The continuous production system is a production flow method used to manufacture, produce or process materials without interruption. Continuous production is called a continuous flow process because the materials being processed, whether in dry or fluid bulk, are continuously in motion, undergo chemical reactions, or are subjected to mechanical or thermal treatment..
In a continuous production system, items are produced to have inventory and not to fulfill specific orders. No storage is necessary in the process, which in turn reduces material handling and transportation facilities.
Continuous production systems are those in which the facilities are standardized in terms of routing and production flow, since the inputs are standardized.
Thus, continuous production denotes the production of large quantities of a single or very few varieties of products with a standard set of processes and sequences. Generally, "continuous" means to operate 24 hours a day, seven days a week, with infrequent maintenance shutdowns.
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- The quantity of production is usually huge, and the goods are produced with respect to a forecast demand.
- Most of these industries are very capital intensive. Therefore, management is very concerned about the loss of operational time.
- The design, the conversion process and the sequence of operations of the product are standardized; that is, similar products are produced. These are in great demand throughout the year.
- Production machinery and equipment are adjusted according to the product design pattern.
- Standardized inputs and special purpose automatic machines are used to run standardized operations.
- Machine capabilities are balanced such that materials are received as input at one end of the process and the finished product is delivered at the other end..
- Rigid quality control is exercised.
Only one type of product or a maximum of two or three types is manufactured in large quantities, as there is not much emphasis on consumer orders.
The main characteristics of this system are the standardization of the product, process, materials and machine, and the uninterrupted flow of materials..
The mass production system offers economies of scale, since the volume of production is large. Product quality tends to be uniform and high due to standardization and mechanization.
This system is used for the manufacture of those articles whose demand is continuous and high. In this case, the unique raw material can be transformed into different types of products at different stages of the production process..
For example, the processing of crude oil in a refinery: kerosene, gasoline, etc. are obtained at different stages of production.
Two or more components are combined to make a finished product. Manufactured parts are assembled into subassemblies or into a final assembly.
It is particularly useful when a limited variety of similar products is produced on a massive scale or in fairly large batches, on a regular or continuous basis..
Each machine must directly receive the material from the previous machine and pass it directly to the next machine.
The main advantage is that the inventory of work in process is minimal. As the material processing is continuous and progressive, there is no waiting period.
- Few work instructions required and less storage space required.
- The quality of production remains uniform, because each stage develops its skill through repetition of work.
- As material handling costs are minimized, full use of automation can be made.
- Any delay at any stage is automatically detected. As a result, there is automatic time control and direct work content is reduced..
- The work in process is minimal due to the balance of the operational sequence.
- Material handling is reduced, due to the established pattern of the production line.
- Control over materials, costs and production is simplified. The repetitive nature of the processes facilitates the control of production.
- The overall cost per unit is reduced, due to the distribution of large fixed costs of specialized equipment in a large production volume. Waste is minimal.
- There is a quick return on capital employed.
The continuous production system is very rigid and if there is a failure in one operation, the whole process is affected. Due to the continuous flow, it is necessary to avoid the accumulation of work or any blockage in the line.
Unless the fault is cleared immediately, it will force the stopping of the before and after stages.
- Heavy losses during slack periods of demand.
- Rigid maintenance of machines.
- Customer tastes cannot be satisfied as only standard product is manufactured.
- Difficult to adapt to new situations and specifications.
- Special purpose machines and tools are required.
Examples are the petrochemical industry, sugar, fertilizers, petroleum refining, chemicals, pulp and paper, natural gas processing, sanitary wastewater treatment, glass, rotary kilns for calcining lime or cement..
A production line that washes, sorts and packs apples 24 hours a day when apples are in season.
A toy assembly line that adds components and parts to items in eight steps. There is always a toy at every step with toys continually flowing from one step to the next.
This process is used in the assembly of automobiles, radios, televisions, computers, and other electrical and electronic devices..
Steelmaking, which involves the continuous melting of raw materials by a blast furnace.
A production line that produces cereal boxes by adding twelve ingredients continuously in twelve steps. Customers can customize the cereal to request different formulations.
For example, one customer wants three ingredients in their cereal and another wants all twelve ingredients. The production line automatically produces the unique cereals based on the customer's detailed specifications.
A surfboard manufacturer produces ten styles of artless boards on a continuous production line. These are stored and then finished with art, to customer specifications.
For example, a hydroelectric dam, where electrical energy is produced continuously.
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