OPERATIONS MANAGEMENT

PROJECT REPORT ON

JOB SHOP PRODUCTION PROCESS

BY

VIDHI SHARMA

IN PARTIAL FULFILLMENT FOR THE AWARD OF DEGREE OF

MASTER OF BUSINESS ADMINISTRATION

(RAJASTHAN TECHNICAL UNIVERSITY, KOTA)

UNDER THE GUIDANCE OF

DR. ABHISHEK SHARMA

(DEPARTMENT OF MANAGEMENT STUDIES)

(PODDAR MANAGEMENT AND TECHNICAL CAMPUS, JAIPUR)

 ACKNOWLEDGEMENT

In preparation of this report by me, I feel great pleasure because it gives me extensive
practical

knowledge. I got an idea about the Job shop production process from this report. I express my

deep sense of gratitude to the faculty Mr. Abhishek Sharma who guided me throughout the

project. Finally, I would like to thank my parents and friends who directly or indirectly

supported me to complete the project and give it firm direction.

Yours, sincerely

Vidhi sharma
 TABLE OF CONTENTS

S. No. Topics Page number

Chapter 1 Introduction 1 - 15

Chapter 2 Company profile 16 - 20

Chapter 3 Data and detailed analysis 21 - 27

of study

Chapter 4 Summary of results and

findings 28

Chapter 5 Suggestions 29 - 31

Chapter 6 Conclusions and directions 32 - 35

for future
 CHAPTER 1

INTRODUCTION

A job shop is a type of manufacturing process in which small batches of a variety of custom
products are made. In the job shop process flow, most of the products produced require a
unique set-up and sequencing of process steps. Job shops are usually businesses that perform
custom parts manufacturing for other businesses. However, examples of job shops include a
wide range of businesses—a machine tool shop, a machining center, a paint shop, a
commercial printing shop, and other manufacturers that make custom products in small lot
sizes. These businesses deal in customization and relatively small production runs, not
volume and standardization.

PRODUCTION PROCESS

The production process definition refers to the steps followed to convert an input into an
output. It involves utilizing and combining economic resources like land and capital and
processing them to provide products and services for consumers. It is simply defined as
changing inputs into outputs.

The business production process has four main characteristics: extractive process, Analytical
process, fabrication process, and synthetic process. The extractive process refers to the
activities done in getting the raw materials from their source. Analytical involves separating
the raw materials into what resembles the original produce. The fabrication process is
concerned with creating more products from the same material, and the synthetic process
combines several products to form a product.

A production process is the method you'll use to turn inputs into muffins to sell. Inputs
include raw materials, such as flour, sugar, oil, yeast, fruits and other ingredients you use for
making muffins. Inputs also include the work you and your employees put into making the
muffins. The production process is the manner in which you organize your muffin making
activities. You have more than one production process from which to choose.

TYPES OF PRODUCTION PROCESS

The Three main types of production are Mass production, Batch production, job production
and just-In-Time production, and flexible manufacturing system. The methods of production
in the types stated differ and can be analyzed using factors like the manufacturing costs, the
capital invested, and job security. Mass production has a higher production cost, and job
production requires a higher capital investment.

● MASS PRODUCTION - The mass production process constitutes assembly lines

and automation technology to provide goods in bulk. The main features of mass
production include division of labor as each production process requires a different
machine, a smooth flow production with product flow clearly defined, standardization
 to achieve high quality, and high startup costs due to the many resources required
before operations.

The following goods are mass produced:

toilet paper

cell phones

automobiles

● BATCH PRODUCTION - The production process in batch production is the same

goods go through different stages to create the same output. It constitutes of batches,
group production, and the same machinery. The main features of the batch process
include repetitive processes, machines of the same type arranged strategically in the
same production process, and a set layout and elements include group customization,
which involves changes to be made and reuse of equipment's

Examples of batch production include the following:

● bakeries
● textiles
● furniture

● FLOW OR CONTINOUS PRODUCTION - flow production also known as

continuous production, occurs when a process runs twenty-four hours a day.
Companies whose products are homogeneous use this production approach to reduce
cost and increase efficiency. These systems are highly automated, and workers act as
monitors rather than as active participants.

