Continuous production offers advantages over batch production in terms of production volume, cost, energy, and quality. It allows for high-volume production in a shorter amount of time, lower unit costs, and better quality control. Continuous manufacturing maximizes product output and eliminates unnecessary start and stop phases. It also contributes to consistent quality and reduces opportunities for human error. This method is compatible with lean manufacturing and can lead to additional savings and environmental benefits.
There are several advantages of continuous production of products over batch production in terms of production volume, cost, energy and quality. High-volume production is possible in a shorter amount of time due to ongoing production and the elimination of unnecessary start and stop phases. Lower unit costs and energy savings can be achieved through automation and reduction of unnecessary labor. Better quality control can also be maintained as there is less opportunity for process change or human error to impact production.
Continuous manufacturing is a method used to maximize the amount of product that is made in a given period of time and production space. Production generally takes place 24 hours a day, all year round without interruption. With the exception of an unusual interruption, the equipment is always in use and the production stream output is equally continuous.
The most obvious benefit of continuous manufacturing is the ability to produce a high output of products in a short amount of time. By running a production line around the clock rather than just during standard business hours, a facility can produce more products. This method also avoids wasting time regularly shutting down and restarting equipment that might otherwise be used for production.
Partly because of this compression of the production process over time, continuous production can also lead to low unit costs. Savings on labor costs also contribute in part to this low unit cost. Less skilled and less expensive labor is used for the few tasks that are not automated, while machines do most of the work and perform complex operations. While the capital cost of the equipment can be expensive, the high initial cost can be recouped with a low per-product unit cost from high-volume production.
Additional savings and environmental benefits can come from energy savings from eliminating steps that do not add value to the final product. Continuous production can avoid some of the cleaning and sterilization required before the equipment can go idle because the equipment is in constant operation. It also avoids much of the transportation required to move materials to and from storage that would be required with batch production. Instead of remaining in storage until operations begin, material in a continuous manufacturing facility is often fed directly into the production line.
This feature makes this method highly compatible with a common manufacturing strategy called lean manufacturing. Lean manufacturing is based on the premise that any process or product not directly involved in delivering customer value is a waste to be eliminated. Eliminating unnecessary expenses through continuous production is one measure that can be taken in implementing lean manufacturing.
Another big benefit of this production method is that it can help ensure consistent quality over a high volume of output. The quality of some products, such as food or some chemicals, is highly dependent on the consistency of the ingredients and the process. By avoiding repeated shutdown and startup processes, it is much easier to ensure that the process remains unchanged.
Continuous production also contributes to product quality by reducing opportunities for human error. Due to the highly automated nature of the operation, people directly perform far fewer steps in this type of facility. This minimizes the possibility that the quality will be damaged by errors such as contamination, damage due to improper handling and so on.
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