Understanding Production Workflows: Discrete Manufacturing vs. Process Manufacturing
Whether you’re assembling circuit boards or mixing adhesives, your shop floor workflows depend on how you manufacture. Understanding the difference between discrete and process manufacturing can clarify which tools and systems your team really needs.
What Is Discrete Manufacturing?
Discrete manufacturing involves producing individual, countable units, each with its own identity. It typically includes part-level traceability, detailed bills of material (BOMs), and unique serial numbers for finished goods. Industries like electronics, metal fabrication, and OEM equipment rely on discrete processes. Work orders route components through defined steps by work center, and revision control ensures that each unit follows the correct configuration. In this model, accuracy and traceability at the part level are non-negotiable.
What Is Process Manufacturing?
Process manufacturing is built around mixing, blending, or chemical transformations. It’s common in industries like plastics, chemicals, food, and pharmaceuticals. Products are typically measured in volume or weight, and formulas replace traditional BOMs. Batches, rather than parts, define production runs. Output may vary based on yield, and the focus is often on consistency and compliance with mixing instructions. Batch control and lab test data often replace serial tracking.
Key Workflow Differences on the Shop Floor
While both models aim to produce usable products, their workflows differ significantly:
- Routing complexity: Discrete involves multi-step routing by work center, while process may consolidate into a single blending step.
- Inventory tracking: Discrete tracks serial or lot numbers per unit, while process uses batch IDs and yields.
- BOM structure: Discrete uses hierarchical, multi-level BOMs; process uses flat formulations with percentage-based inputs.
- Quality documentation: Discrete shops use COCs and serial-based inspections; process shops rely on lab results or in-process testing.
- Rework and scrap: Discrete rework can target individual units, while process rework often involves full batches.
How Cetec ERP Supports Discrete and Hybrid Manufacturing
Cetec ERP is built for discrete workflows, supporting serialized inventory, multi-level BOMs, and detailed routing by station. But many manufacturers operate in hybrid modes. Cetec ERP supports this too, lot control, batch tracking, dimensional inventory, and yield-based reporting all come standard. Whether your team builds machines or blends materials, Cetec ERP gives you the structure and flexibility to manage both.
Key Takeaways:
- Discrete = part-based, serial-controlled; Process = batch-based, yield-controlled
- Production and quality tools must align to manufacturing type
- Cetec ERP supports discrete manufacturers and hybrid shops with complex workflows
Choosing the right production tools starts with understanding how you manufacture. Discrete and process models demand different workflows and your ERP needs to support them both.
Ready to align your ERP with how you actually manufacture? Explore how Cetec ERP supports production teams with real-time routing, traceability, and shop floor tools tailored to your workflow. See how Cetec ERP supports both discrete and hybrid workflows.