What is a manufacturing process? Advantages and disadvantages of manufacturing by process

Manufacturing is the process of creating a finished product from raw materials or ingredients. This action is done by using machines, human labor and other tools, where some manufacturing operations require chemical processes. There are various methods of production systems that are associated with the production of final goods. Process is one of the main methods of production.
 

A manufacturing process is a method of producing a finished product by combining ingredients and raw materials into a specific formula. The manufacturing process is carried out under specific conditions of temperature and pressure to achieve the final product. Processing, baking, pressurization, pasteurization and chemical catalysis are some of the common actions carried out to combine the ingredients used for manufacturing.

Goods produced by manufacturing processes are carried out in batches. The intermediate units of material or products are transferred from one process step to the next in a continuous flow process. Each processing step is carried out in several stages so that when the process reaches its final form, it cannot be broken down into its components.

Manufacturing industries need to monitor the processing parameters and testing is done in batches or at specific intervals based on the volume or mass in a continuous flow process. And all the requirements need to be recorded on paper.

 

By now, you must have understood in detail what a process manufacturing is and even got some idea about its features. Now, let us see the key features used in the process manufacturing method.

- Continuous Manufacturing:

The process manufacturing includes batch manufacturing, where all the manufacturing steps are carried out in different stages. All these stages are performed to maintain continuity while taking a short break from one stage to another. This process is continued until the final product is achieved which cannot be divided into smaller segments.

- Complex supply chain:

Process manufacturing industries focus their operations on specific formulas, master formulas and master batches which are tracked through master batch records (MBRs). This process is very important and challenging in testing and tracking raw materials compared to individual production operations. Therefore, manufacturing operations management solutions, especially manufacturing execution systems (MES), are used to track operational parameters.

- High volume production:

As we discussed above, process manufacturing using batch systems consumes less time in production. The manufacturing process also includes mixing and blending processes using various ingredients that are determined by their properties and increase the efficiency and capacity of production planning.

- High degree of automation:

It is not possible to monitor the manufacturing process by manual monitoring and tasting as several parameters need to be measured. Therefore, industries use a high degree of automation through process manufacturing software to obtain accurate data on the ongoing operations.

- Stringent quality control measures

The last feature is the stringent quality control measures that some specialized chemical industries also engage in. The manufacturing process also followed by tire and battery manufacturers includes both batch and batch manufacturing processes and applies stringent quality control measures.

 

In general, the manufacturing setup process follows a similar sequence of events. These events are:

- Product Envision

First, the manufacturer will narrow down the product they want to produce. This involves having a general idea of ​​the product. It is not necessary to have the exact features of the product in mind at this stage.

- Product Research

Product research begins when the manufacturer has a basic idea of ​​the product. The product features may be listed during this stage. Manufacturers also look for competing products and analyze market demand. A business plan helps outline the production volume and scale-up strategy. Various product materials are shortlisted at this stage.

- Product Design

The product is realized in technical graphic designs. The designs will take into account the dimensions of each product feature. It also finalizes the product material and any other queries for the product. The product then moves to the prototyping stage.

- Prototype testing

`Prototype testing involves creating models of the product. Ideally, the models are as close to the product as possible. The prototype gives the manufacturer an idea of ​​what the product will look like. Any major issues with the product are fixed at this stage.

- Product Production

A limited production run of the product begins once the prototyping phase is over. These production units are intended for end customers. Manufacturers collect feedback from customers about their experience with the product.

- Feedback Loop

The feedback from customers is incorporated into the product. The updated part is then produced with the new changes. Customers can also provide feedback on the new changes. The feedback loop continues for several iterations until the product is perfected.

- Final Release

The final product is officially released to the mass market. In this stage, there is no limit to the quantity of production. Production is carried out in quantities that can meet the demand of the customers.
 

Different types of manufacturing processes in the manufacturing industry are used to convert raw materials into finished products. Below we have identified some of the processes used in the manufacturing industry.
 

This is a basic manufacturing method designed to produce the same type of product on an assembly line. These types of processes follow a repetitive manufacturing process, ensuring a 24/7 production rate. It has minimal setup requirements and one can easily change the speed of operation according to the needs and requirements of the customers.

Companies that manufacture electronics, automobiles or other durable goods like refractive lenses have used repetitive manufacturing processes. This is an ideal method for manufacturing because of its high production capacity in a shorter time while meeting consumer demand. It is often used for high-volume process manufacturing and is even automated with robots and software.
 

Shopfloor manufacturing involves the use of production areas such as workstations and workshops instead of assembly lines. Instead of mass production, each worker contributes a certain part to the product and passes it to another station until the product is completed. This type of manufacturing is slower than other methods and is used in custom manufacturing to create high-quality products.

Because of its flexibility and the need for less machinery, this manufacturing method is widely used by small and medium-sized businesses such as custom shoemakers, commercial printers, etc. But this type of manufacturing process is not used by larger industries. This process is also used in the aerospace and aviation industry to produce high-tech fighter jets and missiles.
 

