Definition & Examples
Discrete Manufacturing vs. Process Manufacturing
Discrete manufacturing and process manufacturing are two fundamentally different types of production. We explain the key differences.
Definition
Discrete and Process Manufacturing in Brief
Discrete manufacturing is the production of countable individual products that are made and assembled from components according to a bill of materials – for example cars, machines or electronic assemblies.
Process manufacturing is the production of goods that are measured by quantity, volume or weight and are made according to recipes – for example beverages, paints or chemicals.
The difference lies in the product: Units or quantities. This leads to differences in planning, master data, traceability and the software used. Process manufacturing shapes the so-called process industry (chemicals, pharmaceuticals, food, beverages), while discrete manufacturing shapes the manufacturing industry (automotive, mechanical engineering, electronics).
Definition: Discrete Manufacturing
What is discrete manufacturing?
Discrete manufacturing is a type of production in which distinct individual products are manufactured.
Each product typically consists of separate components that are defined in a bill of materials and assembled during the manufacturing process.
The final products are countable. Multiple product variants are common.
Examples of discrete manufacturing:
- Automotive production
- Furniture manufacturing
- Household appliance production
Definition: Process Manufacturing
What is process manufacturing?
In contrast, process manufacturing produces goods that are not countable but are measured by quantity, volume or weight.
Instead of bills of materials, process manufacturing uses recipes and formulas. These specify how and in what proportions ingredients must be processed to achieve the desired end product.
Examples of process manufacturing:
- Beverage production
- Paints and coatings manufacturing
- Metal production (e.g. steel and aluminium)
- Chemical industry
- Pharmaceutical industry
Differences between discrete manufacturing and process manufacturing
The fundamental differences between the products of discrete manufacturing and process manufacturing (countable units vs. homogeneous quantities) also lead to differences in production planning, the tools used and various other aspects.
Below, we highlight areas in which discrete manufacturing differs from process manufacturing.
Disassembly into individual components
In a discretely manufactured product, the individual components are often visible in the final product and products can often even be disassembled into their individual parts.
In contrast, with process-manufactured products – such as those created by mixing various ingredients – this is generally not possible.
Bills of materials and routings vs. recipes and formulas
Bills of materials are used in discrete manufacturing and provide a structured list of all components, assemblies and materials required to produce a product. Routings describe the necessary steps in the manufacturing process, including sequence, workstations and tools.
In contrast, process manufacturing relies on recipes and formulas. Recipes specify the required materials or substances for producing a product, including information on proportions and concentrations. Formulas describe the production process and provide details on how variables like pressure, temperature or mixing times must behave (often automated).
Types of manufacturing
In process manufacturing, products are often produced in batches. A batch is a defined production quantity manufactured under consistent conditions. Batch numbers make it possible to trace products back to their batch even after packaging (e.g. bottled beverages). Batches not only ensure consistency but also offer the advantage of traceability. Besides batch production, there is continuous manufacturing: Plants such as refineries, paper machines or glass furnaces run around the clock without fixed batch sizes.
Discrete manufacturing features different types of production. In single-item manufacturing, each product is made individually. In series production, a fixed number of identical products is produced. Lastly, mass production refers to the continuous production of identical products in very large quantities.
Flexibility and degree of automation
Many discrete manufacturing processes offer a certain level of flexibility when producing different products or product variations. This could be achieved by retooling existing equipment or adapting manual assembly processes.
Process manufacturing typically offers less flexibility but often ensures high process stability. Many process industries are heavily regulated and not only the products but also the production processes themselves are continuously monitored. The degree of automation is usually very high.
ERP systems
In both discrete and process manufacturing, the ERP system is central to production planning. However, typical ERP systems for discrete manufacturing differ significantly from those used in process manufacturing.
ERP systems for discrete manufacturing manage bills of materials, routings and engineering data. They are often more order-driven and include configurators to handle different product variants.
ERP systems for process manufacturing must be able to work with recipes, quantities and units. They integrate functions for batch management, documentation capabilities and are often connected to laboratory information management systems (LIMS).
Comparison
Discrete and process manufacturing compared
The key differences between discrete manufacturing and process manufacturing at a glance:
| Criterion | Discrete manufacturing | Process manufacturing |
|---|---|---|
| Product | Countable individual items (units) | Homogeneous quantities, measured by volume or weight |
| Input materials | Parts, components and raw material | Raw materials and ingredients |
| Master data | Multi-level bill of materials and routing | Recipe and formula with proportions and process parameters |
| Core process | Parts production and assembly of components and subassemblies | Mixing, reacting, heating, filling |
| Disassembly | End product can usually be taken apart into its components | End product cannot be separated back into its ingredients |
| Types of manufacturing | One-off, series and mass production | Batch production and continuous manufacturing |
| Traceability | Via serial number or order number | Via batch number |
| Inventory | In units per part and assembly | In units of measure per batch, often with an expiry date |
| Quality control | Per unit or sample, e.g. dimensions and function | Laboratory testing per batch, e.g. concentration and purity |
| Flexibility | High – retooling, variants, manual assembly | Lower, but high process stability and a high degree of automation |
| ERP focus | Bills of materials, routings, engineering data, variant configuration | Recipes, units of measure, batch management, documentation, LIMS connection |
| Typical industries | Automotive, mechanical engineering, electronics, medical technology, furniture, household appliances | Chemicals, pharmaceuticals, food, beverages, paints and coatings, metal production |
Neither type of manufacturing is better or worse – each follows from the product. Many companies combine both, as the next section shows.
