Process Manufacturing
Encyclopedia
Process manufacturing is the branch of manufacturing that is associated with formulas and manufacturing recipes, and can be contrasted with discrete manufacturing
, which is concerned with bills of material and routing.
The simplest and easiest way to grasp the definition of process manufacturing is to recognize that, once an output is produced by this process, it cannot be distilled back to its basic components. In other words, "once you put it together, you cannot take it apart". A can of soda cannot be returned to its basic components such as carbonated water, citric acid
, potassium benzoate
, aspartame
, and other ingredients. Juice cannot be put back into an orange.A plastic card manufactured cannot be returned to its basic components like PVR sheets,transperent sheets. A car or computer, on the other hand, can be disassembled and its components, to a large extent, returned to stock. Process manufacturing is common in the food, beverage, chemical, pharmaceutical, consumer packaged goods, and biotechnology industries. In process manufacturing, the relevant factors are ingredients, not parts; formulas, not bill of materials; and bulk, not individual units. This is more than a subtle difference in terminology; the terms characterize distinct manufacturing approaches.
software cover is needed. Furthermore, conversion rules must be specified to account for the unique requirements of the business in question.
The proportions of ingredients in a formula also highlight the need for another feature, namely scalability. A formula to make 500 liters of a chemical must be scalable to make 250 liters or 1,000 liters. Another aspect of scalability is that it makes possible manufacturing based on how much of an ingredient is available. An example will illustrate this point. If you are making a car and only have two of the required four tires, you cannot make half a car. In other words, you must have all the parts in the required quantities to make the finished product; they are not scalable. But in process manufacturing, if you want to make 1,000 gallons of soda and you only have 500 gallons of the required 1,000 gallons of carbonated water, you have the option of making half as much soda. In process manufacturing you can make as much of a finished product as is specified in the formula for the smallest quantity in stock of one of the ingredients.
Why is this concept important? Compare how often Coca Cola changes the formula for Coke with how often the packaging is changed to announce a special promotion: it would be easier to keep track of the weather than promotions. If the formula and packaging recipes are linked, then every time the packaging changes, the formula would need modification. Likewise, when the formula is changed, all of the packaging recipes would have to be changed. This increases maintenance costs and chances for error. In process manufacturing, the formula for making the product and the recipe for packaging the product exist in separate structures to reduce the ongoing maintenance function.
In the production cycle, a work order is issued to make the product in bulk. Separate pack orders are issued to signify how the bulk material is to be containerized and shipped to the customer. This is important in process industries which make “brite” stock or private labels. For example, large grocery chains sell products, such as soups, soda, and meats, under their own brand names, hence "private labels". But these chains do not have their own manufacturing plants; they contract for these products. In the case of soups, process manufacturers create and warehouse nondescript, unlabeled (hence “brite”) aluminum cans of soup. (Since the cans are filled, sealed, and then cooked under pressure, their shelf life is long.)
By separating the product formula from a packaging recipe, a production order can be issued to make and store the cans of soup and later, when the customer is ready to order soup, a work order can be issued to label the cans according to customer specifications before they are shipped to the store. Thus segregation of the formula and pack recipe makes the world of process manufacturing efficient and effective.
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Discrete manufacturing
Discrete manufacturing varies from Process Manufacturing. In discrete manufacturing, the manufacturing floor works off orders to build something. Examples include toys, medical equipment, computers and cars. The resulting products are easily identifiable...
, which is concerned with bills of material and routing.
The simplest and easiest way to grasp the definition of process manufacturing is to recognize that, once an output is produced by this process, it cannot be distilled back to its basic components. In other words, "once you put it together, you cannot take it apart". A can of soda cannot be returned to its basic components such as carbonated water, citric acid
Citric acid
Citric acid is a weak organic acid. It is a natural preservative/conservative and is also used to add an acidic, or sour, taste to foods and soft drinks...
, potassium benzoate
Potassium benzoate
Potassium benzoate , the potassium salt of benzoic acid, is a food preservative that inhibits the growth of mold, yeast and some bacteria...
, aspartame
Aspartame
Aspartame is an artificial, non-saccharide sweetener used as a sugar substitute in some foods and beverages. In the European Union, it is codified as E951. Aspartame is a methyl ester of the aspartic acid/phenylalanine dipeptide. It was first sold under the brand name NutraSweet; since 2009 it...
