The Complete Guide to Manufacturing Processes

Understanding what a manufacturing process is forms the foundation of any production strategy. The wide variety of techniques and approaches can cause some confusion, but every process can be examined and categorized. This makes it easier to find the right fit for any product or production environment.

This guide explores manufacturing approaches and explains their pros and cons to help you choose the right one. Let's embark on this journey to unravel the intricacies of the manufacturing landscape.

What is a Manufacturing Process?

Before we explore our complete guide to manufacturing processes, we’ll need to determine what a manufacturing process is. Simply, a manufacturing process is the transformation of raw materials into finished goods. Each manufacturing process combines labor, machinery, and digital tools to create a specific product.

However, this doesn’t even begin to scratch the surface of the complexity and capability of modern manufacturing. We have grouped 24 manufacturing processes into five categories based on their primary functions.

1. Sequential Processing
2. Type
3. Market Demand
4. Strategic Purpose
5. Procedure

These factors provide the framework for exploring the categories, processes, and strategies that define modern manufacturing.

The Sequential Breakdown of the Manufacturing Process

Every manufacturing method follows a fundamental three-step workflow: input, transformation, and output.

• Primary Processing: The procurement of raw materials through gathering, mining, cultivating, etc.
• Secondary Processing: The transformation of those raw materials into usable components, including cuting, extrusion, assembly, shaping, welding, printing, refining, etc
• Tertiary Processing: The assembly, finishing, and packaging of the final product, including assembly, packaging, labeling, quality testing, distribution, etc.

The 4 Main Types of Manufacturing Processes

Despite their unique characteristics, all products originate from one or more of these core manufacturing categories.

1. Discrete Manufacturing

Discrete manufacturing focuses on creating individual items, ranging from cars and sports equipment to lamps and shovels. Anything that can be assembled, welded, joined, etc. falls into this category.

Discrete Manufacturing can often be characterized by the production of diverse products. These can change based on customer orders and/or new contracts. In this case, the production line is manned by a combination of people and industrial equipment.

For example, a company could produce metal shelving one month and the metal housing for X-ray scanners the next month. This provides manufacturers with these key advantages:

• Flexible to market demand
• Easily performs product changeovers
• Requires less investment than automated assembly lines

However, this can often make production a bit slower when compared to repetitive manufacturing processes. Plus, employees within this environment may need to constantly learn new procedures as new contracts are procured.

One optimization method for discrete manufacturers is to employ batch or lot production. Discrete manufacturers batch-produce identical units, then quickly change over to the next product set within a contract. This is especially useful for work orders with multiple operations. The counterpart to batch processing is to simply assemble products based on the work order. With all parts and materials available, workers follow work order specifications as products move through the shop floor.

However, getting workers to keep track of these changing worker orders can be difficult without digital guidance. Discrete manufacturers can guide employees through each task by employing platforms such as work instruction software.

This strategy is especially effective for discrete manufacturers that produce products with high variations like Brunswick Boat Group. They automatically send all work order specifications to their work instructions. This enables workers to simply follow the standardized procedure and grab the parts mentioned in the dynamic instructions.

2. Process Manufacturing

Process manufacturing transforms raw materials through chemical or physical changes. Unlike discrete manufacturing, this method utilizes mixing, heating, and fermenting to produce both liquid and solid goods.

Process manufacturing can be a highly efficient production type due to three important factors.

• Efficient: Companies can produce large quantities with highly consistent quality.
• Scalable: As long as there’s space, companies can easily scale up and scale down production based on market demand.
• Automation & Reduced Labor: Process manufacturing operations can be automated with temperature control sensors and automated mixers.

While process manufacturing has a whole host of advantages, it also introduces a certain level of complexity.

• Process Rigidity: All manufacturing steps must follow a specific formula or recipe. Workers complete each step before beginning the next one.
• Conditional Factors: Raw materials need to be under specific conditions, such as heat, time, and pressure.
• Irreversible Transformation: Once mixed, the final product cannot be broken down into its components or base materials. For example, once cake ingredients are mixed, you cannot extract or separate the flour and sugar.

Since process manufacturing products undergo irreversible changes, ensuring quality and standardization is a top concern.

3. Repetitive Manufacturing

This style of manufacturing process is all about high volume and high optimization. This is possible because repetitive manufacturing products have little to no variation. Most products are generally identical to one another, allowing companies to adopt a few key strengths.

1. Large quantity production
2. Full standardization
3. Highly optimized and automated production lines

Highly automated tools, robots, and mass assembly lines are great for repetitive manufacturing companies. Because there are few variables within the product line, machines can perform a majority of the work. And they can do it at incredible speeds while wasting little time or material.

However, this repetitive type of production and optimization also leads to two key weaknesses.

• Slow changeover
• Inflexible product lines

With reliance on automated machinery, companies can’t quickly get their production lines to build new products. It takes time to plan and accomplish any changeover procedure. In some markets, this lack of flexibility is a non-issue. But this is not a viable strategy for companies that want to be responsive to specific customer orders.

