What is discrete manufacturing?
Discrete manufacturing is an approach to industrial production that results in individual final products. This is accomplished by taking incoming materials, parts, components, and/or subassemblies through a series of production steps that may include machining, assembly, etching, fastening, polishing, stitching, packaging, and more. Discrete manufacturing results in final products that are distinct from one another and can be counted. It also typically produces items that can be broken down in their component parts.
These two features distinguish discrete manufacturing from process manufacturing, which produces products typically measured in mass or volume. These products, such as shampoos or fruit juices, cannot be counted individually, and they often undergo irreversible changes that make it impossible to break them back down to their constituents.
Discrete manufacturing examples range from nanotechnologies to airliners. While electronics & semiconductors, automotive & transportation, and aerospace & defense industries represent some of the most prevalent discrete manufacturing examples, a broad spectrum of other industries rely on discrete manufacturing processes to produce their goods. These include:
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Automotive
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Aerospace & defense
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Electronics
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Industrial machinery
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Heavy equipment
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Marine
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Medical devices
It should be noted that the manufacture of numerous products involves both discrete and process operations. To make glass bottles, for example, one must create the glass through process manufacturing, then produce the individual bottles through discrete manufacturing.
Greater flexibility
Empowering manufacturing processes, discrete manufacturing software enhances efficiency by providing greater flexibility and capacity, catering specifically to the production demands of today's smaller lot sizes.
Better management and control
Empower users to efficiently manage and control complex products and intricate supply chains with precision and ease.
Lower production costs
Contribute to lower production costs by streamlining processes, enhancing efficiency, and identifying opportunities for resource optimization.
Improve customer satisfaction
Ensure greater customer satisfaction by facilitating precision in production, timely deliveries, and improved communication throughout the manufacturing process.
Terminology
Before deeper dive into the differences between discrete and process manufacturing, let's first define some important terms:
Work Center
A work center, a term predominantly used in the discrete manufacturing industry, is a specific location or station within the manufacturing environment where a set of related tasks or operations are performed. This can range from a single machine, a group of machines, or even a whole production line, depending on the complexity and scale of the operations. In the discrete manufacturing context, each work center is typically specialized for a specific type of task.
For example, in a bicycle manufacturing plant, one work center might be dedicated to creating the frames, another to painting the bicycle frames, another to assembling the parts together, and so on. This allocation of specific tasks to dedicated work centers enables efficient workflow, precise scheduling, improved quality control, and effective resource utilization within the manufacturing process.
Routing
A routing is a term used in the discrete manufacturing industry. It refers to the sequence of operations or steps that are needed to complete the production of a specific product. It defines the flow of materials and work through the production process, from start to finish. In the context of the discrete manufacturing industry, each step in the routing process represents a specific operation in the production cycle, such as machining, welding, assembling, painting, or inspection.
At each of these stages, the product will undergo a specific transformation or process as it moves towards becoming a finished good. By establishing and following a routing sequence, companies can standardize and streamline their production activities, facilitating improved efficiency, quality control, and cost management.
Resources
A resource, a term predominantly used in the process manufacturing industry, is analogous to a work center in the discrete manufacturing industry. It describes a specific location or station within the production process where a set of related tasks or operations are performed. In the context of process manufacturing, a resource could be a certain machine, a group of machines, or a particular area within the plant that performs a specific function or set of functions.
In a chemical plant, one resource could be a reactor where raw materials undergo chemical transformation, another could be a distillation column for separating mixtures, and so on. Just like a work center, a resource is integral to production process planning, scheduling, and resource management, providing a means to structure, standardize, and optimize the flow of work in a process manufacturing environment.
Bill of Material (BOM)
A Bill of Material (BOM) is a comprehensive list of parts, components, assemblies, and other materials required to produce a product. It is essentially a recipe or blueprint for production. A BOM includes the quantity of each item, specifications, and sometimes even the sequence of assembly. It is an essential tool for production planning, inventory management, cost estimation, and ensuring that all necessary materials are available for production.
For example, in a bicycle manufacturing process, a BOM might list items such as the frame, handlebars, wheels, gears, screws, and paint, along with the quantity required for each to produce a single bicycle.
For example, in a paint production process, a BOM might list items such as basic paint, solvent, pigment, stabilitzers, and additives along with the quantity required to manufacture a certain amount of paint. Usually, the quantities refer to a standard production quantity, for example 1000 kg which you usually produce.