Mass production involves various stages that are either done manually or can be automated using robots and machines. So we can say that it is a combination of repetitive production and shop floor production. All the production processes are assigned to production where the raw materials are processed and set aside unless the next step is performed.

This type of production is commonly used in the food and beverage industry where food ingredients are compressed and stored for a long time. These stored foods are further processed to create the final product and this cycle continues 24/7. This process is also used in the packaging of food products or other products that are at risk of spoilage when exposed to air.
 

Continuous manufacturing is very similar to batch manufacturing and is also a repetitive process. Like repetitive manufacturing, continuous manufacturing also operates 24/7 and produces similar products. With a slight variation in continuous manufacturing, raw materials and ingredients are combined into a recipe that is usually gas, liquid, powder, and slurry.
 

Process manufacturing comes with various perks that help boost production and efficiency. Here are some of the key benefits of process manufacturing.

- Cost Effectiveness

Instead of crafting products by hand or creating complex individual products that require many separate components, process manufacturers seek to create goods in large quantities that can be produced without much human labor. A well-run production line will result in lower labor costs, higher efficiency, and improved profit margins.

- Easy Cost Allocation

One of the most important advantages of process manufacturing systems is that they allow for streamlined management of every aspect of the production line. This allows businesses to direct their resources at the right time, when needed.

Additionally, viewing each step as a vertical process makes it easier for managers to determine how to make adjustments when required and collect data from multiple points in the process to influence their decisions.

- Improve communication and employee morale

When your company’s production goals and processes are transparent, your team knows what they need to do and supervisors can evaluate their performance accordingly. Smooth communication methods also allow employees to provide regular feedback, allowing managers and engineers to make the production process more efficient, improving employee motivation and keeping everyone focused on the goal.

- Improve safety

Like quality, process manufacturing ERP solutions include a number of safety modules to reduce industrial accidents and injuries. Such solutions can also help you complete safety inspections, comply with safety standards, and provide a clear overview of high-risk areas to maintain a safe work environment. Keeping your employees safe while meeting production goals is important.
 

While process manufacturing has various advantages, it also has some disadvantages. Here are some of the disadvantages of process manufacturing.

- Limited Creativity and Customization

With a high level of automation and standardized processing, process manufacturing technology stifles creativity. Flexible manufacturing standards allow your employees to use creativity to cater to specific market segments.

In contrast, process manufacturing relies on a single formula for all products. If your company needs to create complex or unique products for each customer, a single formula is unlikely to yield satisfactory results.

- High Capital Investment

Many process manufacturers are attracted to the cost-cutting advantages of incorporating automation and technology into their manufacturing facilities. While these benefits can result in cost savings and ultimately increased profits, there can be costly upfront costs.

It is important to carefully evaluate the long-term benefits of incorporating different forms of technology into your process manufacturing facility to determine whether the initial cost is worth it.
 

1 - Process Manufacturing:
 

2 - Discrete Manufacturing:
 

 

 

Knowing the manufacturing process by defining it and its benefits is just one part of the bigger picture. Exploring the different industries that use it and giving examples of how it is applied can broaden our understanding. Let’s look at some examples of manufacturing processes in some major industries:
 

The manufacturing process is used in the pharmaceutical industry for both over-the-counter and prescription drugs. These require a high level of quality control management to closely monitor the complex formulation. It is also highly regulated by the government, which requires further quality control. Operations may include mixing, granulation, milling, coating, tableting, filling, and others.
 

The food and beverage industry also uses manufacturing processes as well as packaging companies that allow for the distribution of food and beverages. You can find its uses in dairy and meat products, commercial baked goods, sauces, alcoholic beverages, and juices, among others. Manufacturing processes focus on formula development and maintenance. But there are also production systems and the use of quality control management required to meet health regulations.
 

The chemical industry, often grouped together with tires and processes and abbreviated as CTP, makes up a large portion of manufacturing. This industry uses manufacturing processes to convert raw materials into finished products and intermediates. The chemical industry will also incorporate batch manufacturing. That is, the output of a refinery can be sent directly to a chemical plant, a petrochemical facility, or used as a raw material in the production of tires.
 

The cosmetics and personal care industry is highly competitive and relies on extensive research and innovation to develop new products. The industry produces end products such as sunscreens, beauty creams, toothpastes, and hair products.

Like other process manufacturers, cosmetics manufacturers need to have mechanisms in place to ensure quality, comply with regulations, track shipments, and create formulations and formulas that meet consumer expectations.
 

The manufacturing process plays a key role in improving operational efficiency, improving product quality, reducing costs, ensuring worker safety and environmental sanitation, and helping businesses increase their competitiveness in the industry. Enterprises need to invest in building and perfecting production processes to gain competitive advantage and sustainable development.