Discrete vs. Process Manufacturing: Unpacking Key Differences

Written by: Padma Raghunathan, Product Marketing Manager

In the complex world of manufacturing, understanding the fundamental differences between discrete and process manufacturing can be crucial for businesses aiming to optimize their production strategies. Each method represents distinct approaches to creating products, impacting everything from supply chain management to technology integration. Grasping the nuances between these two methodologies is essential for manufacturers in determining the most effective operational processes.

In This Article:

• Discrete vs. Process Manufacturing – How Do They Differ?
• Fundamental Processes in Discrete Manufacturing
• Understanding Process Manufacturing
• Hybrid Manufacturing: Integrating Discrete and Process Techniques
• Benefits and Challenges of Discrete and Process Manufacturing
• Technological Advancements in Manufacturing
• Choosing the Right Manufacturing Process and Software

Discrete and process manufacturing represent two fundamental approaches in the broader manufacturing environment, each defined by the nature of its production processes, supply chain management and the end products it generates.

• Discrete Manufacturing: A key feature of discrete manufacturing is the production of distinct items. Discrete manufacturers assemble individual components and units from original components, which can often be disassembled. Quality control focuses on individual items and design changes can be implemented unit by unit. Discrete manufacturing industries include automotive, aerospace and electronics.
• Process Manufacturing: Conversely, process manufacturers transform raw ingredients and materials through chemical, thermal or other processes to produce a finished product. The outcome cannot be disassembled into its original components. This manufacturing type is prevalent in the process industry for food and beverages, pharmaceuticals and chemicals.

Key Differences of Discrete Manufacturing vs Process Manufacturing:

• In discrete manufacturing, the final products are items that are countable and distinguishable and have discrete serial numbers.
• Process manufacturing deals with formulas or recipes and produces in batch production workflows.

Inventory management and Bills of Materials (BOM) also vary greatly. Discrete manufacturers usually rely on complex BOMs, whereas process manufacturers depend on strict formula management to comply with regulatory requirements.

Characteristics of Each Manufacturing Type:

Building a Cohesive Shop Floor with Deltek TIPSFE

Transform your shop floor with TIPSFE: streamline work instructions, track skills, monitor tools, enhance process control and go paperless.

Watch the Webinar

Discrete manufacturing can be characterized by the fabrication and assembly of distinct, individual items. Each item has a unique identifier and can frequently be broken down into original components. Discrete manufacturing processes are often defined as operations that include assembling parts along a production line or arranging distinct production stages for constructing complex products.

The critical processes within discrete manufacturing depend on well-structured production planning and may include:

• Assembly lines, whereby a product is built progressively from component parts.
• Dedicated workstations for different production stages might require specialized skill sets or machinery.

Precision in creation and an ability to accommodate changes in design or customer specifications are prominent features of discrete manufacturing operations. Managing each step efficiently is essential for the quality and customization of the final product and for optimizing inventory and supply chain management.

Examples of Discrete Manufacturing Products

Within discrete manufacturing, the range of items produced is vast and varied. Here are some examples:

• Cars: From the engine block to the seat belt buckle, cars are the quintessential example of a product born of discrete manufacturing, involving intricate assembly processes and numerous individual parts.
• Aircraft: Highly complex and assembled with extreme precision, aircraft demonstrate the pinnacle of discrete manufacturing, where each part must meet stringent quality and safety standards.
• Electronic Devices: Include every gadget from smartphones to laptops. Each electronic device involves assembling multiple small parts, such as chips, displays and wiring, into a single functioning unit.

This product diversity illustrates the flexibility and the complexity inherent in discrete manufacturing industries. It's a realm defined by precision, attention to detail and the individuality of each object crafted.

Process manufacturing is a production technique that primarily deals with creating bulk products.

This involves transforming raw materials through various chemical, biological or physical processes into finished goods indistinguishable from one another.

• The characteristics of process manufacturing include a continuous or batch production workflow that results in products that are often liquid, gas or finely divided solids.
• Quality control is integral as variations in the process impact the final product.
• The manufacturing processes typically involve blending, heating, cooling, fermenting or chemical reactions to produce the goods.
• Regulatory requirements are also crucial to this manufacturing environment due to the potential impact on consumer health and environmental safety.

Examples of Process Manufacturing Products

Products resulting from process manufacturing are varied and ubiquitous in everyday life. Here's a brief list of such products:

• Chemicals: Industrial solvents, detergents and plastics.
• Beverages: Sodas, soft drinks, alcohol and processed dairy products.
• Processed Foods: Snacks, canned goods and ready-to-eat meals.

