Mass production is a procedure widely used in industry for mass production of products in large quantities in the most efficient way.
Chain production is characterised by the standardisation of processes, the repetition of tasks and the use of specialised machinery.
This production system seems to be closely linked to the automobile industry, although it is now used in all industries. It was the method that Henry Ford implemented in his car factory in 1913, demonstrating its enormous potential. Three decades later, the Toyota company improved the production line with its Just In Time (JIT) method.
Types of mass production
There are some differences between the different types of mass production. Each method is adapted to the product in question, depending on its characteristics, or the demands of the customer.
Here are some common types of mass production:
- Flow production. The product is manufactured on an assembly line where each unit is assembled by several workers or workstations. Each group of workers is responsible for a specific task in the manufacturing process. The product moves from one station to the next until it is completed. This method is most often associated with the concept of mass production.
- Batch production. In this case, a complete batch is produced at the same time. Products are grouped and manufactured in a single operation before moving on to the next batch. This method is used when there is a demand for a particular product and multiple units can be produced at the same time.
- On-demand production. In this type of production, each unit of the product is manufactured individually according to the customer’s specifications. In contrast to flow and batch production, on-demand production involves the production of unique products in accordance with the customer’s demands. This requires more time and effort to adapt to each customer’s specific requests.
Advantages and disadvantages of mass production
Like any manufacturing system, mass production has many important advantages, but also some disadvantages.
Advantages of mass production
Mass production offers several advantages that make it an attractive option for many companies:
- Cost reduction. By producing in large volumes, the production costs of each unit tend to decrease. This is a basic principle behind the concept of economy of scale, where high production volumes allow for better efficiency and more equitable distribution of resources.
- Increased productivity. By standardising processes and tasks, mass production allows for higher productivity. Repetitive tasks become more efficient while workers acquire specialised skills in the specific tasks they perform. This is something that can be seen on a small scale in everyday tasks.
- Quality is maintained in every product. Standardisation and process control in series production help to ensure consistent quality in all manufactured products. This is especially important in car manufacturing, where the safety and smooth running of each unit is paramount.
- Increased responsiveness to demand. With increased production capacity, companies can respond quickly to possible increases in market demand. This is especially useful in sectors where demand can fluctuate rapidly on a seasonal basis.
Disadvantages of industrial mass production
Mass production also has some disadvantages to consider:
- Lack of flexibility. Due to standardisation and repetition of tasks, mass production can have difficulty adapting to changes in product requirements. Therefore, when modifications have to be made to a product, it can be more costly.
- Risk of obsolescence. In an environment of rapid technological advances and changing markets, mass-produced products may be at risk of becoming obsolete more quickly. This can be a problem if a company finds itself with an inventory of products that are no longer in demand by customers, which is common in today’s technology industry.
- Higher initial investment. Implementing mass production requires significant upfront investment in specialised machinery, tooling and production systems. This can be a financial challenge that smaller companies cannot afford.
Despite its disadvantages, mass production is still used in many industries, often in combination with other production methods, and has proven to be an effective method for producing large volumes of products in a cost-efficient manner.
Mass production, key in the industrial sector
A current example of the successful application of mass production in combination with large-scale manufacturing is the production of smartphones. Thanks to mass production, companies can produce smartphones on a large scale, which has helped to reduce production costs and make them more accessible to consumers.
The advantages of this type of production in terms of efficiency, productivity and quality make it the best option for many companies. By implementing the different types of mass production, companies can take full advantage of this approach to boost their success in the market.
At Atienza y Climent we are experts in mass production, which is why we design and develop projects for all types of industrial sectors. If you are interested in more information, please contact us.
Mass production vs make-to-order: when each one makes sense
Choosing between make-to-order manufacturing and a production run depends mainly on expected volume, upfront investment and how stable the product is. A run makes more sense when there is enough demand to spread set-up costs over many units and the design is already defined.
Make-to-order gives more room to introduce changes between orders, but the unit cost is usually higher.
This comparison shows the main differences:
| Aspect | Mass production | Make-to-order |
|---|---|---|
| Unit cost | Tends to fall as the number of units increases. | Usually higher when producing small quantities. |
| Upfront investment | May require a mould, tooling and production set-up. | Normally needs less investment before production. |
| Lead time | Once production is set up, many units can be made in a planned way. | Depends on each order and the work it requires. |
| Product changes | The part should be well defined before the run starts. | Changes are easier to introduce between orders. |
| Minimum run | Depends on the product, process, mould and target unit cost. | Better suited to small or one-off quantities. |
How many units does a run need to pay off?
It depends on each production run. The cost of the mould or tooling, the material, the cycle time, secondary operations and the total number of parts determine the volume at which a run starts to pay off.
That is why there is no figure that works for every product. Before deciding how many units to make, the upfront investment has to be calculated and spread over the expected volume. This analysis lets you compare different quantities and see how the cost per part changes before approving production.
How the mould is amortised in the unit cost
Amortising the mould means spreading its cost over the units that will be produced. The more parts in the run, the smaller the share of the upfront cost each one carries.
For example, a part that needs a dedicated mould has to absorb that investment on top of material and processing. That is why volume and tooling should be studied together before deciding on the run. Well-planned injection mould manufacturing also helps match the mould to the product and to the expected production needs.
What you need ready before launching a run
Preparing for efficient production avoids costly changes once the mould, materials or production line are already defined. Before manufacturing, several technical and commercial points should be settled so the run delivers what the project really needs.
- Final design: drawings, dimensions, geometries, tolerances and joining methods should be closed before final tooling is made.
- Selected material: each material determines strength, finish, cost, part behaviour and production process.
- Expected volume: knowing the initial units and an estimate of future runs helps size the mould and calculate costs.
- Finishing and assembly: decoration, printing, assembly, packaging or preparation for shipping should be considered before the process is closed.
The more information available before production, the easier it is to calculate costs, lead times and technical requirements on a real basis.
Mass production with a single supplier: from mould to packed unit
Centralising industrial manufacturing simplifies a project that may include technical design, prototyping, tooling, production, finishing, assembly and packaging. Each stage depends on the previous one, so coordinating them within the same process helps catch adjustments before they affect the rest of the work.
It also reduces the need to manage different suppliers for the same reference. The design can be planned around the production method, the mould can be adapted to the expected volume and finishing can be defined before the first units are made.
Working this way lets you move from a validated part to industrial series production and manufacturing with shared planning, from technical preparation to a product ready for storage or distribution.
Talk to a full-service manufacturer
If you have a product ready for mass production, at Atienza y Climent we can study the design, the mould, the volume and the stages needed to turn it into complete industrial production.
Send us your project details and ask us for a quote to assess feasibility, costs and next steps.
Frequently asked questions about mass production
What is the difference between mass production and make-to-order?
Mass production makes many identical units within a previously defined process, while make-to-order responds to specific orders. The choice depends on volume, design stability, set-up costs and the flexibility the product needs.
What are the advantages and disadvantages of mass production?
Its advantages include a lower unit cost at the right volumes, repeatable processes and greater production capacity. On the downside, it may require upfront investment in moulds or tooling and the product must be well defined before production starts.
Can a custom plastic part be mass produced?
Yes. First its geometry, material, tolerances, expected volume and production method must be defined. Processes such as plastic injection moulding make it possible to produce repeated units from a mould designed specifically for the part.
