Depending on the product type, many methods and procedures are employed in manufacturing to generate commodities. One of the main strategies is discrete manufacturing, which is different from other production methods like process manufacturing.
Understanding discrete manufacturing may help firms improve production for increased quality, scalability, and efficiency.
What is Discrete Manufacturing?
The term “discrete manufacturing” describes the process of creating countable products like furniture, appliances, and automobiles.
According to MCA Connect, the process centers on the production of unique, stand-alone objects that are usually put together from bits or components. Basically, these products are constructed from discrete components or assemblies, which are frequently visible in the finished object. This approach is frequently used to create customized products that are high quality and match the exact needs of customers.
Put simply, if companies want to get countable products that are uniquely created, they should opt for discrete manufacturing. This method works with physical, distinct items, as opposed to process manufacturing, which involves creating products through continuous processes.
Since each unit created in a discrete manufacturing process is unique and identifiable as a single product, businesses are able to monitor each item.
Bills of materials (BOMs), which detail the components or pieces needed to construct each product, are usually used in this sort of production. Frequently, these components are made or acquired individually, and throughout the production process, they are assembled.
Because of this, discrete manufacturing is a more flexible but complex process that comprises several steps, such as procurement, manufacture, and assembly.
What kinds of goods work best with discrete manufacturing?
Discrete manufacturing is best suited for items like computers, automobiles, aircraft, and appliances that need to be assembled from separate pieces. It is also employed in sectors that deal with highly personalized goods, such as toys, medical equipment, and furniture.
The Role of Technology in Discrete Manufacturing
Discrete manufacturing has been significantly shaped by technological advancements. The production and design processes have been simplified by contemporary technologies such as computer-aided manufacturing (CAM) and computer-aided design (CAD).
These tools provide producers the ability to digitally create things, model manufacturing, and spot any issues before the real thing starts. Manufacturers may save time and money by doing this since it avoids waste and expensive manufacturing mistakes.
The use of cloud computing is also increasing among discrete manufacturers. A press release from PR Newswire shows that 76% of manufacturers of processes and discrete goods utilize cloud platforms. They usually use cloud computing to streamline real-time collaboration and improve efficiency in the supply chain.
Manufacturing Execution Systems (MES) and Enterprise Resource Planning (ERP) systems are becoming essential tools for controlling discrete production. ERP systems assist businesses in managing their resources, including personnel and commodities, to guarantee efficient output.
Therefore, there has constantly been an increase in the demand for discrete manufacturing ERP. In 2020, the worldwide discrete manufacturing ERP market was estimated by Business Research Insights to be valued at $4514.5 million. But by 2031, it’s predicted to grow at a compound annual growth rate of 11.5%, or $11609.84 million.
MES, on the other hand, tracks production data in real-time and concentrates on the shop floor. When combined, these technologies enable producers to get more insight and control over the manufacturing process. This empowers them to take well-informed decisions that raise output and enhance product quality.
What part does automation play in production that is discrete?
Discrete manufacturing automation minimizes human error, expedites production, and enhances precision in the assembly of sophisticated items. Automated guided vehicles (AGVs), PLCs, and robotics are frequently utilized to tackle hazardous or repetitive jobs, increasing productivity and safety.
Optimizing Production with Lean Manufacturing Principles
One of the fundamental issues in discrete manufacturing is the ability to retain efficiency while handling the complexity of making many unique things. Principles of lean manufacturing, which started with the Toyota Production System (TPS), have become popular as a means of overcoming these obstacles. Lean manufacturing aims to increase productivity and cut waste without compromising product quality.
Waste may take many different forms in discrete manufacturing, including excess inventory, overproduction, and labor that is used inefficiently. Just-in-time (JIT) production is a lean manufacturing technique that reduces the need for big inventories by producing or ordering items just when needed. This strategy reduces the danger of obsolete or outdated inventories while also cutting expenditures.
During the COVID-19 pandemic, many industry experts stated that lean manufacturing and JIT are dead. However, Toyota executives believe otherwise. They say that their TPS is well and running, which is one of the core reasons why Toyota outperformed its rivals during the pandemic.
What distinguishes lean manufacturing from conventional manufacturing techniques?
Lean manufacturing is different from conventional techniques in that it emphasizes efficiency and waste reduction. Production speed and volume are frequently prioritized in traditional systems, which can result in excess inventory, increased expenses, and waste. By streamlining the production process, lean manufacturing guarantees that resources are used effectively and that only essential items are created.
The Importance of Quality Control
Since every item produced in discrete manufacturing must adhere to strict requirements, quality control is essential. Goods in discrete production may be individually inspected. Therefore, problems are frequently more visible than in process manufacturing, where quality discrepancies may be more difficult to discover. Maintaining customer satisfaction and averting expensive recalls depend on each product meeting the necessary criteria.
Manufacturers frequently use strict testing and inspection procedures at different manufacturing stages to preserve quality. For example, arriving materials may be examined before assembly starts, and completed goods might undergo functional testing to ensure everything works as it should. Furthermore, real-time production monitoring using data-driven techniques like statistical process control (SPC) can help spot problems before they impact a significant number of units.
Discrete manufacturers also need to have a digital strategy to monitor the trends in the market. An enterprise-wide digital transformation might be intimidating due to its scale and complexity. Thus, the digital strategy is easier to maintain when it is divided into several categories. Discrete manufacturers may put themselves in a strong position going forward by rethinking their company strategy and moving to digital operations.
Across many sectors, discrete manufacturing is a critical method for creating unique, countable products. Its capacity to produce single pieces, contemporary technology, and lean manufacturing concepts enable businesses to maximize output and satisfy customer needs.
Notwithstanding its complexity, manufacturers are overcoming obstacles and promoting constant development thanks to the expanding role of digital technologies and an emphasis on sustainability. Discrete manufacturers may keep streamlining their operations, one unit at a time, with cautious management and intelligent use of technology.
