4.3: Scales of Production

4.3
Scales of Production
Essential idea: The scale of production depends on the number of products required.


One-off production
One-off production is where only one for a few specialist items are required. If a prototype is made then it is usually part of the realization of the product and so the next step after testing would be batch or volume production.

In one-off production a single (or very few) product (s) is designed and made to a client's specification. Labor and material costs are high, and a high level of design and manufacturing skills are needed. An example of one-off production would be a made-to-measure wedding dress or a commissioned piece of furniture.

Custom made to fit the customer or consumer

Manufacturing costs are high and labor costs are high.

Examples of one-off production

Batch production
Limited production volume - a set number of items to be produced. There is a set amount of products made or manufactured.

Batch production set quantities of a product are manufactured to order. Batch production requires a high-level of design, pattern making and sampling skills. Materials are cost-effective and manufacturing costs are lower than one-off production. 

• automation is required eg. templates
• Making products in set quantities

Garments are designed to fit a range of standard sizes and shapes. The quantity varies from a set of four cushions made by a designer or maker to 20,000 jumpers made for a department store.

Cars may be manufactured in batches

Examples of batch production

Continuous flow production
Definition: A production method used to manufacture, produce or process materials without interruption.

MASS PRODUCTION is the industrial-scale manufacture of large quantities of products, usually on a production line. Standardized production mean that it is suitable for products that rarely need to be redesigned. Mass production is used for products that are needed in very large numbers, such as socks or jeans. Often, products are made overseas where labour costs are lower. 

• high set up costs (machinery)
• low unit costs

CONTINUOUS-FLOW MANUFACTURING is when many thousands of identical products are made. The difference between this and mass production is that the production line is kept running 24 hours a day, seven days a week to maximize and stopping the production process. The process is highly automated and few workers are ever required.

Production lines

Choosing a production method
The best method of production depends on the type of product being made and the size of the market.

• One off production - service sector such as tailors or manufacturing jewellers, one off production is the best production method
• Batch production is used to meet group orders, and batch orders. Appropriate for bakery and clothes manufacturers
• Flow/continuous production is used to produce everyday standardised items such as soap power and canned drinks.

LEVELS OF PRODUCTION:

Advantages and disadvantages of different production methods