, and other ingredients. Juice cannot be put back into an orange.A plastic card manufactured cannot be returned to its basic components like PVR sheets,transperent sheets. A car or computer, on the other hand, can be disassembled and its components, to a large extent, returned to stock. Process manufacturing is common in the food, beverage, chemical, pharmaceutical, consumer packaged goods, and biotechnology industries. In process manufacturing, the relevant factors are ingredients, not parts; formulas, not bill of materials; and bulk, not individual units. This is more than a subtle difference in terminology; the terms characterize distinct manufacturing approaches.
Some process manufacturing vertical markets
- Food and beverages
- Paints and coatings
- Specialty chemicals
- Bulk-drug pharmaceuticals
- Nutraceuticals
- Cosmeceuticals
- CTP SegmentChemicals, Tire, and Process Industries (CTP)Chemical, Tire, and Process Industry Segment is a critical component of the manufacturing space that processes raw materials into finished goods and intermediate products...
- Textiles
Formulation
Formulation is a fairly easy concept, but it is often incorrectly equated with a bill of materials. Formulation specifies the ingredients and the amounts (e.g., pounds, gallons, liters) needed to make the product. The first thing to recognize is that to be able to work with a formula, the units of measure must correspond; a flexible unit of measure conversion engine running under an ERPEnterprise resource planning
Enterprise resource planning systems integrate internal and external management information across an entire organization, embracing finance/accounting, manufacturing, sales and service, customer relationship management, etc. ERP systems automate this activity with an integrated software application...
software cover is needed. Furthermore, conversion rules must be specified to account for the unique requirements of the business in question.
The proportions of ingredients in a formula also highlight the need for another feature, namely scalability. A formula to make 500 liters of a chemical must be scalable to make 250 liters or 1,000 liters. Another aspect of scalability is that it makes possible manufacturing based on how much of an ingredient is available. An example will illustrate this point. If you are making a car and only have two of the required four tires, you cannot make half a car. In other words, you must have all the parts in the required quantities to make the finished product; they are not scalable. But in process manufacturing, if you want to make 1,000 gallons of soda and you only have 500 gallons of the required 1,000 gallons of carbonated water, you have the option of making half as much soda. In process manufacturing you can make as much of a finished product as is specified in the formula for the smallest quantity in stock of one of the ingredients.
Packaging
A packaging recipe is similar to a formula, but rather than describing the proportion of ingredients, it specifies how the finished product gets to its final assembly. A packaging recipe addresses such things as containers, labels, corrugated cartons, and shrink-wrapping. In process manufacturing, the finished product is usually produced in bulk, but is rarely delivered in bulk form to the customer. For example, the beverage manufacturer makes soda in batches of thousands of gallons. However, a consumer purchases soda in 12-ounce aluminum cans, or in 16-ounce plastic bottles, or in 1-liter bottles. And a restaurateur may have the option of getting a 5- or 50-gallon metal container with the beverage in syrup form, so that carbonated water can be added later.Why is this concept important? Compare how often Coca Cola changes the formula for Coke with how often the packaging is changed to announce a special promotion: it would be easier to keep track of the weather than promotions. If the formula and packaging recipes are linked, then every time the packaging changes, the formula would need modification. Likewise, when the formula is changed, all of the packaging recipes would have to be changed. This increases maintenance costs and chances for error. In process manufacturing, the formula for making the product and the recipe for packaging the product exist in separate structures to reduce the ongoing maintenance function.
In the production cycle, a work order is issued to make the product in bulk. Separate pack orders are issued to signify how the bulk material is to be containerized and shipped to the customer. This is important in process industries which make “brite” stock or private labels. For example, large grocery chains sell products, such as soups, soda, and meats, under their own brand names, hence "private labels". But these chains do not have their own manufacturing plants; they contract for these products. In the case of soups, process manufacturers create and warehouse nondescript, unlabeled (hence “brite”) aluminum cans of soup. (Since the cans are filled, sealed, and then cooked under pressure, their shelf life is long.)
By separating the product formula from a packaging recipe, a production order can be issued to make and store the cans of soup and later, when the customer is ready to order soup, a work order can be issued to label the cans according to customer specifications before they are shipped to the store. Thus segregation of the formula and pack recipe makes the world of process manufacturing efficient and effective.
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