Examples of flow production:

● gas and oil

● steel
● chemical
 WHAT IS A JOB SHOP

A Job Shop is referred to as a type of manufacturing process that can handle small
orders for made-to-order (MTO). Here the products are produced in small batches (of
varying quantities) to maximize flexibility.‌‌This often includes products with custom
designs & maintenance, small fabrication orders, and repair services. ‌The operating
periods and sequences of products may differ significantly in job shop production.
The goods are released one time in batches, often known as "jobs."‌‌Job shop
manufacturing processes are distinguished by specific workflows, work centers, job
prioritization, and job-related information.‌‌General-purpose machines are extensively
employed in job shop factories. It helps to enable the manufacture of a variety of
goods in small lot sizes or quantities. This is because they have a wide range of
capabilities and can carry out a wide range of activities.‌‌Job shop owners have the
option of selling their goods directly to customers, doing business with wholesalers,
or producing components for other businesses. ‌

WHEN IS JOB SHOP PRODUCTION PROCESS IS USED?

Job shop production process is used when there is a need of :

1. High variety of products with low volume

2. Use of general purpose machines and facilities
3. Highly skilled operators who take up each job as a challenge
4. Large inventory of materials, tools and parts
5. Detailed planning is essential for Sequencing of each product

CHARACTERISTICS OF JOB SHOP

1. LAYOUT :
In the job shop, similar equipment or functions are grouped together, such as all drill presses
in one area and grinding machines in another in a process layout. The layout is designed to
minimize material handling, cost, and work in process inventories. Job shops use general
purpose equipment rather than specialty, dedicated product-specific equipment. Digital
numerically controlled equipment is often used to give job shops the flexibility to change
set-ups on the various machines very quickly. Because economies of scale are usually not a
part of a job shop's competitive edge, they compete on factors other than price. They compete
on quality, speed of product delivery, customization, and new product introduction.

2. ROUTING :

When an order arrives in the job shop, the part being worked on travels throughout the
various areas according to a sequence of operations. Not all jobs will use every machine in
the plant. Jobs often travel in a jumbled routing and may return to the same machine for
processing several times. This type of layout is also seen in services like department stores or
hospitals, where areas are dedicated to one particular product (men's clothing) or one type of
service (maternity ward).

3. EMPLOYEES :

Employees in a job shop are typically highly skilled craft employees who can operate several
different classes of machinery. These workers are paid higher wages for their skill levels. Due
to their high skill level, job shop employees need less supervision. Workers may be paid a
standard hourly wage or by an incentive system. The role of management is to bid on jobs
and to establish prices for customer orders. The key activity in a job shop is processing
information.

4. INFORMATION :

Information is the most critical aspect of a job shop. Information is needed to quote a price,
bid on a job, route an order through the shop, and specify the exact work to be done.
Information begins with quoting, then a job sheet and blueprint are prepared before the job is
released to the floor. Once on the production floor, employees complete job sheets and time
cards for labor cost calculations and to update records for quoting future jobs when variances
are present While it is often easy to bid on jobs the shop has manufactured before, new jobs
require accurate costing of labor, materials, and equipment as well as accurate assigning of
overhead to the job. Tickets follow each job through the shop, where time and activities are
recorded. Because the job shop makes specialty, custom items, it competes on quality and
customer service and not on price. The job shop has little if any raw materials inventory
because customers bring in the parts and materials to be worked on. The job shop has
work-in-process inventory while jobs are being completed, but typically the customer is
waiting on the order and expects prompt delivery, so there is no finished goods inventory in
this make-to-order environment. Some job shops, like many small businesses, thrive on
managing cash flow. They may work on small jobs to complete them by the end of the month
so they can bill customers for the work.

5. SCHEDULING :

A job is characterized by its route, its processing requirements, and its priority. In a job shop
the mix of products is a key issue in deciding how and when to schedule jobs. Jobs may not
be completed based on their arrival pattern in order to minimize costly machine set-ups and
change-overs. Work may also be scheduled based on processing time, from shortest to
longest. Capacity is difficult to measure in the job shop and depends on lot sizes, the
complexity of jobs, the mix of jobs already scheduled, the ability to schedule work well, the
number of machines and their condition, the quantity and quality of labor input, and any
process improvements.

