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Dr. Vijaya Khader: Development Team
Dr. Vijaya Khader: Development Team
Co-Principal Investigator
Development Team
Dr. Vijaya Khader Prof.(Dr.) S.P. Bansal
Former Dean,
Principal Acharya N G Ranga
Investigator Agricultural
Vice University
Chancellor, Maharaja Agreshen University,
Baddi, Solan, Himachal Pradesh, INDIA
Dr. Vijaya Khader
Former Dean, Acharya N G Ranga Agricultural University
Prof.(Dr.) YoginderVerma
Co-Principal Investigator Prof.Vice Chancellor, Central University of Himachal
Pradesh,Kangra Himachal Pradesh, INDIA
Operation Management
Management
Characteristics of Job and Batch Shop Operating System
Quadrant-I
Description of Module
Subject Name Management
Paper Name Operation Management
Module Title Characteristics of Job and Batch Shop Operating System
Module Id Module- 05
Pre-requisites Basic understanding of Manufacturing setup, processes and
operation management.
Objectives 1. To understand the concept of manufacturing system.
2. Understanding different types of manufacturing system
Keywords Manufacturing System, Job Shop, Batch Shop, Process
Production, Intermittent Manufacturing System, Continuous
Manufacturing System
Learning Objectives:
The Learning objectives of the module are to address the following questions:
1. To know the concept of manufacturing system.
2. Understanding different types of manufacturing system.
3. To know the concept of job shop production system and batch shop
production system.
1. Introduction:
A manufacturing system is the process of arrangement and operation of
machines, tools, material, people and information to produce a value-added
physical, informational or service product whose success and cost is
characterized by measurable parameters. Manufacturing systems interacts with
both internal and external environment of the organization. Internal environment
Operation Management
Management
Characteristics of Job and Batch Shop Operating System
includes marketing, accounts, personnel, operations, and finance. External
environment include customers, labor, unions and suppliers.
A manufacturing system is an approach to making products that is based upon
several factors. These include how much of the product is needed, how quickly
the product must be produced and how unique the product must be to ensure
sufficient sales.
Decision Maker
Operation Management
Management
Characteristics of Job and Batch Shop Operating System
There are mainly two types of manufacturing system which is depicted in
following figure:
Mass Production
Project Production Flows
Batch Shop
Operation Management
Management
Characteristics of Job and Batch Shop Operating System
Customers Order &
Customers Specific Intermittent Production System
No Continuous flow
Of same size GoldSmith Tailor
Operation Management
Management
Characteristics of Job and Batch Shop Operating System
(III) The volume of production is small.
(V) The sequence of operation goes on changing as per the design of the
product.
(VI) The quantity, size, shape, design etc. of the product depends on the
customers orders.
Operation Management
Management
Characteristics of Job and Batch Shop Operating System
take a long time. There are many interrelated tasks in a project which
requires close coordination. Therefore, firms need to focus on coordination
between various interrelated tasks. Projects typically make heavy use of
certain skills and resources at particular stages and then have little use for
them the rest of the time. A project process is based on a flexible flow
strategy. Work flows are redefined with each new project.
Operation Management
Management
Characteristics of Job and Batch Shop Operating System
size customer orders or batch jobs. Job shops typically move on to different
jobs (possibly with different customers) when each job is completed. In job
shops machines are aggregated in shops by the nature of skills and
technological processes involved, each shop therefore may contain different
machines. Job shop process is basically a manufacturing process which
produces piece goods in small batches.
A job shop is a flexible operation that has several activities through which
work can pass. In a job shop, it is not necessary for all activities to be
performed on all products, and their sequence may be different for different
products.
To illustrate the concept of a job shop, consider the case of a machine shop.
In a machine shop, a variety of equipment such as drill presses, lathes, and
milling machines is arranged in stations. Work is passed only to those
machines required by it, and in the sequence required by it. This is a very
flexible arrangement that can be used for wide variety of products.
