The production process is organized in accordance with various criteria and approaches. In order to optimize their production cycles and increase financial results, enterprises are very thoughtful in the methods of manufacturing their products. There are several generally accepted ways to release products.
Serial production is a special form of organization of the production cycle, based on certain technological, economic features, specialization, as well as the product range of the enterprise.
Production factors
The type of production is influenced by a number of its characteristics and features. These are technical, organizational and economic indicators of the enterprise. They are determined by the composition and breadth of the nomenclature, the volume of finished products, as well as its stability and regularity of production.
Depending on the level of specialization and concentration distinguish single, serial and mass production. They are determined by a number of factors. First of all, the type of production is affected by the volume of output and its nomenclature. When organizing the production cycle, take into account the degree of constancy of the list of created products, as well as workload.
One or another type of organization of the production process is applicable to the entire enterprise, its sections or even individual jobs. The assignment of a company to a certain category is rather arbitrary.
Types of production
The main types of production that exist today (single, serial, mass) have a number of characteristic features.
For a single production characterized by a small volume of production of identical products. Their repair or re-release is not provided.
In mass production, finished products are produced in batches. Moreover, they are made with a certain frequency. Distinguish between small-scale, large-scale and medium-series type of output.
Mass production is characterized by the largest scale. The products in this case are manufactured continuously and in large quantities. This takes a lot of time.
The main features of serial production
Serial type of production is the most common type of organization of output in many industries. Products in this case are characterized by structural uniformity. They are produced in series of small, medium or large sizes. Intervals are repeated at regular intervals. During the production cycle, it takes some time to produce products, as well as breaks when the equipment is at rest.
The concept of "series" should be understood as a certain number of products of the same type that are created by a single enterprise.
The nomenclature of goods in this type of production is quite large. This indicator looks more diverse only with a single approach to organizing the release of goods. A certain part of the products is similar in technological and constructional features.
Features and Benefits
The organization of mass production has a number of characteristic features. One of them is the repeatability and periodicity of the finished product manufacturing process. This makes the production cycle rhythmic.
The release of goods is carried out in large or relatively large volumes. This makes it possible to unify the products being created, as well as the technological processes themselves. At the same time, products can be manufactured in accordance with standards and norms. This provides the opportunity to apply them in structural rows in large batches. With this approach, their cost is reduced.
In addition to improving the quality of finished products, as well as reducing their cost, organizations have the opportunity to purchase special equipment, sharpened for the production of standard parts and assemblies. Productivity in this case also increases.
Main features
The characteristic of mass production allows you to highlight the main features of this method of organizing the release of goods. These include the manufacture of series with a wide range of similar parts and assemblies. Production activity in this case is decentralized in workshops, departments, etc. Their specialization is growing.
Production is carried out both on the basis of orders and previously unknown customers. Workers have an average skill level. Manual labor is characterized by small volumes.
Production cycles are short. The technological process is typified. In this case, high-tech equipment is used. Quality control is automated. Statistical methods for managing product standards are applied.
disadvantages
Serial production is a system that has several advantages. But also this approach to the organization of production has some drawbacks. First of all, it should be noted the long cycle time with irregular operation of the equipment.
Frequent readjustments, maintenance of equipment, machine tools requires a significant investment of time. In this case, non-production costs increase. There are big breaks in production. They arise as a result of preparatory work for the manufacture of goods, parts.
With the wrong approach to the organization of the production process, the cost of products can increase, as well as reduce turnover. At the same time, the indicator of labor productivity may also decrease. Therefore, the process of organizing the serial production of goods must be approached seriously, perform a number of calculations and planning.
Subtypes
Serial production is conditionally divided into small, medium and large production. This separation is conditional. This is due to the presence of some characteristic features of a single and mass production principle in some subtypes.
Some features possessed by mass and mass production are successfully combined in a large-scale subcategory. At the same time, the series have a large scale. A large amount of time is spent on their manufacture. Breaks between batches are small and rare.