BACKGROUND OF THE STUDY

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 involves the
use of flexible flow strategy, with resource organized around the process. Most jobs have a
different sequence of processing steps.

. Job shop involves very skilled workers. First, the job details are get from the company. Then
mockup or design is made on the computer. The computer then sends details to the machine
and the machine then output the final product.

The jobs which are done by the shop are usually not in bulk but for small orders. The quality
of products is good as compared to the batch shop. In the batch shop, the quantity of products
is high and there are some chances that some products may not be of good quality. But in the
case of job shop, each product is made carefully and the quality of the product is high.

A job shop is a type of manufacturing company that make custom products. You can consider
a hospital as a job shop also. The hospital behaves as the shop and patients in the hospital are
considered as jobs.

Computer technology plays a vital role in the job shop. The high skilled graphic designers are
employed for making the designs of the products. There are two or three types of
manufacturing machines placed in the shop to carry out the work.

The example of job shop includes drill passes, milling machines, grinding machines that
produce metallic and plastic parts for the vehicles and industrial machines.

FEATURES OF JOB SHOP PRODUCTION PROCESS

Following we have discussed the characteristics of Job Shop Manufacturing. Let’s learn:‌‌

1. Customers frequently submit numerous small-batch orders (jobs) with unpredictable

process requirements at unpredictable times.

2. A job's quantities, material requirements, routings, priorities, target lead times, and margin
may all change.
3. An order may specify the manufacturing of a collection of related components or a variety
of components, the development of subassemblies from those subassemblies, and the final
assembly.

4. While competing for the same resources, many jobs may be operating simultaneously
through the system along their own routings.

5. Processing a work might entail some external operations.

6. Production tasks might be carried out in a particular order or according to predetermined

priority relations.

7. The operations and relations might vary from job to job.

8. The setup and cycle times of every operation can change based on the task.

9. How quickly operations are setup may also depend on the sequencing of the jobs.

10. A single resource or a large number of resources, such workers and machines, may be
required for an operation.

11. Workers and multipurpose machines could be considered resources.

12. Resources may be subject to individual calendars (working hours) and calendar
exclusions.

13. One or more alternative resources may or may not be shared in order to reduce the
amount of time needed for a protracted operation.

14. The system allows for the transfer of materials for a project either as a single batch or in
small transfer batches.
 INDUSTRIES THAT EMPLOY JOB SHOP PRODUCTION PROCESS

A job shop may produce a wider range of goods than a production line. This can do so
sequentially and one after the other. Job shops can be found in the following industries:‌‌

• Make-to-order (MTO) production units

• Engineer-to-order (ETO) production units

• Custom manufacturing units

• High-mix, low-volume production units

• Order-driven production units

• High-variety production units‌‌

Job shops, in particular, include many different types of companies, such as:‌‌

Paint Shop

Fabrication shops,

Commercial Printing Shop

Bespoke woodworking companies,

Forge shops,
Machine shops,

Mold shops,

Tool & die shops,

Furniture makers,

Labs,

Repair companies,

Particular service companies, etc. ‌ Production management in job shops like fabrication units
is typically akin to the management of multiple, concurrent projects that share a lot of
common resources. However, they have a limited amount of capacity.

EXAMPLE OF JOB SHOP PRODUCTION PROCESS

Many different manufacturers use job shop manufacturing, and in our example, we'll look at
how it's used within our business.

Design :

Customers can personalize products or design elements. Due to the special setup required, job
shop manufacturing enables manufacturers to customize each individual item.

The customer can select the type of finish they want for their components or goods in
addition to choosing from a variety of materials.

Customers can pick whether they want their components or products painted or even
engraved in addition to the other choices available.
Preparing Materials through Cutting

Once the order is placed and the supplies have arrived, the sheet metal is cut to the
specifications in compliance with the customer's order.

One of our knowledgeable operators will cut the material into the required form at the
particular workstation we have set aside for that purpose. specifically, strips or discs made of
metal. Therefore, workstations are ideal for avoiding backlogs and delays.

Rolling & Welding (Dependent on component)

If the sheet metal had been cut into strips, the ends would first be joined by welding after the
strips had been rolled.

