Intermittent Production, also known as batch production, involves the production of different products in separate batches on the same production line. This manufacturing strategy allows for quick transition between various product types, maximizing the utilization of resources and enhancing productivity.
Types of Production Processes
There are several production processes in manufacturing:
- Continuous Production: A non-stop production process for making standardized products in large quantities.
- Intermittent Production: Producing different products sequentially on the same line, as batches.
- Project-Based Production: Tailor-made, highly customized production for one-off projects.
- Mass Customization: Combining aspects of mass production with the ability to produce customized products.
Key Advantages of Intermittent Production
- Flexibility: Adaptability to produce different products on the same line.
- Resource Efficiency: Efficient use of resources by minimizing downtime.
- Cost-Effectiveness: Economical for manufacturing varied products without significant capital investment in multiple production lines.
Implementing Intermittent Production
- Planning and Scheduling: Detailed scheduling to minimize downtime between batches.
- Inventory Management: Efficient management of raw materials and work-in-process inventories.
- Quality Control: Strict quality checks to ensure consistency across different product batches.
- Training: Workforce training to handle diverse tasks and equipment efficiently.
Examples and Application
Example 1: A cosmetics company may use intermittent production to manufacture different types of skincare products—like lotions, creams, and serums—on the same production line.
Example 2: In the automotive industry, a plant might produce different car models on the same assembly line, one batch at a time.
Historical Context
Intermittent Production has roots in early 20th-century manufacturing practices. Henry Ford’s mass production techniques initially overshadowed batch production, but the need for flexibility brought intermittent production into prominence in diverse industries.
Comparing Production Strategies
- Continuous vs Intermittent: While continuous production focuses on high volume, single-product output, intermittent production excels in variety and flexibility.
- Project-Based vs Intermittent: Project-based production is highly customized per project, whereas intermittent production balances customization with standardized processes.
Related Terms
- Batch Production: Another term for intermittent production.
- Lean Manufacturing: Systematic method for waste minimization without sacrificing productivity.
- Supply Chain Management: Overseeing and managing the flow of goods from origin to consumption.
- Agile Manufacturing: Strategy that combines flexibility and responsiveness to changing market demands.
FAQs
1. What industries benefit most from intermittent production?
Industries that produce a variety of products with minor variations benefit significantly, such as automotive, electronics, and seasonal apparel manufacturing.
2. How does intermittent production handle inventory management?
Efficient inventory management systems are employed to ensure smooth transition between different product batches, preventing excess inventory and stockouts.
3. What are the main challenges of intermittent production?
Transition downtime, quality control across different batches, and the need for versatile machinery and workforce are notable challenges.
4. Can small businesses adopt intermittent production?
Yes, intermittent production is particularly advantageous for small to medium-sized enterprises that need to produce a variety of products without investing in multiple production lines.
References
- Heizer, J., & Render, B. (2020). Operations Management: Sustainability and Supply Chain Management. Pearson.
- Stevenson, W. J. (2014). Operations Management. McGraw-Hill Education.
- Slack, N., Chambers, S., & Johnston, R. (2010). Operations Management. Financial Times/Prentice Hall.
Summary
Intermittent Production is a versatile manufacturing strategy that maximizes resource use and productivity by producing different products in batches on the same production line. Its flexibility, cost-effectiveness, and resource efficiency make it an ideal choice for diverse industries, balancing the need for variety with standardized production processes. Efficient planning, inventory management, workforce training, and strict quality control are vital for the success of intermittent production systems.
