4.3 Scales of Production

Essential idea:

The scale of production depends on the number of products required.

Nature and Aims of Design

Nature of Design

Decisions on scale of production are influenced by the volume or quantities required, types of materials used to make the products and the type of product being manufactured. There are also considerations of staffing, resources and finance. (1.15)

Aims

Aim 9: The growing phenomenon of mass customization brings consumers into the design process, allowing them to make choices that make a product unique, to make it their own. Companies have developed “design stations” in their retail stores where consumers can create virtual 3D models, “try them out” using digital technology and place their order.


Guidance

As DP Design Technology student you should:

Guidance:

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Summary

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생산 규모는 필요한 제품의 수에 따라 달라집니다. 이는 디자인의 성격과 목표에 영향을 받습니다. 생산 규모를 결정할 때는 필요한 양이나 수량, 사용되는 재료의 종류, 그리고 제조되는 제품의 유형을 고려해야 합니다. 또한 직원, 자원, 재정 등도 고려해야 합니다. 대량 맞춤화의 증가 현상은 소비자를 디자인 과정에 참여시켜 제품을 독특하게 만들고 자신의 것으로 만들 수 있게 합니다. 기업들은 소비자가 가상 3D 모델을 만들고 디지털 기술을 사용하여 "시험해보고" 주문할 수 있는 "디자인 스테이션"을 소매점에 개발했습니다.


적절한 생산 규모를 선택하는 것이 중요합니다. 각각의 생산 규모는 장단점이 있으며, 생산 과정에 최적화된 다른 규모가 있습니다. 일회성 생산은 하나 또는 몇 개의 제품만 생산되는 방식입니다. 이는 고객의 구체적인 요구와 사양에 맞게 이루어집니다. 일회성 생산은 특수한 기술과 도구 세트, 그리고 시간이 필요하며 높은 비용으로 반영됩니다. 개발도상국에서는 지역 경제를 위해 일회성 생산이 중요한 역할을 합니다.


일괄 생산은 특정 수량의 제품을 제조하는 방식입니다. 각 단계에서는 특수한 기계, 공정 및 작업자의 조합이 필요합니다. 일괄 생산은 낮은 단위 비용과 시장 수요와 계절적 생산에 대한 조정이 가능한 장점이 있지만, 제품을 저장해야 하므로 비용이 추가될 수 있습니다. 대량 생산은 매우 큰 규모로 생산하는 방식입니다. 이는 재설계가 거의 필요하지 않은 매우 큰 수량의 제품을 생산합니다. 대량 생산은 노동 비용이 낮은 지역에서 주로 이루어지며, 초기 투자 및 특수 장비로 인해 맞춤화가 거의 불가능합니다.


BMW 7 Series 자동차의 대량 생산은 연속 흐름 제조 방식을 사용합니다. 이는 자동화된 로봇 생산 기술을 활용하여 24시간 내내 생산을 지속하는 고도로 자동화된 과정입니다. 이 방식은 단위당 가장 낮은 비용과 높은 기계화 및 자동화 공정을 갖고 있지만, 유연하지 않은 생산 라인과 매우 높은 초기 투자 비용이라는 단점도 있습니다. 대량 맞춤화는 대량 생산 방법을 사용하여 맞춤형 제품을 제공하는 것을 목표로 합니다. 이를 위해 소비자의 요구와 선호에 맞춤화되며, 단축된 제품 개발 주기와 높은 반응성을 갖고 있습니다. 하지만 단축된 제품 수명 주기와 통합 시스템에 의존해야 한다는 단점도 있습니다.


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生产规模是根据所需产品的数量来确定的。它受到许多因素的影响，包括所需的容量、材料类型和正在制造的产品类型。此外，人员配备、资源和财务等因素也需要考虑进去。作为一名DP设计技术学生，你应该了解一次性生产、批量生产和连续流程之间的区别，并选择适当的生产规模。


一次性生产通常根据客户的具体需求和规格进行，但由于需要高度专业化的技能和工具，以及时间成本较高，所以生产成本也相对较高。然而，在发展中国家，一次性生产在当地经济中起着重要作用，因为它利用当地的材料、手工艺人和资源为当地社区创造产品。在高端手工艺品领域，消费者期望物品是独一无二的，因此愿意支付更高的价格。


批量生产是制造一定数量的物品，通常需要协作的设计师、工程师和专家团队。它可以实现一定程度的定制，并且可以调整和响应市场需求和季节性生产。与一次性生产相比，批量生产的单位成本较低，但需要存储商品，增加了成本。


