Production- Flow

• Similar to batch methods - except that the problem of rest/idle production/batch queuing is taken away.
• Flow has been defined as a "method of production organisation where the task is worked on continuously or where the processing of material is continuous and progressive,"The aims of flow methods are:- Improved work & material flow - Reduced need for labour skills - Added value / completed work faster
• Flow methods mean that as work on a task at a particular stage is complete, it must be passed directly to the next stage for processing without waiting for the remaining tasks in the "batch". When it arrives at the next stage, work must start immediately on the next process. In order for the flow to be smooth, the times that each task requires on each stage must be of equal length and there should be no movement off the flow production line. In theory, therefore, any fault or error at a particular stage

MUST:

1.  There must be substantially constant demand  - If demand is unpredictable or irregular, then the flow production line can lead to a substantial build up of stocks and possibility storage difficulties. 
2. The product and/or production tasks must be standardised - Flow methods are inflexible - they cannot deal effectively with variations in the product.
3. Materials used in production must be to specification and delivered on time - Since the flow production line is working continuously, it is not a good idea to use materials that vary in style, form or quality. Similarly, if the required materials are not available, then the whole production line will come to a close - with potentially serious cost consequences. 
4. Each operation in the production flow must be carefully defined - and recorded in detail 
5. The output from each stage of the flow must conform to quality standards - Since the output from each stage moves forward continuously, there is no room for sub-standard output to be "re-worked''. 

• Requires considerable planning, particularly in ensuring that the correct production materials are delivered on time and that operations in the flow are of equal duration.
• E.g. the manufacture of motor cars, chocolates and televisions.

 ADVANTAGES

• Flow production is capital intensive (uses a high proportion of machinery in relation to workers)
• High number of products can roll off assembly lines at very low cost
• Firms can benefit from economies of scale, which should lower the cost per unit of production.

DISADVANTAGES

• With so much machinery it is very difficult to alter the production process.  This makes production inflexible and means that all products have to be very similar or standardised and cannot be tailored to individual tastes. 
• The work can be pretty boring for employees involved.  Keeping staff motivated is therefore an important issue for management.