What is batch production?
Batch production, or batch manufacturing, is one of the main types of manufacturing. It means that the product is made in batches, with every item in the batch going through a series of steps at the same time and in the same order, until the entire batch is complete.
Batch production is usually used for smaller product runs, or to make products with certain changes and customizations that will be the same for each item within the batch. It’s a way of ensuring standard quality, while also enabling customization and variety between batches.
Batch manufacturing stands in contrast to continuous manufacturing. It’s often used for vertical industries such as software chip manufacturing, pharmaceuticals, and food and beverage production.
Why do process plants use batch production?
There’s no single “right” or “wrong” production method, but certain approaches are more appropriate for specific manufacturing verticals. Batch production is most suitable for plants that receive smaller orders, and/or need to produce multiple customized versions of items.
The advantages of batch production include:
- More efficient use of both machinery and employee time
- A higher ability to supervise product quality
- Better customization and personalization for small batches and specialty production
- Reducing waste by ensuring the right amount is produced for each batch
However, there can also be disadvantages. A certain amount of time can end up being wasted while machinery is set up between batches and settings are reconfigured. Whenever there’s human involvement, errors can creep in, and if there’s a mistake made when setting up a batch, the entire batch goes to waste.
How can process plants make the most of batch production?
By applying batch production to the right types of products and using advanced tools, process plants can reduce the inefficiencies of batch production to make it more efficient.
Smart machinery that uses artificial intelligence (AI) and data from IIoT sensors can communicate with each other and automate reconfiguration, removing the risk of manual errors and speeding up turnaround time between batches.
With advanced technology and data-driven decision-making, batch production can be effective, efficient, and profitable.