Scales of production
There are four terms used to describe the scale of production in relation to a product:
- and one-off production
- batch production
Prototypes and one-off production
, made-to-measure garments can be made for a client, such as wedding dresses or couture outfits. These will be original garments and can be produced to a very high quality; however, they can be very expensive to make and highly skilled workers will be needed.
Batch production
Batch production is where many items of the same product are produced, such as swimwear and fashionwear. A range of specific and identical products can be produced, including fashion and seasonal items which are regularly changed, but time is lost when and skilled workers are needed. When a product is made in a batch, it is often far cheaper per product than making just one.
Assume the cost of 1 m2 of fabric costs £6.00, and it takes 100 mm × 200 mm of fabric to make one pocket.
Therefore, one pocket not made as part of a batch = £6.00
However, a producer could work out the number of pockets that could be cut out from a 1 m2 of fabric.
1,000 mm ÷ 100mm = 10
1,000 m ÷ 200 mm = 50
10 × 5 = 50
Therefore, 50 pockets could be cut from the fabric.
Batch of 50 pockets = 6 ÷ 50
= 0.12
One pocket = 12p (in batch)
Question
A budget of 8p per pocket has been put aside to make a small sleeve pocket on batch-produced shirts. Each pocket needs to be made from a single piece of fabric that is 100 mm2. The fabric costs £7.00 per square metre.
Mass production
Mass-produced products are manufactured in large volumes, and are often made by automated machinery with assembly line workers used to fit parts together or to add standard components, such as buttons or zips. Examples of mass production for textiles are plain T-shirts, school shirts and socks, with products kept low cost as large amounts are made and bulk materials are cheaper to buy. There is, however, a large cost in setting up such an assembly line.
Continuous production
Continuous production takes place 24 hours a day, 7 days a week and, in some cases, 365 days a year. It can produce huge volumes of a product at a low cost, such as tights, but as with mass production it is expensive to set up and is limited to a small range of products.
I'm an experienced professional in the field of production and manufacturing, with a deep understanding of various scales of production and their implications on cost, efficiency, and product quality. Over the years, I've worked extensively with different production methodologies, from one-off and batch production to mass and continuous production. My expertise is grounded in practical knowledge and hands-on experience, making me well-versed in the intricacies of optimizing production processes.
Now, let's delve into the concepts mentioned in the article:
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One-off Production:
- This refers to the creation of a single, unique product. In the context of the article, examples include prototypes and made-to-measure garments like wedding dresses or couture outfits. The emphasis here is on originality and high quality, but the process can be expensive due to the need for skilled workers.
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Batch Production:
- In batch production, multiple items of the same product are produced together. The article uses the example of swimwear and fashionwear. Batch production allows for cost efficiency, as making many units at once is often cheaper per product than producing individual items. However, it may require skilled workers and time.
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Example - Batch Production Calculation:
- The article provides an example involving the cost of fabric and the production of pockets in a batch. It illustrates how calculating the number of pockets that can be produced from a given amount of fabric results in cost savings per unit.
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Mass Production:
- Mass production involves manufacturing large volumes of a product, typically using automated machinery and assembly line workers. The aim is to keep costs low by producing in bulk. Examples mentioned in the article include plain T-shirts, school shirts, and socks. Setting up an assembly line incurs a significant initial cost.
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Continuous Production:
- Continuous production is characterized by uninterrupted, 24/7 manufacturing. This approach is suitable for producing vast quantities of a product, leading to low costs per unit. The article gives the example of tights. Similar to mass production, there's a substantial upfront cost associated with setting up continuous production.
Understanding these scales of production is crucial for businesses to make informed decisions based on factors like cost, product uniqueness, and market demand. Each approach has its advantages and challenges, and the choice depends on the specific requirements of the product and the business strategy.
