BATCH PRODUCTION SYSTEM: FEATURES, ADVANTAGES, EXAMPLES - DUDAS - 2025

The batch production system is a manufacturing method where products are manufactured in specific groups or quantities, within a time frame. A batch can go through a series of steps in a large manufacturing process to make the desired end product.

Batch production is used for many types of manufacturing that may require smaller quantities of production at one time, to ensure specific quality standards or process changes.

Source: pixabay.com

This production system is also known as discontinuous production, because the material accumulates in front of each of the production processes. Each of the steps in the production process is applied at the same time to a complete batch of items. That batch does not move to the next stage of the production process until the entire batch is done.

Comparison with other production systems

In this system, instead of manufacturing items continuously or individually, manufacturing moves in groups or batches.

It is different from mass production or continuous production methods, where the product or process does not need to be checked or changed as often or as periodically.

Both order production and batch production are similar in nature, except that in batch production the quantity of product manufactured is comparatively greater.

Batch manufacturing is traditionally used in companies that have implemented the lean manufacturing philosophy.

characteristics

Process cost reduction

The batch production system is used to reduce the cost per hour of each of the processes, considering that the greater the number of parts produced by a given process, the more the cost per hour is reduced.

However, it does not take into account downtime due to lack of material and inventory build-up in process.

Demand not continuous

This method of production can be done when the demand is not extensive or periodic enough to initiate a production system that relies on one-piece flow.

In these situations, the aim is to achieve an optimal production lot size to maximize the necessary resources and raw materials, and to satisfy the customer's demand, reducing the current inventory to the maximum.

Push system

The batch production system is a push manufacturing system; that is, the next process will take the product when the preliminary process finishes and will take what has been produced.

The production process from behind is pushing production, regardless of the production rate of subsequent processes.

The machines are in chronological order directly related to the manufacturing process.

Lot Size

The batch size should be as small as possible, making a trade-off between operator or machine use and inventory build-up.

When the batch size is too large, cycle times increase because there is too much downtime and unnecessary inventory transport.

Changes in the product

The batch production method is used so that any temporary changes or modifications to the product can be made, if necessary, during the manufacturing process.

For example, if a product needs a sudden change in material or some details changed, this can be done between batches.

This is different from assembly production or mass production, where such changes cannot be easily made. The time between batches is called the cycle time. Each lot can be assigned a lot number.

Slow change in machines

The changes that are needed to adapt the machine to one type of product or another are usually slow. That is why each change is used to produce parts of a certain type.

Consequently, the system is not very flexible, because it does not allow the production of several product models at the same time.

For this reason, it is very difficult to work on demand with this production system, and it is generally produced to have stock.

Greater physical space

Companies using batch production require large facilities to accumulate in-process inventory. By doing so, this inventory runs the risk of being lost, broken, or causing workplace accidents.

In the same way, large warehouses are also required to keep the finished product waiting to be delivered to the customer.

Advantage

- Due to smaller batch manufacturing, batch production is good for quality control. For example, if there is an error in the process, it can be fixed without so much loss, compared to mass production.

- Works well when small production runs are needed, such as candy stores, which bake only the cookies that are needed.

- It makes sense when the demand for a product is not enough to keep a dedicated machine or production process working continuously.

Variety of products

- The company that uses it may have a variety of products instead of a single type, thus giving the customer a wider choice and, therefore, a greater possibility of sale.

- Ideal for custom or seasonal orders, or trial builds of a new product.

- It allows to use a single production system to make different seasonal items.

- The company reduces the risk of concentrating on a single product, producing a variety of different products of the same type.

- You have the flexibility to produce a variety of different products, or different product variants.

Economic advantages

- You can save money by taking less risk for newer plans and products. As a result, this allows batch manufacturing to be changed or modified according to business needs.

- It is more economical to produce a complete batch rather than a single product, as the machines can be used more effectively.

- It requires a low specialization of the employees, since they only know the process in which they work.

- Generally has lower capital costs.

Disadvantages

- If a prototype has an error, the rest of the same products will have that failure, since the machine replicates it exactly. This wastes valuable time and the loss of materials is costly.

- Smaller batches require more planning, scheduling and control over the process and data collection.

- Labor is required to move items from one stage of the batch process to another, in addition to the labor required for batch manufacturing.

- The production system is not very flexible, as it cannot adapt to customer demand.

- Raw materials and resources are not used optimally enough, because there are numerous stops waiting for the next batch.

Inactivity time

- The main disadvantage of batch production is that there is a period of downtime between individual batches, during which the machinery settings are changed. This brings productivity to a complete halt.

- The production equipment takes up a lot of space. When idle, this space is not being used to earn money.

- Reconfiguring the production system to produce something different results in downtime. In lean manufacturing parlance, these are resources that go to waste.

- If the product is constantly changed or modified throughout the process, it can also cost you some downtime.

- The downtime increases, and with it the production costs.

Examples

Industrial blowers, electric motors, tools, and book and packaging printing are generally done by batch system.

For some situations and products, batch production is the only realistic method. At a local sandwich shop, they make the cookies for each day by dropping pieces of dough on the cookie sheets and placing the flakes in an oven.

A day's supply of fresh cookies is available in batch form, in no time. In this case, baking in small batches makes sense, because small amounts of fresh produce are needed.

If a company sells large quantities of boxed cookies with a long shelf life, batching may not be the most efficient option.

Instead, a combination of batch and continuous process might be preferred: dough is mixed in batches, while cookies are formed, baked, and packaged in a continuous process.

Toyota case

Minimizing time wasted for setup and change is key to optimizing this production system.

Lean manufacturing methods recommend for this problem to complete as much of the changeover work as possible before downtime. This is called a one minute die change.

The goal is to minimize changeover time as much as possible, and then continue to look for ways to decrease it even more.

For example, with the Toyota production system, it took 12 hours to three days to change the metal stamping dies used to make car bodies.

This was reduced to just 90 minutes through the use of precision positioning equipment. That was a huge improvement, but they didn't stop there - further refinement of the process cut the changeover time to just ten minutes.

These metal stamping dies weigh several tons and require positioning within a tolerance of one millimeter. The turnaround time at Toyota could be reduced from three days to just ten minutes, greatly improving the efficiency of its batch production system.

References

1. Wikipedia, the free encyclopedia (2019). Batch production. Taken from: en.wikipedia.org.
2. Graphic Products (2019). Batch Production. Taken from: graphicproducts.com.
3. Lore Central (2019). Batch Production System Advantages and Disadvantages. Taken from: lorecentral.org.
4. Nikhita Bagga (2013). Batch Production. Get Revising. Taken from: getrevising.co.uk.
5. Mba Skool (2019). Batch Production. Taken from: mbaskool.com.
6. Knowledgiate (2017). Batch Production System. Taken from: knowledgiate.com.