6 Types of Manufacturing Processes
Because manufacturing processes can be broken down into several different variants, we’ve created a comprehensive guide to the various definitions and will discuss how one may work for one business over another.
What is a Manufacturing Process?
A manufacturing process is a series of steps and techniques used to transform raw materials into finished goods. Multiple processes are available to suit the needs of various industries, each with its own established rules and procedures.
Six Types of Manufacturing Processes
Repetitive Manufacturing
Repetitive manufacturing is the ongoing production of goods in a short period of time. The goods created through a repetitive manufacturing process usually follow the same series of tasks repeatedly performed by the same employees or machinery.
Repetitive manufacturing is best used when manufacturers have a specific finish date they are shooting for or a specific production rate they want to hit. Setup is generally minimal and noninvasive to the production line–meaning it’s an extremely cost-efficient method of production that requires low skill levels.
This manufacturing process can help speed up production when a business has a steady stream of similar orders with little to no variance. However, since there isn’t much variance, all items will be affected if there’s a fault in production.
Discrete Manufacturing
Discrete manufacturing creates individual, distinct products by assembling separate parts. This process is suitable for manufacturers who produce a variety of items, such as clothing units in different colors and styles. Some examples of discrete manufacturing include vehicles, cell phones, computers, clothing, and more.
Items manufactured via a discrete manufacturing process rely on a bill of materials (BOM) and usually flow through an assembly line, linear, or routing way. The finished products can be highly complex with low volume (such as computers) or less complex with high volume (such as nuts and bolts).
Job Shop Manufacturing
Job shop manufacturing involves the creation of custom products or goods built to unique customer specifications on a per-job basis. Job shop manufacturing can also be known as made-to-order manufacturing and is a customer-demand-driven manufacturing modality.
Job shop production involves a custom/bespoke and is used to fulfill small to medium-sized orders. Generally, job shops will move on to different jobs once the current job is completed.
Rather than manufacturing on a large scale, job shops in the manufacturing industry will know well in advance what they will be making and how much they will be producing. One key challenge of job shop manufacturing is coordinating inventory levels and purchases to ensure the completion of the job, which puts added pressure on accurate estimates and quotes to determine ROI and labor requirements.
Batch Process Manufacturing
The batch production process moves raw materials through the production line in batches, meaning a set quantity is typically created per batch with a small break or pause in between.
Unlike discrete manufacturing, process manufacturing uses recipes and formulas to create products that can be assigned as individual units. The finished product usually cannot be broken back down to the original ingredients, typically because irreversible chemical reactions occur during manufacturing.
This manufacturing method tends to be flexible, can handle product variants, and calls for greater quality control. However, it does have higher work-in-progress inventory levels and high idle time during downtime due to machine changeovers.
Continuous Process Manufacturing
Continuous process manufacturing is a flow production method used to manufacture a final product without interruption. Similar to repetitive manufacturing (in the sense that it runs all the time), continuous manufacturing focuses on raw materials traditionally used in process manufacturing–which is the mixture of liquids, powders, or slurry.
The difference from batch process manufacturing is that the entire process goes through one movement in one location. Raw materials entering the starting point will be left as finished products further down the line.
Continuous process manufacturing is seen as a way to overcome the perceived inefficiencies of batch process manufacturing, which can include long hold times, supply chain disruptions, and low machine utilization (such as waiting for batches/steps to be completed before moving on). Examples of continuous manufacturing include food, pharmaceuticals, paper, pastes, and metal smelting.
Additive Manufacturing (3D Printing)
Additive manufacturing constructs three-dimensional (3D) objects using data from computer-aided design (CAD) software and/or 3D object scanners. By using hardware to deposit material or composites layer-by-layer, the manufacturing process constructs goods into precise geometric shapes controlled via a computer-controlled process.
Additive manufacturing software enables successful 3D printing jobs by helping prepare all work, optimizing designs, minimizing design to manufacturing lead times, and reducing the total cost of operations through minimal print time and material consumption. Managing an additive manufacturing process workflow via software can help a business oversee order turnaround time and maximize machine utilization rates.
Products made with additive manufacturing include smaller items such as apparel and jewelry and even larger items such as automobiles and houses.
