5.1 Production Methods for Growing Businesses By Mrs Hilton
Lesson Objectives Candidates should be familiar with flow production and the how this can create efficient use of resources. Candidates should understand how specialisation and division of labour can impact on efficiency. Candidates should consider how production might be made more efficient by the use of lean production techniques, egJust In Time and the impact these might have on employees (such as training and motivation).
Starter • Tell me everything you know about flow production • Lets put this into a mindmap • http://www.text2mindmap.com/ • Give it extra legs so you can add more information
What do you notice About these pictures?
Video • http://www.bbc.co.uk/learningzone/clips/added-value-in-processed-food/12268.html • Corn Flakes • http://news.bbc.co.uk/1/hi/uk/7990080.stm • (Easter egg production) • http://news.bbc.co.uk/1/hi/business/7733602.stm • Frozen pizza
Questions • Automation? • Processes? • Staff specialisation? • Quality? • What can you add to your mindmap?
Theory • Continuous flow production is when many thousands of identical products are made. • The difference between this and mass production is that the production line is kept running 24 hours a day, seven days a week to maximise production and eliminate the extra costs of starting and stopping the production process. • The process is highly automated and few workers are required.
Theory – flow production Production is organised so that different operations can be carried out one after the other, in a continuous sequence. The main features are as follows: • large quantities are produced • a standardised product is made i.e all the same • semi-skilled workforce • large amounts of robotics, machinery and equipment (capital intensive) • large stocks of raw materials and component parts are required
Flow Production • Highly specialised machinery used • Continuous production • Mass produced goods • Factory set out in permanent assembly lines • Capital intensive
ADVANTAGES unit costs are reduced through economies of scale the process can be highly automated, many operations carried out by robots and other types of machinery Quality systems can be built into production DISADVANTAGES Set up costs are very high product is standardised worker motivation can be low breakdowns can prove costly as the whole production system may come to a halt. Supply may exceed demand Theory – Flow production
Try a question • Explain one advantages and one disadvantage to imber showers of using flow production • 6 marks
Answer • Level 2 – explain the advantage / dis 6-4 marks • Level 1 Identify an advantage / dis 2 marks • No valid response 0 • Level 1 response: • The work involved in flow production is repetitive and boring which is a disadvantage • Why is this level 1?
How to get full marks • Dis = 3 marks Ad = 3 marks • An advantage of flow production is that it is a very efficient way of making goods. It is cheaper to make each item using flow rather than batch or job. Also more machinery is used which once it has been bought is cheaper to run than having employees.
Words that score well • Specialisation • Bottleneck • High output • Low quality • Employees need to become experts • Cheaper • Similar products • Efficient
Words that get 0 • Fast • Better
Plenary • How is flow production an efficient use of resources?
Lean production • http://www.leansimulations.org/2012/09/more-lean-paper-airplanes-another-lean.html