First Inspection and Tooling

The sheet metal discs or welded components are inspected in accordance with ISO 9001:
2015 standards, as is the case with all processes. The tooling is then selected based on the
requirements of the customer order.

Metal Spinning

The metal spinning process begins once the materials have been prepped and cut. In this
instance, welded metal discs or metal strips are formed over a tool. To the customer's
specifications, the component is finished and shaped.

Finishing and Secondary Fabrications

The component will undergo a polishing process after its shape is finalized. The cleaning
procedure includes the procedures of deburring and polishing. If more secondary fabrications
are required, we'll drill holes before anodizing or painting, for example.
Final Assessment and Delivery

The items undergo one more inspection before being packaged and shipped.

When workstations are divided in this fashion, it is simple to move the components to the
subsequent operation. The availability of personalization options would further suggest that
the things are not in the same order.

ADVANTAGES OF JOB SHOP PRODUCTION PROCESS

Job shop production is the best manufacturing process for any modern organization. Even the
majority of firms can go back to its roots.

This is not to say that this process is perfect. Thus, let's discuss its shortcomings so that you
are aware of them and can be ready for them.

Following we’ve discussed the benefits of job shop manufacturing. Let’s discuss:

1. Increased Flexibility

You can manufacture and produce a much wider variety of items. It is because the machines
aren't made specifically to make one type of product.

2. Improved Supervision

In job shop production, the departments are in charge of organizing the machines into
functional groups. Each department's manager has more extensive knowledge to ensure more
productive days.
3. Operators Pick up Cutting-Edge Knowledge and Abilities

Almost every operator can concentrate on one machine and study this department. It is
because machines are organized by department. This could boost each department's activity
and manufacturing efficiency.

4. Highly Qualified Individuals

For this type of manufacturing process to be successful, you will need employees that are
highly skilled in the particular trade of your company.

In other words, you can let workers finish their jobs since their level of experience will
ensure that they deliver a high-quality finished product on time.

5. Better Equipment Utilization

When using the job shop method, every piece of equipment is used as fully as is practical.
Large machines and expensive machinery are therefore not as necessary.‌‌

6. Product Monitoring on the Ground

The products move while going through their own stages, making it simple to watch their
growth.‌‌

7. Lower Spending

Simply buy the appropriate tools, put them in the best locations for your items to move
through throughout manufacturing, and you're good to go. ‌
Simply make further orders to finish the merchandise and satisfy customer demand.
Installation of a new workstation shouldn't disrupt the ongoing procedure.‌‌

8. Better Utilization of Resources

Focusing on each product will allow you to efficiently use all of your resources to complete
orders.‌‌

9. Customizable Product Designs

The workshop production method allows customers to customize their orders. As a result,
each product is unique, and the buyer can participate in the manufacturing process.

DISADVANTAGES OF JOB SHOP PRODUCTION PROCESS

There are always drawbacks to take into account with positives. The drawbacks of job shop
manufacturing are listed below.‌‌

1. Heavy Production Costs

Manufacturing in a job shop is more expensive. It is because managing materials and moving
parts from one department to another is so expensive.‌‌

2. Costly Material Management

In manufacturing, managing the materials can be expensive and challenging. Materials must
be exchanged, which could be confusing, if one machine is not prepared to take on a task or
the machine worker is not accessible.‌‌

3. High Flow of Materials

Because job shop manufacturing is carried out by departments, the pieces must be transferred
to the subsequent department for completion. Due to the necessity of transferring components
around the whole facility before an activity is finished, job shop manufacturing has a high
material flow.‌‌

4. Longer Lead Times for Production

Each part of the batch must be completed before the item can move on to the next stage of
production. If one component is running late, the entire batch will as well, resulting in a long
lead time and low production rates.‌‌

5. High Degree of Work

Your workload could be heavy if you have a lot of orders. However, the opposite is equally
undesirable. Low to no orders suggest insufficient utilization of the resources. However, there
is a chance that both will be stressful.‌‌

The negative aspects of a job shop could be frightening. Although there is a possibility that
you will encounter these issues, there are things you can take to avoid them.‌‌
 CHAPTER 2

COMPANY PROFILE

BHEL is one of the largest engineering and manufacturing companies of its kind in India
engaged in design, engineering, construction, testing, commissioning and servicing of a wide
range of products and services with over 180 product offerings to meet the ever-growing
needs of the core sectors of economy. It uses job shop production process.

