What Is Batch Production in Manufacturing?

Companies use batch production for manufacturing similar – but not necessarily identical – products in large quantities. Although the products may be similar, manufacturers need batch scheduling to optimize operational efficiency.

In the batch method, manufacturing companies order machines sequentially based on the progression of the production process. Unlike mass or assembly production, where teams can’t easily make changes, this method enables teams to make modifications with ease.

Examples of Batch Production

This production method is standard among companies that want to manufacture products similar to others they produce on demand. Manufacturers use specialized equipment to facilitate this production process. Some of the most widely used machines in this production method are the following:

• Conveyors
• Robotic pick and place machines
• Robotic palletizing and packing machines

Manufacturers can customize their production processes to match the output they need. Engineers can create an automated system that meets even the most unique production needs.

Ideally, companies can produce a broad range of products using this method. Common items that manufacturers make using batch processes include these products:

• Pharmaceuticals
• Clothing
• Newspapers
• Books
• Baked food
• Fast foods
• Electronic devices and accessories

Batch Production vs. Job and Mass Production

Manufacturers differentiate the types of processes they use based on the volume of production, the types of products they produce, and the interchangeability of the machinery used to create their products. The most common processes are batch production, mass production, and job shop manufacturing.

Batch Production

Flexibility in large numbers characterizes this method. It involves products that are similar but not necessarily identical.

For example, a large bakery might manufacture a wide range of products, including yeast donuts, cake donuts, pies, cakes, rolls, and bread, in large quantities. Some of the ingredients in each product might be similar, such as flour and sugar. 

Other ingredients differ, such as the type of fruit used for pies. Many of the products use the same machines, but others require an additional machine, such as rollers for pie crusts or dough mixers capable of kneading bread mixtures.

Mass Production

Using the mass production method, manufacturers produce massive volumes of the same products using automated processes whenever possible. Whether automated or standardized, these processes repeat continuously to ensure that every item in its final form is identical to the others.

In addition to automation, this method utilizes specialized laborers, each performing the same steps along the assembly process. Mass-producing products is more cost-effective but less flexible than the other familiar methods. Typically, products undergoing mass production include processed foods, automobiles, textiles, toys, and electronic devices.

Job Shop and Custom Production

Job shop and custom production methods utilize separate workstations furnished with similar tools and machines to produce small batches of unique products. Each workstation performs distinct tasks within the process.

Because the products are unique – customized to customer specifications – the production workflow moves in separate directions. In a small furniture factory, for instance, one chair might first go to a carpenter’s station to create the frame and then to the upholsterer, who measures it for padding, and then back to the carpenter for finishing. Another chair might start at the carpenter’s station to create the frame, then proceed to the glue workstation for veneer application, and finally return to the carpenter for finishing.

Comparing Batch Production with Mass and Job Production: A Chart

Differences In	Batch Production	Mass Production	Job and Custom Production
Volume	Large numbers of products	Massive numbers of the same products	Small batches of mixed product types
Flexibility	Somewhat flexible	Inflexible	Flexible by design
Cost Efficiency	Medium production costs	Low production costs	High production costs
Setup Time	Flexibility requires longer setup times	Shorter setup times with continuous production processes	Long setup times due to frequent changes in machines and processes
Examples	Large bakeries, fast food, pharmaceuticals, designer apparel	Automobiles, processed foods, toys, some electronics	Musical instruments, fine furniture

When Is Batch Production the Right Choice? 

Business models that benefit the most from this production method include the following:

• Companies that produce items by blending raw materials following a recipe or formula
• Businesses that receive frequently repeated orders for single products, such as seasonal products
• Manufacturers who produce low volumes of one product at a time
• Companies that need to vary production by order size or product type but wish to optimize costs with an efficient workflow

Examples of Companies That Use Batch Methods

• Bakeries: Bakeries blend their raw materials according to recipes to make a variety of goods. They produce these goods in large quantities using many of the same machines.
• Pharmaceuticals, paints, cosmetics, and household chemicals: Like bakeries, these industries use formulas to blend raw materials into finished products in batches and then package them into containers for distribution.
• Apparel: Ready-to-wear garment manufacturers usually assemble raw materials into batches of the same styles of finished pieces according to size-specific patterns.
• Flat pack furniture: Manufacturers create these products in parts for customers to assemble at home or in the office. These popular furnishings receive frequently repeated orders since they’re usually cheaper to purchase and ship than fully assembled pieces.
• Electronic devices and their components: Manufacturers produce electronic devices and parts, such as PCB boards and processors, in batches. Even though manufacturers use mass production during the assembly stages of manufacturing the devices themselves, they usually use batch methods to install components onto PCB boards.

Batch Production Pros and Cons

Batch production isn’t the perfect choice for all manufacturers. But for those who meet the above criteria, it presents the most efficient method for producing goods. Examining the pros and cons of this method can help you decide if it’s the optimum one for your company.

Batch Production Pros

• More cost efficient: It is usually more cost effective to manufacture a batch than an entire product at a time. Also, if a batch is spoiled or damaged, it is cheaper to discard the batch as opposed to recalling thousands of finished products.
• More flexible: Manufacturers can easily modify batches. Not so with assembly or mass production. What’s more, teams can complete semi-finished products at a later date, reducing the risks of concentrating on individual products.
• Better equipment utilization: Batch production also better utilizes machinery, working continuously to reduce overall costs. Furthermore, it also reduces overall waste by controlling production quantities.

