Products are diversified and several orders are handled simultaneously in different work centers, scheduling and follow-up becomes a difficult task.
Before issuing manufacturing orders, need for new raw materials and tools, overloading and under-loading of particular machines or work centers must be anticipated.
Dispatching has to be done efficiently to avoid delays and bottlenecks in the production process.
Continuous production is normally associated with large quantities of production and with a high rate of demand. Continuous production is justified when the rate of production can be sustained by the market.
Two types of continuous production can be â€“
(a) Mass production and
(b) Flow production.
In mass production, a large number of identical articles are produced, but in spite of advanced mechanization and tooling, the equipment need not be specially designed for the component to be manufactured.
In flow production, the plant and equipment and layout have been primarily designed to manufacture a particular product. A decision to switch over to a different kind of product needs basic changes in the equipments and the layout, especially when special purpose machines and complex material handling systems are used.
PPC in continuous production is usually far simpler than in a job or batch production. Extensive effort is required for detailed planning before production starts, but both scheduling and control need not be elaborate usually. The output is either limited by available capacity or regulated within given limits to conform to production targets, based on periodic sales forecasts.
PPC in the process industry is relatively simple. Routing is automatic and uniform. Standard processes and specialized equipments are used. As the products are standardized and goods are produced to stock and sell, scheduling is easy. Departmental schedules are derived from master production schedules. Dispatching involves issue of repetitive orders to ensure a steady flow of materials throughout the plant. The main task of PPC in process industry is o maintain a continuous and uniform flow of work at the pre-determined rate in order to utilize the plant and equipments fully and to complete the production in time.