4. Job Shop Manufacturing

Job shop manufacturing is about producing custom products that require unique processing at medium to low volumes. This type of manufacturing process has little room for automated actions and heavily relies on skilled labor. For this reason, production volumes are significantly lower.

Think of it like a tailor making custom suits. Other suit brands might be able to produce incredible volumes of products for the market. But if anyone wants a unique one-of-a-kind suit, they’ll need to see a tailor.

In the same way, when someone needs a custom part or machine, they need to approach a custom manufacturer.

With its focus on customized production, job shop manufacturers are incredibly flexible to the needs of their customers. However, because these products are typically made to order, lead times are also much slower than for other manufacturing processes.

Watchfire Signs leverages digital work instructions to ensure process accuracy across its custom billboard production. By standardizing repeatable processes and calibrating specifications and measurements for each unique order, the company maintains consistency despite high product variability.

The 4 Manufacturing Processes By Market Demand

Now that we have a firm grasp of the main types of manufacturing processes, let’s take a look at how to break modern production methods down by market demand.

1. Make-to-Stock (MTS)

Make to Stock (MTS) is a forecast-driven production strategy where companies manufacture goods to meet anticipated consumer demand. A prime example of this method is seasonal clothing manufacturing. Clothes are mass-produced using repetitive manufacturing processes before explicit customer demand.

Essentially, MTS is a push manufacturing approach. Production and inventory levels are predetermined and sales are based on the quantity produced. One of the key advantages of this manufacturing process is that orders are fulfilled immediately from pre-made inventory. This significantly speeds up lead times.

The drawbacks include high initial costs associated with inventory development. Plus, companies can overproduce or underproduce if demand projections prove to be incorrect.

2. Make-to-Order (MTO)

Businesses that use the Make to Order (MTO) approach only make their product once the customer order has been received. This allows manufacturers to build the appropriate quantity based on actual current demand. Its also enables companies to engineer products to the exact specifications of the customer.

Low inventory costs and virtually no stock obsolescence are the main advantages of the MTO approach. Every time production begins, the product has already been sold. Similarly, this manufacturing process allows manufacturers to build products that require large amounts of capital without putting up enormous initial investments amid sales uncertainty.

One drawback of this approach is that manufacturing cannot start until the order is received. Thsi can then cause longer lead times. However, in industries like aerospace and automated machinery, lead times do not need to be as fast as in the consumer goods industry.

MTO manufacturers can also create small buffer inventories to help mitigate the inherently longer lead times of this manufacturing process.

3. Assemble to Order (ATO)

Assemble to Order (ATO) is a hybrid production method where subassemblies and components are manufactured and staged before a customer order is received. Once the order is placed, workers assemble these subcomponents into the final customized product for immediate fulfillment. At its core, ATO is the fusion of MTO and MTS methods.

• The flexibility of MTO (Made to Order): Customers get to select the specific components of the finished product.
• The faster lead times of MTS (Made to Stock): The bulk of manufacturing is completed before the client places an order. This is possible because the subassemblies are pre-manufactured.

While this manufacturing process seems like the best of both worlds, it does require a specific product type. Computer manufacturers like Dell and HP are prime examples of ATO processes. Motherboards, computer chips, and processors are quickly assembled when work orders come through.

4. Engineer-to-Order (ETO)

Engineer-to-order (ETO) is a manufacturing process where products are entirely conceived and engineered from scratch. Within this manufacturing process, the volume is low and the product variation is high. Complex industrial equipment, defense systems, and construction/infrastructure projects typically follow this manufacturing approach.

While similar to the MTO method, ETO provides the greatest amount of flexibility and customization. Rather than merely purchasing a final product with a few customizations, companies commission the creation of the product. They are involved from the design phase to the end of product finalization.

In this case, a job shop manufacturing process or a company with an R&D department is best suited for this type of work.

The 3 Manufacturing Processes by Strategic Purpose

Manufacturing processes often focus on the physical methods used to create goods. However, modern manufacturing also encompasses digital integration, supply chain strategy, and data-driven optimization. These strategies and tools are used to enhance production and fulfill manufacturing goals.

For this reason, let’s expand our exploration of manufacturing processes. Next, we'll look at key methods and systems used within the modern industry.

1. Lean Manufacturing

Lean manufacturing is a production methodology that focuses on two key goals.

1. Minimizing waste for the company.
2. Maximizing value for the customer.

By carefully identifying where a manufacturing process is wasteful and where value can be optimized, manufacturers can positively transform their operations for the better. But the question is, how do manufacturers identify wasteful areas and produce greater value?

While there are specific lean manufacturing methods like 5S, Kaizen, Poka-Yoke, Value Stream Mapping, and many more, each one requires a critical amount of data to be effective.

In this case, modern manufacturers need to turn to a digital and intelligent form of manufacturing processing.