Here's a quick overview of its profile :

Core strengths
Diverse portfolio: BHEL offers over 180 products and services across various sectors,
including:

Power: Thermal, hydro, gas, nuclear & solar PV, transmission & distribution equipment.

Transportation: Locomotives, electric traction systems, etc.

Defence & Aerospace: Critical equipment like naval guns, aircraft engines, etc.

Oil & Gas: Steam turbines, compressors, etc.

New areas: Battery Energy Storage Systems (BESS), EV chargers, etc.

Manufacturing prowess: BHEL boasts 16 manufacturing facilities across India, showcasing

exceptional engineering and production capabilities.

National significance: BHEL is the only manufacturer of nuclear steam turbines in India and
plays a crucial role in the country's nuclear power program. It's also a trusted supplier to the
Indian Navy and Defence sector.

Global reach: BHEL exports its products and services to over 70 countries worldwide.

KEY ACHIEVEMENTS

Technological advancements: BHEL is actively involved in R&D, with four of its major
units awarded the "CII-EXIM Bank Award for Business Excellence 2021."

Sustainability focus: BHEL is committed to cleaner energy solutions and developing

environmentally friendly technologies.
Economic and social impact: BHEL contributes significantly to India's economic growth
and employment generation, supporting the development of critical infrastructure.

BHEL proudly carries a clear vision and mission that drive its ongoing efforts as a leader in
the energy and infrastructure sector. Here's a closer look at both:

VISION : A global engineering enterprise providing solutions for a better tomorrow. This
vision emphasizes BHEL's aspirational role as a leading provider of solutions that not only
contribute to global development but also create a more sustainable and prosperous future.

MISSION : Providing sustainable business solutions in the fields of Energy, Industry &
Infrastructure. This mission outlines BHEL's core focus areas:

● Energy - Supplying and developing efficient & environmentally friendly power

generation solutions across various technologies (thermal, hydro, nuclear, solar, etc.)

● Industry - Providing critical equipment and expertise for sectors like transportation,
oil & gas, and other industrial applications.

● Infrastructure - Contributing to building vital infrastructure for the nation,

including power transmission & distribution networks, water management systems,
etc.
 BHEL's vision and mission are further supported by its core values, which include:

Governance: Transparency, accountability, and ethical t.

Excellence: Continuously striving for the highest standards in everything they do.

Respect: Valuing and treating all stakeholders with fairness and dignity.

Commitment: Dedication to fulfilling promises and achieving goals.

Innovation: Fostering a culture of creativity and developing new technologies for a better
future.

Teamwork: Collaborating effectively across all levels to achieve shared goals

These vision, mission, and values together paint a clear picture of BHEL's ambition to be a
global leader in providing sustainable solutions for a better tomorrow, both within India and
internationally.

HOW BHEL USES JOB SHOP PRODUCTION PROCESS

While BHEL's main production system leans towards batch production but , job shop
production does play a role in certain aspects of their operations. Here's how:

1. FABRICATION AND ASSEMBLY -

• BHEL manufactures large and complex equipment like boilers, turbines, and generators.
These often require custom-made components with unique specifications

•. The fabrication and assembly of these parts often involve a job shop approach.requirement.
Highly skilled workers operate specialized machines to shape, weld, and assemble individual
components based on specific design drawings and requirements.

•This customized production allows BHEL to cater to diverse customer needs and tailor
equipment to specific project demands.

2. PROTOTYPE DEVELOPMENT AND TESTING -

•Before launching new products or technologies, BHEL invests heavily in research and
development. This involves creating prototypes and conducting rigorous testing.

•Job shop production is well-suited for such activities, allowing engineers to experiment with
different designs and materials efficiently.

•The flexibility and adaptability of job shops enable BHEL to quickly build and modify
prototypes, gather data, and iterate on their designs before full-scale production.

3. MAINTENANCE AND REPAIR SERVICES -

• BHEL offers comprehensive maintenance and repair services for the equipment it
manufactures. These services often involve on-site work at customer facilities.