A job shop uses general purpose equipment and relies on the knowledge of
workers to produce a wide variety of products. Volume is adjusted by adding
or removing labor as needed. Job shops are low in efficiency but high in
flexibility. Rather than selling specific products, a job shop often sells its
capabilities.
A job shop process creates the flexibility needed to produce a variety of
products or services in significant quantities. Customization is relatively high
and volume for any one product or service is low. The work force and
equipment are flexible and handle various tasks. A job shop process primarily
Operation Management
Management
Characteristics of Job and Batch Shop Operating System
involves the use of flexible flow strategy, with resource organized around the
process. Most jobs have a different sequence of processing steps.
(II) A job shop production system utilizes general purpose machines and
facilities.
(III) The operators of job shop production system are highly skilled who can
take up each job as a challenge because of uniqueness.
(II) The operators of the job shop production system will become more
skilled and competent, as each job gives them learning opportunities.
They are capable of doing multitasking.
(III) In job shop production system the organization can utilised full potential
of operators.
(IV) There is an opportunity for creative methods and innovative ideas in job
shop production system.
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Operation Management
Management
Characteristics of Job and Batch Shop Operating System
2.3.2.3. Disadvantages of Job Shop Production System:
Some of the disadvantages of job shop production system are as under:
(I) The job shop production system is a costly system due to frequent set
up changes.
(II) This system involves higher inventory cost as it requires higher level of
inventory to operate systematically.
(III) As the job shop production system requires higher level of inventory,
therefore the space requirement is very large for proper maintenance of
the inventory.
(IV) Job shop manufacturing will require skilled workers who will be
involved in a variety of tasks. If skilled workers are not available then
this system will not function properly.
Operation Management
Management
Characteristics of Job and Batch Shop Operating System
variety, and quantity. The primary difference is that volumes are higher
because the same or similar products or services are provided repeatedly.
The American Production and Inventory Control Society (APICS) define
batch production as, “a form of manufacturing in which the job passes
through the functional departments in lots or batches and each lot may have
a different routing”.
It is characterized by the manufacture of limited number of products
produced at regular intervals and stocked awaiting sales.
In batch production system items are processed in lot or batch and the
produced product is unique. It utilizes specialized labour for each operation.
Organization and planning is more complicated in batch production system.
In batch production system new batch is undertaken for production only when
the work on all items of a batch is completed.
(II) In batch production system plant and machinery set up is used for the
production of item in a batch and change of set up is required for
processing the next batch.
(III) The manufacturing lead time and cost are lower in batch production
system as compared to job production system.
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Operation Management
Management
Characteristics of Job and Batch Shop Operating System
(I) Better utilisation of plant and machinery is possible under batch
production system.
(III) In batch production system the per unit cost is lower as compared to
job production system.
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Operation Management
Management
Characteristics of Job and Batch Shop Operating System
not produced on customer’s orders. Here, the inputs and outputs are
standardized along with the production process and sequence.
Following figure highlights the concept of a continuous production system.
Production is on a large
Scale Food Industry Fuel Industry
Operation Management
Management
Characteristics of Job and Batch Shop Operating System
(III) In a continuous production system the products are produced on
predetermined quality standards.
Operation Management
Management
Characteristics of Job and Batch Shop Operating System
when Henry Ford, upon request from US government, produced bomber air
craft’s for USA.
Following URL shows how Henry Ford and his engineers perform something
unthinkable in the history of air craft assembling:
https://youtu.be/iKlt6rNciTo
Following URL shows the historic footage of how mass production of famous
Model T was done there:
https://youtu.be/IXkxl8dSXb4
(IV) In mass production system the probability of human error and variation
is also reduced, as tasks are predominantly carried out by machinery.
Operation Management
Management
Characteristics of Job and Batch Shop Operating System
(I) In mass production system higher rate of production with reduced cycle
time.
(III) Manufacturing cost per unit is very low in mass production system.
(III) Line layout needs major change with the changes in the product
design.
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Operation Management
Management
Characteristics of Job and Batch Shop Operating System