Hybrid Manufacturing
Hybrid manufacturing: When both types come together
In practice, many manufacturers cannot be assigned clearly to one type of manufacturing. Often a product is first made as a batch in process manufacturing and then processed further, packaged and labelled as discrete units. Typical scenarios:
- Pharmaceutical industry: The active ingredient is produced as a batch according to a recipe. The tablets are then counted, packaged and serialized – a discrete step.
- Food industry: Doughs or fillings are mixed in batches, while the finished baked goods or packs are then counted as units.
- Electronics manufacturing: Solder pastes, potting compounds and coatings are processed according to a recipe, while the assemblies themselves are built discretely according to a bill of materials.
- Beverage production: The beverage is made as a batch in a tank, and bottling creates countable units that remain traceable via the batch number.
For planning, this means that both logics – bill of materials and recipe, order and batch – have to be mapped in the same systems. Manufacturers with such hybrid set-ups therefore place special requirements on their software.
Software
Which software suits which type of manufacturing?
In addition to the ERP system, production mainly relies on a manufacturing execution system (MES) and on production and machine data acquisition. Their tasks differ depending on the type of manufacturing:
- Discrete manufacturing: Confirming orders and operations, recording unit counts, scrap and set-up times, calculating KPIs such as OEE and tracking assemblies via serial numbers.
- Process manufacturing: Creating and recording batches, logging process parameters such as pressure, temperature and mixing times, assigning quality data from the laboratory (LIMS) and providing documentation for regulatory compliance.
Standard software is usually tailored to one of the two types of manufacturing. Companies with hybrid set-ups or very specific workflows therefore often add their own applications – for dashboards, batch records or checks at the workstation, for example.
manubes
Flexible application development for discrete manufacturing and process manufacturing
Our manubes platform integrates intuitive no-code design tools for data models, visualizations and workflows. This allows manufacturers to quickly develop their own applications, tailored exactly to their specific requirements.
With the Datamodel Designer, data models can be adapted to the respective type of manufacturing: In discrete manufacturing, for example, around orders, unit counts and serial numbers; in process manufacturing, around batches, quantities and process parameters.
manubes utilizes edge components and industrial standard interfaces to facilitate data exchange with machines and devices, databases, shopfloor systems and IT applications such as ERP or LIMS.
Companies in both discrete and process manufacturing benefit from more effective production management with manubes.
Example applications:
- Real-time dashboards for monitoring machine and process data, KPIs and order progress
- Configurable push notifications for various devices
- Automated generation and distribution of production reports
- Barcode or QR code scans for material verification
The image shows an example of an OEE dashboard with manubes.
Frequently asked questions about discrete and process manufacturing
What is discrete manufacturing?
Discrete manufacturing is the production of countable, distinct individual products. They are made and assembled from components defined in a bill of materials – for example cars, furniture or household appliances.
What is the difference between discrete and process manufacturing?
The main difference lies in the product: Discrete manufacturing produces countable units according to a bill of materials and routing, while process manufacturing produces quantities according to a recipe and formula that are measured by volume or weight. This leads to differences in types of production, traceability, flexibility and ERP systems.
What is an example of discrete manufacturing?
Typical examples of discrete manufacturing are automotive production, mechanical engineering, electronics manufacturing and the production of furniture or household appliances. Examples of process manufacturing include beverage production, the chemical and pharmaceutical industries, paints and coatings, and metal production.
What is batch manufacturing?
Batch manufacturing is a type of process manufacturing in which a defined quantity is produced under consistent conditions. Each batch receives a batch number that allows products to be traced even after bottling or packaging.
What is the process industry?
The process industry comprises the sectors that mainly produce through process manufacturing – such as chemicals, pharmaceuticals, food and beverages, paints and coatings or metal production. Its counterpart is the manufacturing industry with discrete manufacturing, for example automotive, mechanical engineering and electronics.
What is the difference between discrete and continuous manufacturing?
Discrete manufacturing produces countable individual items, whereas continuous manufacturing is a form of process manufacturing in which plants such as refineries or paper machines run around the clock without fixed batch sizes. The output is measured as a quantity, not as individual units.
What are the main types of manufacturing processes?
A common classification distinguishes three types: Discrete manufacturing of countable items, batch process manufacturing in defined quantities and continuous process manufacturing without fixed batch sizes. Discrete manufacturing is further divided into one-off, series and mass production.
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