•The unpredictable nature of these jobs makes them suitable for a job shop approach.

•BHEL technicians travel with necessary tools and spare parts, allowing them to diagnose
and fix problems on the spot, adapting to various situations and requirements.
 CHAPTER 3

DATA AND DETAILED ANALYSIS OF STUDY

Controlling the flow of materials inside job-shops involves several decisions such as the
acceptance or rejection of an incoming order, the order's due date definition, the releasing and
the dispatching of the job. This study applies a multiple decision-making scheme involving
these four decision phases to examine the sensitivity of job-shop performance to different
order release parameters. The performance criteria of shop workload and order delivery were
collected to demonstrate the influence of the most significant order release parameters: the
queue workload limit and the planning parameter of the latest release date. The influence of
each parameter is evaluated by computational simulations. The way we compute the machine
workload limit affects not only the workload but also delivery performance measures.
However, surprisingly, the latest release date has not a significant impact on shop-floor
performance measures. The effect of the queue workload limit in an input-output control
mechanism on delivery and workload related performance measures had not been studied up
to date. Neither any analysis had investigated the influence of the latest release date calculus
on the performance of the job-shop.

In job shop production the routing and scheduling of jobs is much more complex than in
other production systems. The workflow of each production job is given by a job description
which defines the required sequence of the necessary production steps. The decision when to
schedule a job and which resource shall be used for each production step depends on the job
requirements, the actual availability of the resources and other circumstances. Productions
control ,ProductionModel , WorkCenterWorkCenter
 Job Shop specific Classes

For the Simulation Based Job Shop Production Analyser some specific classes have been
developed on top of the general simulation classes. These are special classes for modeling the
job shop such as Shop, Department,WorkCenters , ShopMachines and Scheduler. With these
it is possible to build hierarchical models of the job shop facility. Some more special model
classes may be added due to specific customer requirements. Further customer specific rules
for the routing and scheduling can be integrated into the production control module. The
Shop module represents the upper level of a job shop production model. A Shop may contain
several Departments which represent the organizational structure of the facility. The
Department module is used to model production areas. A Department may contain several
WorkCenters which are assigned to a certain processing tasks. A Department does not
provide processing features itself; it serves as organisational unit to group production
facilities. The WorkCenter is the module which offers certain processing tasks for the jobs. In
a WorkCenter there may be several machines located which fulfil the required processing
tasks. A WorkCenter contains an input and an output buffer. All material flow is sent into the
input buffer. For the jobs in the input buffer it has to be decided, which lot shall be produced
next on a particular machine respectively resource. This production control decision is done
by the Schedulerusing rule based dispatch algorithms. The ShopMachines are the material
flow modules to perform an operation. In a job shop model machines are always located in a
WorkCenter. The Scheduler is a very flexible production control module wich allows to
model rule based production planning and control algorithms. A scheduler can be used on
different model levels. On the upper model level the Scheduler is used to schedule jobs into
the system, on level of a WorkCenter it is used to decide which job shall be processed next.

New job shop models

New job shop models are generated completely from the database. This is a very powerful
and flexible feature towards efficient modelling. Through this approach models can be even
defined in third party software products for production planning and control. Further, if

necessary the job shop class library can be extended by additional customer required classes
in order to fit to the needs of the respective project. The Simulation Based Job Shop
Production Analyser is open for modelling and simulation of any job shop production.
However the system has been developed due to the need of complex semiconductor
production systems. In the following an industrial application of the Simulation Based Job
Shop Production

Job shop production processes are diverse and can vary depending on the specific product
being manufactured and the resources available. However, some general types of processes
commonly found in job shops include:

1. ONE - OFF PRODUCTION - This involves creating a single, unique product to a

customer's specifications.It can be anything from a custom piece of furniture to a
prototype for a new machine. Often labor-intensive and requires skilled workers who
can adapt to changing requirements.

2. BATCH PRODUCTION - Multiple units of the same product are produced in a

single run .The batch size can vary depending on the product and the customer's
needs. More efficient than one-off production, but still relatively flexible.

3. JOB LOT PRODUCTION - Similar to batch production, but the jobs are smaller
and more varied. A job lot production shop might produce a variety of different parts
for a single customer, or it might produce small batches of different products for
multiple customers.