2. Cloud Manufacturing

Cloud manufacturing leverages technologies like cloud computing, IoT, data analytics, and digital threads to create an interconnected network of cyberphysical resources. These resources help manufacturers collect and analyze data while controlling production orders and scheduling.

For example, a worker-centric MES like VKS Enterprise leverages cloud manufacturing in the following ways.

• On-demand Knowledge Access: Workers access live work instructions, digital forms, and KPIs instantly. This ensures everyone follows the correct process with accurate data at every station.
• Interconnected Resources: Manufacturers sync workers with tools, PLCs, and IoT sensors. This creates a smart ecosystem where machines and databases communicate directly to improve efficiency.
• Real-Time Error Proofing: The system tracks operator actions, parts used, and quality checks in real time. This active monitoring prevents mistakes before they happen, significantly reducing scrap rates.
• Streamlined Data Collection: Digital forms and scanners replace paper logs, capturing data automatically during production. This ensures information is accurate, searchable, and stored in a single system.
• Production Scheduling: Leaders manage work order priorities through live dispatch screens. This transparency ensures that both the workforce and equipment operate at peak capacity.
• API Connection: Work instruction software connects directly with ERPs, CMMS, QMS, LMS, and more. This "single source of truth" eliminates manual data entry and keeps all departments synchronized.

3. AI Manufacturing

AAI has been a hot topic for the past few years, if not the decade and beyond. Specifically, AI manufacturing is the utilization of artificial intelligence to improve manufacturing processes across a few factors.

Data analytics is a key focus as manufacturers progressively pull more and more data from their disparate systems. And the more data you have the more intelligent analysis you need. This data can then be used to gain actionable insights and intelligently optimize processes.

Additionally, AI manufacturing allows for higher levels of automation where machines and robots work autonomously with little human intervention. Machine learning algorithms also identify patterns and allow automated systems to make data-driven predictions and/or autonomous decisions. Or, in the case of cobots, AI is facilitating greater collaboration between workers and their cyber-physical counterparts.

The 10 Principal Manufacturing Procedures

Now that we’ve properly categorized manufacturing processes and their strategies, we can take a look at the top 10 manufacturing procedures used by modern manufacturers.

• Casting: A liquid substance (most often metal) is poured into a mold with a hollow cavity. The liquid metal then solidifies and is removed from the mold, attaining the desired shape.
• Molding: This procedure shapes a wide range of materials into complex geometries. Techniques like injection molding allow manufacturers to produce intricate parts with high precision and speed.
• Forming: This manufacturing procedure relies on pressure (bending, rolling, stamping, extrusion, etc.) to permanently form materials such as metals or plastic into specific shapes. Unlike machining, this procedure sees no material removal.
• Machining: This is a subtractive procedure where material is removed from a workpiece until a desired shape is achieved. A classic example of machining is creating a screw where groves are carved into the shaft of a metal rod.
• Powder Metallurgy: Metal powders are used to make intricate metal parts without the need for subtractive processing. This procedure is also used when making unique materials that do not suit melting or other types of forming.
• Treatment: This procedure uses heat, chemicals, and/or mechanical methods to alter the properties and characteristics of a material. This procedure is performed after it has been formed.
• Joining: Through actions like welding, soldering, adhesive bonding, and more, joining is the connecting of parts or materials into one unified structure.
• Assembly: Similar to joining, assembly is the process of connecting or fastening base components together to create a final product. Methods used for assembly include mechanical fastening, fitting, clipping, riveting, and more.
• Additive: Through the use of a layer-by-layer printing process, manufacturers print three-dimensional products. This 3D printing procedure can use a wide range of materials from plastics and metals to ceramics and composite materials.
• Finishing: From hardening, painting, and polishing to coating, cleaning, and texturing, finishing procedures aim to improve a product’s appearance, functionality, and durability.

Which Manufacturing Process is Right for My Business?

At the end of this article, you may ask yourself which manufacturing process is best for your business. As we've explored above, answering that question well is highly dependent on these 4 key factors.

• Market Demand: As we explored, the market is largely going to dictate the method and the timing of your production. From customization and skilled labor to mass production and automation, market demand is the number one consideration.
• Material State: Evidently, the state of your materials, components, and chemicals will also play a key role in the processes you use. In other words, you wouldn’t use process manufacturing to make physical computer chips.
• Resource Availability: Using either plentiful or rare resources will determine the process you use. If materials are easy to source, then your production can run continuously and even use subtractive processing. But if your resources are seasonal or rare, your production strategy will need to focus on low waste production. -** The Capabilities of your Factory and Workforce**: If your manufacturing environment is under-equipped, or if your workforce is under-prepared, the manufacturing process cannot move forward.

VKS is a work instruction software that enhances the capabilities and knowledge retention of every manufacturing employee. From automated production lines to job shop productions, people are at the core of every manufacturing business. They are the ones managing machines, assembling components, quality testing, and ensuring that every product maintains the value your customers deserve.

For this reason, manufacturers are bolstering their processes by standardizing their procedures and strengthening their workers. So the question is, how will you enhance your manufacturing process?