大规模生产是非常大规模的生产，通常适用于需要大量数量且不需要重新设计的产品。它的优点在于高产率和低劳动力成本，但由于高初投资和专用设备，几乎无法进行定制。此外，分销和运输也会增加最终成本，并对碳足迹产生影响。


宝马7系汽车的生产采用连续流水线制造，这是一种高度自动化的过程，可以实现24小时/7天的持续生产。连续流水线具有单位成本最低、高度机械化和自动化的工艺流程等优点，但由于高度专业化的设备和工作流程，生产线不够灵活。


大规模定制旨在使用大规模生产方法交付定制产品。它允许消费者选择设计的各个方面，并使用计算机辅助制造系统生产定制产品。大规模定制能够根据用户需求和要求进行高度定制，并将消费者整合到价值链中。然而，它也面临着产品寿命周期短和依赖于集成系统的挑战。


总之，生产规模的选择取决于产品的需求和特点。一次性生产适用于个性化需求较高的产品，批量生产适用于一定数量的定制和调整，而大规模生产适用于需要大量数量且不需要重新设计的产品。连续流水线和大规模定制则是在大规模生产中的两种不同方法。学生们应该了解这些不同的生产规模，并根据具体情况选择适当的方法。


The scale of production refers to the volume or quantity that a product will be produced at. The scale of production plays a role in the type of production process used, as different processes are optimized for different scales.

Economies of scale

Designers and companies will select a manufacturing scale depending on the size of the market.  Economy of scale refers to the increased cost savings associated with higher production runs. But larger, more complex and efficient manufacturing processes require a greater initial investment in equipment and labor needed to produce larger quantities.

One-Off Production

One-off production is what its name represents. Only one or very few items are produced. This type of production is usually made to very specific needs and specifications by a client. Typically, this type of production requires a set of highly specialized skills and tools, and time, which is often reflected in a higher cost. It is common for a one-off design to be designed and manufactured by the same person. 

In developing countries, one-off production is an important role in the local economy as it utilizes local materials, craftspeople, and resources to create products for the local community.

In high-end crafts such as jewelry or metal working, consumers expect the item to be a one-off, and as such are willing to pay a higher price.

Advantages

Disadvantages


EVA suits for astronauts are highly specialized and designed for individual astronauts
Prosthetic limbs are often designed for the individual, with associated high costs. This barrier to entry has inspired many designers to innovate by developing low cost, high performing prosthetic limbs. 
High performance racing yachts, like this Oracle yacht that competes in the AC35, are made from specialized materials for a specific purpose.

Batch Production

Batch production refers to a set number of the item be manufactured. Batch production process are typically broken down into discrete steps, with each subsequent step dependent on the previous one. Each step would involve a combination of specialized machines, processes, and workers. 

Because the processes need to be integrated, batch production is often dependent on a team of designers, engineers, and specialist to collaborate. 

Advantages

Disadvantages

These Prusa 3D printers print the parts for the other 3D printers. This is an interesting combination of batch and continuous production. The printing system is highly customizable, and their autonomous nature allows for 24/7 production.
Seasonal or products with short lifespans, like bread, are often produced in batches.

Mass Production

Mass production is production at very large scale. Typically these are products that are needed in very large quantities that require little redesign. A major consideration with this type of production method is labor costs —mass produced items are typically produced in regions with low labor costs. Because mass produced items may be made far away from their intended market, the transportation and distribution of the products can add to the final costs as well as contribute to the carbon footprint (See LCA and Carbon Footprint)

Advantages

Disadvantages

Mass production of the BMW 7 Series automobile 

The opening scene from Edward Burtynsky's documentary Manufactured Landscapes captures the physical scale and human  aspect of mass production.

Continuous Flow

Continuous Flow Manufacturing is similar to mass production in that involves the large-scale production of goods. However its key difference is that it is a highly automated process that leverages automated and robotic production technologies to keep production going 24 hours a day/7 days a week. The automation reduces the labor costs and maximizes the production efficiency.

Advantages

Disadvantages

Comparison of batch production to continuous flow production.
Continuous flow production is ideal for products like soft drinks, which need to be produced in huge quantities of identical products. When integrated with a Just-In-Time (JIT) production systems, the cost associated with storage and distribution of the product is minimized.

Mass Customization

Mass customization aims to deliver a customized product using mass production methods. Such systems typically allow the consumer to select aspects of the design, such as color, texture, and certain elements. The customized product is then produced using Computer Aided Manufacturing (CAM) systems.



Advantages

Disadvantages

Nike By You provides a service whereby users can customize their shoe color, materials, and components.