These items reflect the wide range of goods produced in the process industry, where batch or continuous manufacturing yields products for direct consumption or as ingredients in other manufacturing or production processes.

Products that straddle the line between discrete and process manufacturing present unique challenges.

These items often require a blend of both manufacturing types due to the diverse nature of their components and production processes.

For example, a commercial aircraft or fighter jet might be assembled as a distinct item (discrete manufacturing), including components produced through chemical processes (process manufacturing). It may contain components like advanced composite materials and specialized adhesives created through process manufacturing, while the final assembly is discrete. Manufacturers of such hybrid products must adeptly manage both environments, utilizing systems that support both processes.

This mixed production planning involves discrete supply chain management for individual units and process industry practices, such as batch production workflows and continuous manufacturing for raw materials.

Maintaining high-quality control standards and precise inventory management across both disciplines ensures a seamless and efficient manufacturing process, yielding high-quality finished products.

Discrete manufacturing offers high customization and flexibility in operations, enabling manufacturers to quickly respond to specific customer requirements and create complex products from original components. This advantage is crucial in environments where product differentiation is critical.

However, this customizability often results in a complex supply chain and challenging inventory management. Discrete manufacturing requires careful production planning and detailed BOMs to ensure each unit meets quality control standards. Inventory management is critical, as manufacturers must track numerous individual items, both raw materials and components.

In contrast, process manufacturing excels in efficiency and scalability. It benefits from batch production workflows, allowing continuous manufacturing that systematically meets regulatory requirements. However, this type of manufacturing can be rigid, offering limited customization and posing challenges when adjustments to formulas or production processes are needed.

Industry 4.0 has revolutionized discrete and process manufacturing by integrating advanced technologies like IoT, Artificial Intelligence (AI) and robotics. These innovations pave the way for enhanced efficiency, more precise quality control and adaptive production processes.

This technological shift emphasizes modularity and flexibility in producing distinct items in discrete manufacturing. Process manufacturing sees advancements in real-time monitoring of materials transformation.

Enterprise Resource Planning (ERP), Manufacturing Execution System (MES) and Quality Management Systems (QMS) provide a backbone for this industrial transformation. These systems allow for:

• Improved supply chain management
• Real-time inventory tracking
• Optimized production planning and execution
• Enhanced regulatory compliance

Automation and data analytics are essential features in both manufacturing types. They bolster manufacturing operations by streamlining processes and predictive maintenance, reducing downtime and informing decision-making. As a result, the manufacturing environment significantly benefits from improved production efficiency and product quality, whether it involves discrete manufacturing processes or continuous manufacturing.

A Comprehensive Guide to Digitizing Your Shop Floor

Revolutionize your shop floor operations by harnessing modern tools and adopting a digitally enabled approach to managing end-to-end business processes.

Download the Guide

Selecting the appropriate type of manufacturing process and corresponding software is crucial for companies aiming to optimize their production systems.

1. Understand the Nature of Your Product: Assess your product's characteristics and production requirements to determine the most suitable manufacturing strategy. Consider factors such as complexity, volume and customization. Understanding these aspects will guide the choice of manufacturing process and ensure alignment with production goals and customer demands.
2. Consider the Manufacturing Method: When choosing a manufacturing method, evaluate how it aligns with your product's characteristics and production goals. Discrete manufacturing suits products requiring assembly from individual parts, offering flexibility and customization, ideal for industries focused on product differentiation. In contrast, process manufacturing is geared toward the continuous production of homogeneous goods, prioritizing efficiency and consistency, making it ideal for large-scale production of standardized items like chemicals or food. Selecting the correct method ensures optimized efficiency, quality and alignment with market demands.
3. Evaluate the Software Capabilities: When evaluating software for your manufacturing needs, ensuring it aligns with your chosen method is crucial. For discrete manufacturing, the software should offer robust features like inventory management, BOM tracking and assembly line monitoring, often with integration capabilities to enhance design precision. For process manufacturing, the software must excel in managing formulas, batch production and compliance, with robust process control and automation features to maintain consistency and quality. The right software should support your current processes and offer scalability and adaptability as your production needs evolve.
4. Check for Specialized Features: When selecting manufacturing software, looking for specialized features that cater to your specific production needs is essential. In discrete manufacturing, tools with advanced planning and scheduling capabilities, AI and robust integration capabilities can significantly enhance precision, automation and efficiency. For process manufacturing, process control systems and real-time monitoring are vital for maintaining consistency in batch production and ensuring regulatory compliance. These specialized capabilities can help streamline operations, reduce errors and improve overall productivity, making them essential for optimizing your manufacturing process.