JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD B.Tech IV PRODUCTION PLANNING AND CONTROL Previous Question Paper (December - 2020 - R16)

Production systems are categorized based on the nature of the product, volume of production, and variety of product mix. The three primary types are Job Shop, Batch, and Mass/Continuous production.

1. Job Shop Production
This system involves the production of small quantities of products designed and produced as per customer specifications. Characteristics include:

• High variety of products with low volume.
• Use of general-purpose machines and equipment.
• Highly skilled operators capable of handling varied tasks.
• Large inventory of raw materials and work-in-progress.
• Complex production planning and scheduling due to frequent changes.

2. Batch Production
In this system, products are produced in batches or lots. It is a middle ground between job shop and mass production. Characteristics include:

• Moderate variety and moderate volume of production.
• Equipment is used for a specific batch and then reset for the next.
• Standardized sequence of operations for each batch.
• Lower unit cost compared to job shop production.
• Requires efficient material handling and inventory control to manage batch transitions.

3. Mass Production
This involves the continuous production of standardized products in large quantities. Characteristics include:

• Very high volume with very low product variety.
• Use of special-purpose machines and automated production lines.
• Flow-line layout where work moves sequentially from one station to the next.
• Low skill requirement for operators as tasks are repetitive.
• High initial capital investment but very low unit production cost.
• Balanced production lines to minimize idle time.

4. Continuous Production
An extreme form of mass production where the product is produced in a continuous flow, often used in process industries like oil refineries or chemical plants. Characteristics include:

• 24/7 operation with no interruptions.
• Highly automated and integrated systems.
• Material flows through the process without human intervention.
• Very high capital intensity and low labor cost.
• Strict quality control and maintenance protocols to prevent system downtime.