Production Management Discrete Manufacturing vs.

Production Management

Discrete Manufacturing vs. Process Manufacturing

Piasecki (2003) defines discrete manufacturing as the manufacturing of distinct items such as pencils, light bulbs, telephones, and bicycles. Piasecki (2003) defines process manufacturing as a process where a product is transformed via mixing or chemical processes. Examples given of process manufacturing include refining crude oil, extracting metal ores, and combining materials to make paint products. Other common examples of process manufacturing include chemicals, food, cosmetics, and plastics. It is also important to note that many organizations will combine both types of manufacturing. For example, in drinks, cosmetics, and food, the first part of the process is likely to involve process manufacturing. The bulk product will then be packaged via a discrete manufacturing process.

The main disadvantage of discrete manufacturing is that there is typically a higher cost to producing individual products. This occurs because discrete manufacturing generally involves a production process involving many steps, with each of the steps needing to be carried out for each individual product. This creates a high demand on labor. Another disadvantage is that maintaining the quality of each individual product is more difficult than it is for process manufacturing. This occurs because it is generally impossible to test and ensure the quality of every product. For this reason, quality is general tested via sampling. While this helps to ensure an acceptable level of quality, it is not able to ensure the quality of every single item produced (Schermerhorn 1989). Another issue is related to the number of steps involved for the production of the final product. Brandimarte and Agostino (1995) notes that discrete manufacturing typically involves some kind of production line. This means that the product passes from one individual or department to another, with the final product of one department being the initial product for the next. This creates a requirement to effectively manage the production process to make use of all resources. This becomes especially important when problems occur and the product is not available to the next department as expected. This can create inefficiencies in the production process. The advantage of discrete manufacturing is that the process is often quite flexible. This means that a manufacturer can often handle both an increase in demand and a decrease in demand by adapting its output to suit. This includes that there is generally only a minor increase in the cost per unit if less items are produced. Another advantage is that any error in the production process that damages the product will typically only damage one or a few products.