Methods of Operation (Production) (Cambridge (CIE) A Level Business)

Capital Intensive Operations

• Capital-intensive production predominately uses machinery and technology in the production of goods and services

  • Large-scale production of standardised products is likely to be capital-intensive

  • Manufacturing in developed countries where labour costs are relatively high is likely to be capital-intensive

  • E.g. Vehicle manufacturers such as Ford use robots and other production technology to manufacture cars, with supervisors overseeing the quality of output
    
    

Evaluation of Capital Intensive Production

Labour Intensive Operations

• Labour-intensive production predominantly uses physical labour in the production of goods and services

  • The delivery of services is usually more labour-intensive than manufacturing

  • In countries where labour costs are low, such as Bangladesh and Vietnam, labour-intensive production is common

  • Small-scale production is likely to be labour-intensive

  • E.g. UK schools are labour-intensive operations as teachers plan and deliver lessons and provide pastoral support
    

Evaluation of Labour Intensive Production

An Introduction to Production Methods

• Production is the transformation of resources (e.g. raw materials components and processes) into finished goods or services

  • Goods are physical products, such as bicycles and T-shirts

  • Services are non-physical items such as hairdressing, tourism and manicures
      

Diagram: The four Production Methods

The type of production method used often depends on the nature of the product being made
  

• The method of production used by a business will depend upon a number of factors

  • The level of output required to be produced

  • The nature of the product

  • Whether the product is standardised or customised

  • The level of automation used in production

Job Production

• Job production is where products are made to meet the specific requirements of individual customers

  • Each item is produced separately (a job) and the production process is tailored to the unique specifications of the customer's order
    

• Examples of job production include

  • Furniture made to order, where customers can choose the design, dimensions, materials and finishes

  • Tailored clothing such as suits or wedding dresses where each garment is made to fit the specific measurements and preferences of the individual customer

  • High-end jewellery pieces, especially those with unique designs or personalised engravings

• Job production has the potential to add significant levels of added value and can therefore be very profitable

  • Specialised products made by skilled craftspeople can command high prices because they are unique and can be made to meet customer needs very precisely

  • This would arguably be lost if other methods of production were to be adopted

Characteristics of job Production

• Customisation

  • Each product is customised according to the customer's specific requirements, allowing for personalised goods or services to be created

• Low volume

  • Job production is typically used for unique or specialised products that are not produced in large quantities

• Variability

  • Since each product is made to order, there can be significant variation in the production process and materials used

• Skilled labour

  • Job production often requires skilled labour, such as craftsmen or technicians, as the manufacturing process may involve intricate tasks or specialised techniques

• Long lead times

  • Due to the customisation and individual production approach, job production usually has longer lead times compared to other production methods and the time required to fulfil each order can vary depending on its complexity and the availability of resources
     

An Evaluation of Job Production

Batch Production

• Batch production occurs when products are produced in groups or batches

  • A certain quantity of products is produced together before moving on to the next batch

  • Each batch goes through the entire production process, from raw materials to the finished product, before the next batch begins

  • Batches are usually of a standardised size and composition and follow a certain sequence of operations
     

Diagram: Goods made Using Batch Production 

Commonly used in industries such as pharmaceuticals, beauty products and food processing
 

• Batch production strikes a balance between customisation and cost-effectiveness, making it a suitable production method for industries that deal with diverse product ranges and varying customer needs
   

An Evaluation of Batch Production

Mass (Flow) Production

• Flow production occurs when a product is produced in a continuous sequence of operations on a production line

  • It involves the movement of materials or components through a series of workstations or machines with each workstation performing a specific task or operation

  • As a product moves along the production line it undergoes a series of operations, such as assembly, testing, packaging or quality control until it is completed
     

• This method is commonly used in industries that produce high volumes of standardised products such as automobiles and consumer electronics
  

Characteristics of flow Production 

• Division of labour

  • Different tasks are allocated to different workstations or machines, allowing workers to specialise in a specific task

• Standardisation

  • The manufacture of identical products helps to ensure consistency and the smooth flow of production

• Continuous movement

  • The product moves continuously from one workstation to another, minimising idle time and maximising productivity

• High volume

  • Flow production is suitable for high-volume manufacturing as it enables the efficient production of large quantities of identical or similar products

• Automation

  • Flow production often involves the use of machinery and automated equipment to perform repetitive tasks quickly and accurately
    

An Evaluation of Flow Production

Mass Customisation

• Mass production is usually achieved through flow production and involves the manufacture of large quantities of standardised products, resulting in low costs per unit compared to other methods of production
  

• Customisation is usually associated with job production or small-scale batch production, allowing customers to design products from scratch
   

• Mass customisation seeks to bridge this gap by offering flexibility with a range of customisable options within a standardised production process alongside the low unit costs typically associated with flow production

  • It uses technology, such as computer-aided design (CAD), flexible manufacturing systems and data analytics to efficiently accommodate customer preferences
    

A comparison of mass production, customisation and mass customisation
 

• The process of mass customisation typically involves three key stages
   

The Three Stages of Mass Customisation

An Evaluation of mass Customisation

• Mass customisation offers several advantages for both businesses and customers
  

  • Customers can obtain products that match their unique preferences and requirements and are likely to be highly satisfied, which leads to positive feedback and loyalty

  • Businesses can adapt to changing market demands effectively by offering a wide range of product variations without the expense of full customisation

  • Using standardised components and processes allows businesses to achieve economies of scale, reduce stock costs and improve overall production efficiency

  • Mass customisation can differentiate a business from competitors, attract new customers and create a perception of high value and innovation
    

• However, mass customisation

  • Usually requires heavy capital investment in technology

  • Tends to lead to higher variable costs than for standardised, mass produced items

Problems of Changing from one Method to Another

• A business may want to change its method of production for several reasons

  • It wants to achieve higher levels of output

  • It wants to increase quality

  • Labour costs have increased

  • Costs of running machinery, such as power, have increased
    

• However, it could face a range of challenges in making changes to its method of production

  • Increasing the scale of production is likely to require extensive capital investment in machinery, facilities for the storage of inventory and training of workers in new processes

    • Using loans to finance this investment will increase fixed costs and would likely increase the business's level of gearing, making it more difficult to borrow more finance in the future
      

  • Changing the method of production will place different demands on workers

    • Some workers' skills may no longer be required, leading to the need for redundancies

    • Others may be resistant to change, concerned about the impact on their day-to-day working life and experiences

    • Adjusting to roles that require lower levels of skill or creativity could demotivate workers, lowering their productivity
      

  • A business needs to ensure that increased demand can be sustained before making significant changes

    • Detailed market research and sales forecasting that firmly established future demand should be carried out

    • Outsourcing may be a more suitable solution in the short-term before capital is invested in non-current assets and staff development