Have you ever heard the old adage 'one step at a time'? Well, that's exactly what flow production is all about. It is one of the most common and efficient production management techniques used by companies. Let's discuss what flow production is and how it works.
Flow production definition
Flow production, also known as continuous production, is an important method for organising production of a given product.
Flow production is defined as a continuous and uninterrupted production method. The process of flow production connects a series of workstations into an assembly line. The goal of flow production is to increase productivity, reduce costs and minimize waste. It is usually adapted in mass production of products like cars, electronic goods, or clothes.
Unlike job production and Just-In-Time production, which only produce the items once an order is made, flow production is adopted for mass-market products such as cars, doughnuts, chocolate bars, soft drinks, and electric goods. These products can be produced all year round since there is an ongoing demand for them.
Characteristics of flow production
Most big brands use flow production to quickly produce a large number of similar products whose demand is continuous and ongoing.
For example, clothing is a mass-market product with continuous demand from customers. Fashion retailers around the world such as H&M and Zara apply flow production to produce clothes in large quantities and keep up with demand.
The ‘flow’ in flow production means that items will move continuously during the production process. One task is quickly followed by the next. As a result, the amount of time to finish each task is often the same.
In a factory, there are machines in close proximity that process an item from one stage to the next. This is also referred to as an assembly line, or a series of workers or machines that manufacture a succession of similar goods.
The assembly line of a chocolate manufacturer consists of a mixer, a refiner, a concher, a melter, moulds, and a packing machine (see Figure 1). After being processed by each machine, a chocolate bar is ready for distribution and consumption.
Figure 1. Chocolate assembly line, StudySmarter
Flow production advantages and disadvantages
Flow production is used for mass-producing goods. It is useful for creating a continuous flow of identical products. It is important to note, however, that flow production comes with both advantages and disadvantages.
ADVANTAGES OF FLOW PRODUCTION | DISADVANTAGES OF FLOW PRODUCTION |
- Short lead time
- Low level of inventory
- Economies of scale
- Structured material flow
- Short transportation distances
- Cheaper ordering costs
| - Special machines
- High set-up costs
- Danger of stoppage
- High maintenance costs
- Repetitive work
- Demotivated workers
|
Table 1 - Advantages and disadvantages of flow production
Advantages of flow production
Flow production comes with many benefits, including:
Short lead-time: Lead time is the time between the start of a process and its completion. Flow production reduces the lead time, as items move along a continuous flow of automated machines. A short lead-time means that the product can be delivered more quickly, which improves customer satisfaction.
Disadvantages of flow production
Flow production is not without its disadvantages. Here are some minus points for adopting flow production:
Special machines - Machines in flow production are expensive and perform only one function. Thus, it is difficult to replace them if something breaks down.
High set-up costs - There's a high cost for setting up special machines or installing a new production program.
The danger of stoppage - If one station breaks down, the whole assembly line will stop as well.
High maintenance costs - Big, bulky machines require regular maintenance.
Repetitive work - Factory workers may feel demotivated doing the same work every day.
Example of flow production
Zara is one of the world's largest clothing retailers. Its apparel and accessories are mainly produced by factory workers in developing economies.
Zara's factories are linked to underground tunnels with high-speed monorails where the fabric is cut, sorted, then assembled into clothing items. The finished products are then shipped to stores for distribution (see Figure 3).
Figure 2. The continuous flow of clothes production in a factory, StudySmarter
The flow production process at Zara is highly successful, as the brand is able to launch a new design every two weeks. In fact, Zara is often viewed as a supply chain icon in the clothes retailing industry.
The advantage of flow production in Zara:
Flow production allows Zara to produce its products quickly at a very low cost. This also reduces the price and makes Zara's clothing items more competitive in the market.
The disadvantage of flow production in Zara:
To achieve a large volume of clothes at the least cost possible, Zara's workers are forced to work very long hours in an unsafe environment for a very low wage. Due to mass production, Zara's clothes only have average quality. Not many of them can last for a long time.
Flow production is an effective production method that helps companies save time, money, and effort in producing a high volume of goods. However, it also incurs a lot of cost in the initial stage and requires regular maintenance.
Flow production - Key takeaways
- Flow production is defined as a continuous and uninterrupted method of production. The process of flow production connects a series of workstations into an assembly line.
- Examples of products made by flow production include: cars, clothes, food products, or electronic goods.
- Flow production is continuous and is often adapted in mass production
- The main advantage of flow production is that it can save time, money, and effort in producing mass-market products.
- The main disadvantage comes from high initial costs and maintenance.
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