Continuous production

Shutting down and starting up many continuous processes typically results in off quality product that must be reprocessed or disposed of.

In the more complex operations there are sequential shut down and start up procedures that must be carefully followed in order to protect personnel and equipment.

[2] Many processes such as assembly lines and light manufacturing that can be easily shut down and restarted are today considered semi-continuous.

The oldest continuous flow processes is the blast furnace for producing pig iron.

The blast furnace is intermittently charged with ore, fuel and flux and intermittently tapped for molten pig iron and slag; however, the chemical reaction of reducing the iron and silicon and later oxidizing the silicon is continuous.

Semi-continuous processes, such as machine manufacturing of cigarettes, were called "continuous" when they appeared.

The Cromford mill of 1771, designed by Richard Arkwright, was the first factory to use a continuous process from raw material to finished product in a series of operations.

The Fourdrinier paper machine, patented in 1799, was one of the earliest of the Industrial Revolution era continuous manufacturing processes.

It produced a continuous web of paper that was formed, pressed, dried and reeled up in a roll.

These typically involve the various departments such as maintenance, power, engineering, safety and operating units.

All work is done according to a carefully sequenced schedule that incorporates the various trades involved, such as pipe-fitters, millwrights, electricians, mechanics, laborers, etc., and the necessary equipment (cranes, mobile equipment, air compressors, welding machines, scaffolding, etc.)