Batch manufacturing produces identical items in a series of processes, but can cause inefficiency due to machinery resetting. Planning, training, maintenance, and computerized control are necessary for success. Productivity balancing and maintenance planning reduce interruptions.
Batch manufacturing refers to the production of a specific quantity of identical items in a series of processes. This style of manufacturing may be driven by the steps required to produce a completed product or it may be a function of the amount of materials a set of machinery can handle at one time. While batch production is necessary in some situations, it can cause inefficiency due to the time it takes to reset machinery before a new batch can start. For items that require multiple production steps, planning is essential to ensure that items that have completed a section of the process are not backed up waiting for the next function. Successful batch production also relies on good operator training, proper equipment maintenance, and computerized control.
When a business sets up a batch process, it must evaluate the steps that must be completed to produce a finished item. If the machinery of a production stage can rely on a continuous supply of raw material, the batch process is not limited in that section. Conversely, if a batch of material sufficient to create a certain number of units needs to be blended and heated before it can move to the next production point, the process cannot continue until the batch of blended material is ready. Implicit in mass production is the concept of goods moving from station to station as each function is completed.
A significant amount of time in batch production can be required to reset machinery, change raw materials or test the quality of the first samples from the batch. This is referred to as downtime and is a measure of the efficiency of the manufacturing project. Computerized management and control software can help workers achieve smooth transfers from one type of goods to another.
Productivity balancing is also important in series production. If the first station can produce 250 units in ten minutes and the second station can produce 500 units in thirty minutes, the first phase will have 750 units completed by the time the second phase produces 500. This imbalance will result in an inventory backlog . The reverse situation will result in machinery at the second station idle and waiting for product to exit the first station. A balanced production line produces equivalent quantities in similar times to keep goods moving.
Careful planning of maintenance in support of the production line can reduce the possibility of equipment failure and the consequent interruption of serial production. Well-trained workers can recognize problems and respond quickly to limit downtime. Computerized performance analysis improves consistency and alerts employees to off-spec materials.
Protect your devices with Threat Protection by NordVPN
