Process Manufacturing

Process manufacturing is an approach to producing goods in which ingredients or constituents are mixed together and then subjected to a series of actions until the product reaches its final formulation and state. Actions performed on the combined ingredients vary widely and include curing, baking, pressurizing, pasteurizing, and chemically catalyzing or reacting
A process manufacturing industry is often required to track processing parameters and testing results for each batch, or at set intervals based on volume or mass in continuous-flow processing. This requirement may be handled through paper records, but process industries are adopting electronic batch records (eBRs) for manufacturing more and more to streamline recordkeeping
Process Manufacturing Industries

Once a product has been made through process manufacturing and reaches its final form, it typically cannot be broken back down into its constituents.
Key industries that rely on process manufacturing include consumer packaged goods (CPG), food and beverage (F&B), and fine and specialty chemicals.
Goods produced through process manufacturing are made in batches – finite quantities usually measured in mass or volume – or via continuous-flow processing. In batch processing, the sequence of process operations for a particular product is performed on a batch-by-batch basis. In continuous-flow processing, units of the materials/intermediate products move from one processing step to the next with no breaks, such that each processing step is being performed on a continuing basis, proceeding from one unit to the next.
Process Manufacturing vs Discrete Manufacturing

Process Manufacturing

Discrete Manufacturing

Process manufacturing relies on creating formulas or recipes to produce a product

Discrete manufacturing assembles parts in a prescribed process to produce a distinct item

Process industries make products in bulk quantities, such as pharmaceuticals, food and beverage, and paints

Discrete manufacturers produce or assemble component or finished products recognized by serial numbers or labeling products

Products cannot be broken down into constituent parts

Products cann be broken down and dispose constituent parts

Uses formula or recipe

Uses a bill or materials (BOM)

Process manufacturing offers many advantages to businesses, including improved efficiency, cost savings, increased scalability, and higher-quality products

Discrete manufacturing offers advantages in terms of flexibility, efficiency, quality control, customization, and speed

Examples of Process Manufacturing are Food and beverages ,Refined oil, Gasoline, Pharmaceuticals, Personal care products, Cosmetics, Specialty chemicals, Plastics, Metals, Paints, Alcohol

Examples of discrete manufacturing are Automobiles, aeroplanes, Medical devices, furniture, Apparel, toys, Electrical , Communication and electronic devices

Process Manufacturing Software

MES for process industries must provide material management capabilities that not only track these raw material characteristics but also the characteristics of intermediate and final products as a set of ingredients undergoes conversion through the process steps.

MES for process industries is the need for both formula management software and spec management software. A single specification for a product – for example, a unique and recognizable taste for a company’s orange juice – may require different formulations from region to region to account for the differences in orange sugar content and flavor, which depend on the variety, growing region, and growing season.
Key features of MES for discrete manufacturing include:

✓  Adaptability and Customization to New Formulas/Recipes

✓  Management of Co-Products and By-Products

✓  Supply Chain Optimization, Cost Tracking

✓  Tracking of Shelf Life

✓  Instant access to production documentation

✓  Real-time shop floor visibility

✓  Enhanced manufacturing operations and WIPs (work-in-progresses)

✓  Quality Management and market Compliance

✓  Supports Different Measurement Units

✓  Able to Track and Trace Lots



Benefits of Process Manufacturing Software

Modern MES for process industries allows process manufacturing companies to implement highly efficient and flexible operations while also ensuring the highest quality in their finished products.
Additional benefits:

✓  Shorter cycle times and greater on-time deliveries

✓  Less demand on limited resources

✓  Assurance that production does not outpace maintenance requirements

✓  More efficient movement, storage, and tracking of materialss

✓  Visibility of current and historic manufacturing operations performance

✓  Decision support to correct and improve in-process functions

✓  Streamlined compliance and reduced cost of quality