What is Process Manufacturing?

Process manufacturing refers to the processing of objects through uninterrupted production equipment, through a series of processing equipment to make chemical or physical changes in raw materials, and finally get the product.

Process manufacturing

Right!

Process manufacturing refers to the processing of objects through uninterrupted production equipment, through a series of processing equipment to make chemical or physical changes in raw materials, and finally get the product.

Chinese name

Process manufacturing includes two types of repetitive manufacturing and continuous manufacturing. Repeated production is also called mass production. It has many similarities with continuous production, the only difference is whether the products produced can be separated. Reproduced products can usually be separated one by one.

Process-based manufacturing refers to the processing of objects through uninterrupted production equipment, through a series of processing equipment to make chemical or physical changes in raw materials, and finally to obtain products. Due to the strong variability of materials in process manufacturing and the many constraints on process flow, it has caused significant differences in production and logistics management from discrete industries. It is different from the discrete manufacturing enterprises. It has unique requirements for "process manufacturing", the management of production processes with attached products and joint products, and the management of inventory. It is significantly different from the discrete manufacturing enterprises.

Process Manufacturing Manufacturing Enterprise

A. Production plan

a) The plan is simple to formulate, and is often issued in the form of daily output, and the plan is relatively stable;

b) The capacity of production equipment is fixed.

B. Production process control

a) The process is fixed, and the work center is arranged in accordance with the process route. The time through the work centers is nearly the same;

b) work centers are specialized in producing limited similar products, tools and equipment are designed for specialized products;

c) The materials are driven from one work point to another by some machines, and there are some work in process inventory;

d) The production process mainly focuses on the control of the quantity, quality and process parameters of the materials;

e) because the workflow is automatic, implementation and control are relatively simple;

f) Production picking is usually carried out by backflushing.

Continuous Manufacturing Enterprise

1) The formulation management requirements are very high, such as the security and confidentiality of the formulation;

2) The quality of the product needs to be tracked, often from finished products to semi-finished products, suppliers, etc., so the batch management requirements are high;

3) Some products often have a shelf life;

4) Co-products, by-products, and grades often appear in the production process.

Process Manufacturing Process Decomposition Analysis

The process production process is decomposed as follows: the process of producing and processing materials is decomposed into various logical stages, and the size and thickness of each stage are determined by specific conditions (such as measurement and statistical methods, management methods, material changes, resource inputs, etc.) and set. Each stage has more than one recipe. The recipe consists of the input and output of resources (materials, labor, machinery, and miscellaneous expenses, etc.) and constraints (such as quality control, process index control).

Simple or complex production processes can be formed by connecting the various process stages in series or in parallel according to the production processing order. Each stage can have multiple outputs and inputs.

The input of materials in each stage can be from inventory, it can also be provided from the output of the previous stage, and it can also be the recycled processing material returned by the downstream stage. And the output of each stage can be to the inventory, can also provide raw materials for the next stage, can also be sold directly, and may have losses, waste and by-products. The various stages required by the enterprise according to product selection are combined to form a production specification. For example, the production specification of product A in the figure above consists of three stages, and the second stage also produces by-products. After the production process network is established, according to the actual situation on the site, define the input and output and constraints of the resources for each formula, and define the time rate required for each production stage. For multiple outputs, they are called co-products. The average method, the method of controlling one of the products, the weighted average method or the maximum and minimum batch method are used to determine the relationship between co-products, that is, the quantity and cost relationship between them is determined.

What needs to be explained here is that a stage can be used by multiple recipes and production specifications, but each stage in a production specification can only be used once. A production specification defines a manufacturing process to produce one or more finished, semi-finished, or by-products. After the various formulas at each stage are defined, the raw materials required by various products, the operating time of machinery and equipment, operating personnel, miscellaneous expenses, and auxiliary materials (such as chemical catalysts, fermentation agents for wine making, etc.) are automatically calculated and removed. Data other than personnel. Provide the order basis for the purchase of production preparation materials (while checking the inventory), and the calculated cost can also be used as the standard cost. When multiple products need to use the same machine at the same time, provide production scheduling for production managers according to job requirements.

The characteristics of materials in process production are very important, such as danger, volatility, service life, sanitary quarantine, stability of ingredients, preparation time, etc., so that materials must be fully considered in production scheduling, procurement, storage layout, and material distribution. characteristic. In order to maintain continuous production it is also necessary to consider the amount of safety stock. Due to the volatility of the material composition and the instability of the production process, compensation plans need to be considered. This is the dynamic formulation.

According to the actual situation, the elements of the basic framework of production management are well established. For large-scale enterprises, the relationship between divisions, factories, production lines, and operation control areas must be set up for effective management. At this time, each activity of the production process is closely related to procurement, warehouse, finance, sales, equipment status, and so on. For example, when a batch of materials is sent to the production line, the warehouse will issue a batch of suitable materials according to the production plan. The QC system will automatically indicate the production stages that this batch of materials will go through, and the inspections to be performed at each stage. At the same time an accounting Branches are automatically posted to the general ledger and so on. It is required to fully reflect the financial, supply and sales information on production.

Considering the market forecast, existing customer orders, and existing product inventory, etc., the master production schedule (MPS) is formulated, and the material demand plan is generated. The equipment capacity limit is added, and the equipment maintenance plan is fully compared. Short-term plans. At this point, the entire production management process has basically been opened up.

After the start of production, input the entire process, step-by-step resource input, material output, and inspection results at each point into the ERP system. This process can be performed manually or automatically by the system, depending on the specific conditions. In this way, the system records the status of the entire process in real time.