonal and Variable Demand Products
  • Adjustability: Quickly adjusts production volumes to match demand, suited for industries like fashion and food & beverage.
• Prototyping and New Product Development
  • Pilot Runs: Effective for small quantities of prototypes and iterative design improvements.
• Repair and Maintenance Services
  • Replacement Parts: Efficient for producing parts for heavy machinery, automotive repair, and industrial equipment maintenance.
• Job Shop Operations
  • Custom Orders: Handles diverse products with different specifications in limited quantities.
• Medical and Pharmaceutical Manufacturing
  • Precision: Suitable for producing medical devices, instruments, and pharmaceutical products with stringent quality requirements.

Steps

• Order Receipt and Processing
  • Review: Orders are reviewed for specific requirements, quantities, and deadlines.
• Product Design and Specification
  • Design Work: Involves creating or updating design drawings and technical specifications.
• Production Planning
  • Scheduling: Detailed schedule for manufacturing, including sequence of operations and resource allocation.
• Material Procurement and Inventory Management
  • Procurement: Identifying and procuring necessary materials and components.
  • Inventory Management: Ensures materials are available when needed.
• Machine Setup and Preparation
  • Configuration: Setting up machines and equipment according to batch specifications.
• Batch Production
  • Execution: Carrying out production in batches, following the schedule and instructions.
• Quality Control and Inspection
  • Inspection: Implementing quality control measures throughout the production process.
• Packaging and Storage
  • Final Steps: Packaging products and storing finished goods for shipment.
• Shipping and Delivery
  • Logistics: Arranging transportation for timely and accurate delivery.
• Continuous Improvement
  • Evaluation: Ongoing evaluation and improvement using feedback from production, quality control, and customer satisfaction.

Challenges

• Complex Scheduling
  • Coordination: Balancing production runs, managing changeovers, and ensuring timely completion can be difficult.
• High Setup Costs and Time
  • Changeovers: Frequent changeovers increase setup costs and reduce overall production efficiency.
• Inventory Management
  • Variability: Managing inventory for variable production schedules and batch sizes is complex.
• Quality Control
  • Consistency: Ensuring consistent quality across different batches with unique specifications is labor-intensive.
• Resource Allocation
  • Efficiency: Allocating labor, machinery, and materials efficiently is challenging due to varying demands.
• Workforce Skills and Training
  • Versatility: Requires a skilled workforce capable of adapting to changing production requirements.
• Process Optimization
  • Continuous Improvement: Tailoring Lean or Six Sigma efforts to accommodate diverse production needs is complex.
• Cost Control
  • Variability: Managing costs with variable production runs and inventory management requires careful planning.
• Lead Time Variability
  • Consistency: Meeting customer delivery expectations is challenging due to inconsistent lead times.

Intermittent manufacturing systems provide significant flexibility and customization capabilities but also come with challenges such as complex scheduling, high setup costs, and stringent inventory and quality control requirements. Effective management and continuous improvement are essential for optimizing these systems.