Batch Production Cons

• Higher costs than mass production: While batch production is cheaper than mass production, it can nevertheless incur extra costs. When making smaller batches or different production runs, this method can cause delays, resulting in additional costs to prepare equipment and deal with delays. Making products in batches can also increase storage costs if manufacturers must store each batch before completing the final products.
• Unsuitable for every product: Batch methods work best for specific products, such as those that can be manufactured in groups and particular quantities.
• Downtime risks: Batches that must observe strict quality control or compliance measures can cause downtime if errors occur.
• Customization challenges: While manufacturers can make custom products using batch production, it isn’t possible to personalize a single item in a batch without disrupting the entire system.

Conquering the Limitations and Challenges of Batch Production

Even under the best conditions, batch production has its share of pain points. To optimize operations, you need to find ways to meet these challenges:

Downtime During Changeovers

Changeover time refers to the period between finishing one product run and starting another. Switching products often requires cleaning up after the previous run, changing materials and equipment, and checking that everything is ready to begin the next run.

One strategy you can use to reduce the downtime that happens during changeovers is the single-minute exchange of die (SMED) method. Instead of waiting for the equipment from the previous batch to stop, complete as many pre-manufacturing steps for the next batch before the equipment stops.

Secondly, find ways to streamline any remaining steps. Standardizing workflows and providing employees with digital instructions can streamline the remaining processes.

Inventory Holding Costs

Holding too much inventory can cause you to spend more money than you need for storage costs, insurance premiums, and the waste that occurs when stock spoils or becomes obsolete.

Knowing your inventory levels in real time can help you know earlier when you’re at risk of having too much stock in your inventory. Tracking the ratio of sales for each product, too, can give you a better estimate of how much of each you need to keep in stock.

Using a just-in-time (JIT) approach to inventory management, too, can help you have only as much stock as you need to meet customer demand. Additionally, streamlining production and logistics to avoid time-wasting procedures can help you get inventory off the shelf and into customers’ hands much faster.

Risk of Batch Defects

One of the best ways to reduce the risk of batch defects is to check the first product that comes off the production line for any defects. If there are any, find out what went wrong and correct them. Secondly, utilizing a leading-edge manufacturing execution system (MES) can help streamline the process of tracking batch defects and their causes, allowing you to take corrective actions.

Quality Control Complexity

Even if you check the first product that comes off the line, there’s no guarantee that your machines will function properly during the whole process. For that reason, having a robust quality control system in place before shipping or selling your products is essential for ensuring customer satisfaction. Having an MES with a quality control system can help you reduce waste, maintain product quality, manage quality testing, and document the results.

Use Cases of Batch Production

Here are a few use cases that can help you see how this production method could benefit your manufacturing process.

1. In a Bakery

   The batch method is typically a good fit for bakeries. Depending on how much equipment and employees you have, you can run one to several batches at a time. In a small bakery, for instance, this method allows you to prepare a batch of whole wheat bread in a production run.

   While the loaves you’ve manufactured are in the oven, you and your team can clean the equipment and prepare the ingredients for the next production run – say, white bread. Expanding your operations is as simple as purchasing additional mixers and ovens and hiring enough employees to run multiple batches simultaneously.

   If you need to change the equipment to complete custom orders, this production method is flexible enough to accommodate them. It takes only a slight tweak to the workflow to change your regular layer cake pans to ones more suitable for a wedding cake, for example. Add an extra step – decorating – and you can easily work in custom orders.

2. In a Pharmaceutical Company

   Batch production is the standard method for pharmaceutical companies. Here’s why it’s such a good fit.

   Since this method enables your company to track each medication, you can trace which teams participated in the manufacturing process, the facility where the process took place, and the exact formula that your teams used to make each batch. Such traceability can pinpoint any defective drugs to recall and how to adjust each formula to produce a more effective product.

3. In a Cosmetics Company

   Small-batch manufacturing enables your cosmetics company to customize products for every season. For instance, lipstick with sunscreen for summer. Then, when winter looms, you can change your machinery and ingredients to create lipstick with extra moisturizers to fight off winter dryness.
   

Tools and Software to Support Batch Production

Having a leading-edge MES can streamline your production processes and reduce operational inefficiency. It can help you do all the following tasks – and many more.

• Plan batch sizes: A manufacturing execution system helps you gain control and visibility over the entire production process. With it, you can identify production bottlenecks and adjust batch sizes to optimize your workflow, reducing work-in-process inventory.
• Manage raw materials: An MES can manage inventory levels, track the movements of raw materials, and ensure that you have all the raw materials you need to keep your production schedule on track.
• Production scheduling: Eyelit’s MES can integrate seamlessly with your ERP and supply chain management systems. With the data it extracts from these tools, it can create a production schedule that considers your available materials, labor availability, order priorities, and equipment capacity.
• Schedule changeovers: With the information your MES receives from your higher-level planning systems, it can designate time for changeovers in your production schedule.
• Work order management: Using the production schedule, an MES provides work orders to your workstations and teams. These work orders contain all the specifications, instructions, and documents to ensure they can perform their tracks. The MES also tracks every work order’s progress, updating the work-in-process in real time.
• Machine and equipment integration: Using sensors and communication protocols, Eyelit’s MES integrates with your shop floor equipment and machines to monitor their health and collect and exchange production data.
• Track batch history and compliance: The Eyelit MES tracks batch history to ensure each batch adheres to its respective compliance requirements. With it, you can ensure excellence in product quality and regulatory compliance, improving operational efficiency while reducing risks.

What Advanced Planning and Scheduling Software Do I Need for Batch Production?

To optimize batch production, your company needs superior software that customizes production plans to meet your specific business objectives.

Eyelit Technologies provides AI-powered planning and scheduling software used by numerous manufacturing giants, like Honda, Nissan, and Ford. Our leading-edge MES and other solutions stand out for their real-time optimization technology, empowering you to create accurate manufacturing plans and schedules in record time.

Reduce production downtime and optimize operational efficiency in your production workflows. Reach out to the Eyelit team today!