If the parties are small, in these types of cycles certain features of a single method of manufacturing goods are determined. This approach is often used to create a small batch of parts on special order. And recently, a similar approach has been greatly improved. The use of computer technology can reduce the cost of working time, produce several different types of parts on the same production line.
Calendar distribution
The rhythm, the effectiveness of the production of finished products in batches allows you to organize a calendar development. Serial production requires distribution in several stages.
If parts, assemblies or blanks are planned to be produced a whole year, they are distributed by month. After that, in the planning period, the time fund is determined, during which the equipment will work to produce the required item.
The remainder of the time is also estimated. It is used to create other goods that are provided for in the production program. Such products are distributed in accordance with calendar plans for the terms of contracts with suppliers and customers.
Create Sets
Serial production enterprises can produce whole sets of products, the production time of which is at close time intervals. These types of parts, assemblies are combined. Such kits allow relatively uniform loading of equipment. Thus, the number of nomenclature combinations, which are fixed in individual months, is reduced.
A set of certain details is assigned to the selected segment of the calendar period. The company is interested in periodically repeating such combinations throughout the year. This allows you to establish a rhythmic release of products.
The annual program on the nomenclature and volume of creation of finished goods must be fully implemented for the calendar period. Moreover, when creating product sets, various combinations of manufacturing parts are calculated. This makes it possible to check the capacity utilization.
Operational Production Planning System
Serial production is a rather complex type of organization, in which there is a consolidation of several detail operations for one workplace. Therefore, several systems are used for operational planning . These include the development of future production for cycle sets, for backlogs, as well as for complete numbers. Plans are created based on a continuous production process.
To determine future cycle sets on the basis of inter-workshop indicators, the initial documents are the plan for the manufacture of goods for the year, as well as information on the composition of the set. They list all the parts, blanks that are part of the composition. The planning department takes into account calendar standards for each unit of production and the entire set.
This approach allows the company to properly organize mass production, to increase the productivity of equipment and labor. Correction of planned cycles during the formation of sets provides an opportunity to choose the most profitable option for creating finished goods.
Benefits of Cycle Set Planning
Serial production of products cannot be effectively carried out without planning for the workshops and backlogs of the enterprise. Analysts calculate the planned launch dates for cyclic recruitment. This work is carried out for each workshop of the company. Planning is carried out on the basis of previously established deadlines and the order of submission of sets for their assembly. In this case, the normative indicator of the duration of each cycle is taken into account. The whole system should function smoothly, fulfilling the tasks of the enterprise.
Planning provides the company with a number of benefits. The manufacture of goods occurs rhythmically, allowing you to reduce the downtime of equipment and lay-out blanks, components and parts.
Backlog Planning
The most flexible in the planning process is the system of development of programs for backlogs. First, the fundamental level is determined for calculating the backlog for parts and nodes in each workshop. When organizing the production process, the task is to maintain the level of production of goods by structural units in accordance with the calculated level. The volume of planned tasks for each product is determined in days or five days relative to the final output.
It is economically feasible to reduce the fitting operations of structures, since the dimensional stability of the parts makes it possible to reduce the specific gravity of each manual operation of workers. They perform several specialized operations.
Group Process Development
Serial type of production is diverse and complex organization. It includes machine-tool, machine-building enterprises. For medium and small-scale production, it is advisable to apply the method of group planning.
The essence of this approach involves the development of group processes and the creation of an appropriate base of equipment. All details are divided by type. At the same time, their technological, structural similarities, as well as the same equipment used, are taken into account.
When planning, the most complex part is distinguished from each group, in which structural elements similar to other products are determined. If it is not, an integrated unit of production is being developed. On it they design equipment, machine tools. This allows you to make any part of the group. This approach makes serial production cost-effective.
Serial production is the most common form of organizing the process of manufacturing finished goods. Knowing its features, as well as applying planning methods, the analytical service is able to increase the profitability of the finished product, improve technological cycles.