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Understanding the different types of manufacturing is essential when building any product. From custom one-off jobs to high-volume assemblies, there are many different methods of manufacturing that cater to different industries, demands and budgets. Below are 9 common manufacturing methods and their uses.
Repetitive Manufacturing
Repetitive manufacturing is designed for consistency and high volume. It typically involves producing the same product continuously on a dedicated assembly line. Production lines are set up for non-stop operation for long periods with only occasional halts. This is an economical option for producing identical products, but it is not suitable for products that require any type of customization.
What are some examples of products that use repetitive manufacturing? Everything from toothpaste tubes to appliances. Henry Ford famously popularized repetitive manufacturing when mass producing the Ford Model T and it is a method still used by many car manufacturers today.
Batch Manufacturing
Batch manufacturing strikes a balance between volume and variety. Identical products are mass produced in limited ‘batches’. Once this batch is produced, the assembly line can then be set up for a different product. This allows companies to produce limited runs on seasonal items or test out new variants.
Many food and clothing companies that produce different variants or collections throughout the year may use batch production. The downside of batch production is that it can be quite costly having to set up assembly lines for each new batch. This method is typically most economical for companies that don’t have too many different products to produce or companies that need to mass produce products with only slight variations between each batch.
Discrete Manufacturing
Discrete manufacturing involves taking lots of different components and assembling them together to create individual products that can be counted and tracked. This method of manufacturing allows a small level of customization and is often used for many complex electronic products.
Examples of products that use this manufacturing method include laptops, aircraft and furniture. Each item is often given a serial number that allows it to be traced for quality control or recalls. While this method of manufacturing has many advantages, it does require precise planning to source all the right components and assemble them together efficiently.
Job Shop Manufacturing
Job shop manufacturing can be seen as more of an artisan method – it’s ideal for high levels of customization per item on a low volume scale. Such products take more time and money to produce as they often require specialist equipment and highly skilled labor (which could include hand-making certain components), and so such products are usually sold at a premium price.
Types of products that rely on this manufacturing method include tailored suits, prosthetics, wedding cakes and custom printed/engraved gifts. Prefabricated building parts and spacecraft parts are also produced this way in a workshop for maximum precision.
Additive Manufacturing
Additive manufacturing is more commonly known as ‘3D printing’. This innovative manufacturing method involves taking materials like plastic and metal and sculpting these materials into intricate highly customizable shapes. This is done using a specialist machine that produces the item layer by layer using a digital model.
3D printers are excellent for quickly producing prototypes of complex products. They can also be used to create highly customized items like prosthetics and can even be used to reproduce old parts that are no longer available to buy (like old car parts). Unfortunately, the upfront costs of a 3D printer can be high. And although faster than traditional subtractive methods like carving from a block, 3D printing is still relatively slow compared to some repetitive manufacturing methods like vacuum forming.
Toll Manufacturing
Toll manufacturing is also known as contract chemical manufacturing. This method involves companies sending raw materials to a manufacturer to be blended together. It is a method commonly used to produce items like paints, dyes, medicines and beverages.
Why is it called toll manufacturing? Because the manufacturer charges a ‘toll’ for their service, which is based on the volume and weight of the chemicals used. The machinery used to produce these toll chemicals is often expensive to set up – designed to handle lots of different materials and create precise mixtures. Due to the way this manufacturing method is charged, it is best suited to limited batches rather than continuous production.
Just-In-Time Manufacturing
Just-in-time (JIT) manufacturing is a method used to produce last minute orders. Rather than creating large batches, items can be made to match the changing demand – which is excellent in volatile markets, helping to reduce excess stock.
When it comes to foods with short expiry dates, JIT manufacturing can prevent excess items being produced which cannot be sold in time. This method of manufacturing is also commonly used for custom individual products. Of course, such manufacturers need to have a factory that is set up to handle these last minute orders – quite often JIT manufacturers will specialize in a certain type of product or take on a limited number of loyal clients that they are able to quickly set up a new assembly line for.
White Label Manufacturing
White label manufacturing involves creating generic products that other companies can rebrand and sell as their own. Examples include products like toilet paper, flour and hand sanitizer – many grocery stores use the exact same product but sell it under their own brand.
These products are typically sold to customers as a cheap alternative to more higher priced unique brands. For example, many superstores will sell a range of different premium coffee brands, along with a low cost own brand version on the bottom shelf. White label manufacturers should not be used to produce premium products.
Continuous Manufacturing
Continuous manufacturing is similar to repetitive manufacturing. But whereas repetitive manufacturing may still have occasional breaks, continuous manufacturing is designed to run non-stop (only stopping for occasional maintenance). It is a method commonly used for many ultra-high-demand commodities like paper, petroleum and vegetable oil.
Such manufacturing systems require machinery that can run 24/7 without experiencing wear and use a lot of energy. They can still be highly profitable though provided that there is a continuous demand for the product.
