What is production system and its types?

This step introduces the basics of production systems, their components and what systems are usually made up of.

A production system transforms input to output. Meaning, it’s the systems that manufacture a product consisting of whatever components is needed to make it a reality.

Let’s take a closer look at how input and output work with a system:

The black box in the picture represents the production system itself. On the left we have what goes into the system (input) and on the right is what comes out of the system (output).

Input goes into the system. When going through the system, it becomes transformed in some way making the output different than what came in, resulting in something with different characteristics. Of course, a system may have more than one input and output.

There are usually five types of ways of transforming input into output:

• Separating – One item enters and two or more exit. Example: A wooden plank is cut into two.
• Putting together – Several items enter and one exits. Example: Wooden planks that are glued together.
• Detaching – And item enters and exits shaped differently, alongside waste. Example: A block of wood is shaped with a lathe.
• Forming – An item enters and exits in a different shape, without waste. Example: A piece of metal is shaped by hammering the object.
• Quality adaptation – An item enters and exits with different characteristics. Example: Surface treatment of a metal object.

It is not always easy to directly understand what happens in the black box – often we simply accept that it’s there. Further on in this activity we will examine what might happen within the production system black box. This is a large part of understanding production systems.

Components

Components are simply the parts that together make up a larger system.

If we take this FutureLearn course as an example of a system, all of the steps are components and so are all of the learners taking the course. The content-steps of the course and learners then work together towards the goal of enriching everyone’s knowledge.

Components can be material, digital, and nonmaterial alike. An idea or organisation can also be a component of a system, so components can sometimes be difficult to define.

It is when the components of this course are assembled into a system that we achieve the goal. And the components only work in the context of the other components.

Give some examples of systems and list some of the components they are made up of. Try thinking of both material and nonmaterial components that make up some systems that you are familiar with. Are some components more important than others?

Please share your answer in the comment section, and discuss with other learners.

Interviwer may ask about what are the types of production systems?  Because every firm has their own production type. 

1. Continuous flow type production system.

The example of continuous type of production system are : chemical plants, oil refiners, etc 

2. Mass production system

In mass production components are produced in large quantities and minimal variety. The mass production system is product layout. The example of mass production system are : manufacturing of nut and bolts, and springs. The mass production system utilize automated transfer lines, which are highly efficient in production of large quantities of a fixed product. 

3. Batch production system.

In batch production inon system, the components are produced in medium quantities and medium variety. The examples of batch production system are :manufacturing of marine engines, vehicles, clothes, etc. The batch production systems utilize flexible manufacturing systems (FMS). Flexible manufacturing system is a machine cell, consisting of a group of per processing workstations interconnected by an automated material handling and storage systems. The setup q is computer controlled and can be programed as per the process sequence requirement of the particular batch of components. 

4. Job production system.

In job production system the components are produced in low quantities, based on the order
The minimum lot size can be one unit. The examples of job production system are: manufactoring of jigs,fixture, dies, etc.  The job production system uses stand alone machine including  CNC machines,which are highly flexible and can accommodate huge product varieties. The drawbacks are low production rate and large setup time. 

The four types of production systems can be distinguished in terms of production quantity and product variety ( flexibility) as shown in fig 

comparison between production systems

More Resources /articles

All the production processes cannot be separated from the production system in the company. The production process is the activity of converting raw materials into a product that can be used by consumers, commonly called finished or semi-finished goods. Companies need production systems to be able to run the production process.

The production system is developed based on the company’s product line and regulated to meet the company’s goals. It is a collection of several elements that are connected and cannot stand alone, consisting of two components: functional and structural. Functional components include supervision, planning, and control, while structural components include machinery, materials, labor, and equipment.

There are various types of production systems; however, we will only discuss production systems based on processes and objectives. You can check out the following production systems:

1. Process-Based Production System

The first is the process-based production system, divided into the continuous process and intermittent process types.

The continuous process is a production system that produces goods on a large scale continuously and usually produces goods based on a demand forecast. The goods here are mass-produced and meant to be stored as inventory. The goal is to be able to meet sudden spikes in the demand for these goods by increasing the company’s inventory. An example of an industry that applies a continuous process is the packaged food industry.

The second process-based production system is the intermittent process, which is a production system that runs based on consumer demand. Usually, this type of production process produces goods on a smaller scale. In the intermittent process, consumers can order custom products that the production process needs to adapt in the production funnel. The intermittent process’s application is typically used for services such as custom tailoring or bespoke furniture.

2. Production Systems Based on Operational Objectives

The second type of production system is a system based on the purpose or objective of its operations. There are four types of production systems based on their objectives:

1. The first production system is the Engineering to Order (ETO) production system. The ETO system is executed when consumers ask producers to produce goods or products starting from the design process.

2. The second production system is the Assembly to Order (ATO) production system. The ATO system is a type of production system that starts when the manufacturer has an operational module and a standard design. Manufacturers only need to assemble products based on the modules and designs that have been provided.

3. Another production system is the Make to Order (MTO) production system. The MTO system is a production system that runs when a producer has received an order.

4. The last production system is the Make to Stock (MTS) production system. This production system is designed for items meant to be stored or stocked in the warehouse. The production process will finish before there is an order from the consumers.

Well, those are all you need to know about the production system and its types. If you want to build a manufacturing company, you should look for an industrial area that has the complete facilities and a strategic location close to transportation routes.

One industrial area that has a strategic location is Karawang New Industry City (KNIC). Located close to the capital city of Jakarta and with a lot of access makes KNIC a suitable area for building and renting warehouses.

In addition, KNIC has 6 access points to national infrastructure such as the Jakarta-Cikampek toll road, the Jabodetabek LRT, the Trans Java line, the Jakarta-Bandung Railway, the Kertajati International Airport, and the Patimban port. In addition, KNIC is also supported by facilities such as premium electricity, natural gas, and fast internet connections to support the performance of manufacturing companies.