4. FLOW PRODUCTION - A more continuous process than the other types of job
shop production.Products move through a series of workstations where they are
gradually assembled or processed. Often used for high-volume products, but can also
be used for low-volume products if the process is carefully designed.

Other types of job shop production:

 ● Make-to-order production: Similar to one-off production, but the product is
made to order rather than being a prototype.

● Contract manufacturing: A manufacturer produces parts or products for

another company under contract.

● Custom manufacturing: A manufacturer specializes in producing custom

products for a variety of customers.

The type of job shop production that is right for a particular business will depend on a
number of factors, including: The type of product being produced: Some products are more
suited to one type of production than others.

The volume of production: High-volume production is often better suited to flow

production, while low-volume production is often better suited to one-off or batch
production.

The customer's needs: Some customers may require a very specific type of production,
while others may be more flexible.

The skills and experience of the workforce: The type of production that a shop can do will
be limited by the skills and experience of its workers.

DETAILED ANALYSIS OF JOB SHOP PRODUCTION PROCESS

Job shop production is a versatile manufacturing approach ideal for creating a wide range of
unique or low-volume products. Unlike assembly lines, job shops handle diverse projects
with varying processing needs, making them highly adaptable but also more complex to
manage. To delve deeper, let's analyze the key stages of the job shop production process:

1. ORDER ACQUISITION AND PLANNING -

● Customer Inquiry: The process begins with a customer inquiry or order for a
specific product. Understanding the product requirements, specifications, and
deadlines is crucial.
 ● Quotation and Negotiation: The job shop prepares a quotation based on
material costs, labor, machine usage, and overhead. Negotiations may occur to
reach a mutually agreeable price and timeline.

● Order Confirmation and Planning: Upon order confirmation, the job shop
develops a detailed production plan. This includes

● Bill of Materials (BOM): Listing all raw materials and components needed for
production.

● Routing: Defining the sequence of operations and machines required for each
product component.
2. MATERIAL PROCUREMENT AND PROCEDURE -

● Purchasing: Based on the BOM, the job shop purchases the necessary materials and
components from suppliers. Ensuring timely delivery and quality control is vital

● Inventory Management: Managing raw materials and WIP (work-in-progress)

efficiently is crucial to avoid shortages or excess inventory costs.

● Preparation: Materials may undergo pre-processing steps like cutting, shaping, or

cleaning before entering the production stage.

3. PRODUCTION AND ASSEMBLY -

● Setup and Changeover: Machines are configured and adjusted for each job as per the
routing plan. Minimizing setup times improves efficiency.

● Processing: Components undergo various operations on different machines like

drilling, welding, painting, or assembly. Quality checks are performed at key stages.
 ● Material Handling: Efficient movement of materials between machines and
workstations optimizes production flow.

4. INSPECTION AND QUALITY CONTROL -

● Quality checks: Components and finished products are inspected throughout the
production process to ensure conformance to specifications and quality
standards.standards
● Non-conformance management: Defective parts are identified, and corrective actions
are taken, such as rework or scrapping.

5. FINISHING AND SHIPMENT -

● Packaging and labeling: Finished products are packaged and labeled according to
customer requirements and shipping regulations.

● Delivery: Products are shipped to the customer on time and within budget.

CHALLENGES AND CONSIDERATION IN JOB SHOP PRODUCTION PROCESS

Scheduling complexity: Optimizing scheduling for diverse jobs with varying processing
times and resource needs can be challenging.

Resource utilization: Ensuring efficient utilization of machines and workers while

minimizing idle time is crucial for cost control.

Material management: Efficient procurement, inventory control, and handling of materials

are essential to avoid delays and waste.

Flexibility and adaptability: Job shops need to be adaptable to handle unexpected changes
in orders, material availability, or production issues.
 TECHNOLOGY AND TOOLS FOR JOB SHOP PRODUCTION

Manufacturing execution systems (MES): Software applications that track and manage
production data, schedules, and workflow in real-time.

Computer-aided scheduling (CAS) tools: Optimize job sequencing and resource allocation
to improve efficiency and reduce lead times.

Inventory management systems: Track and manage raw materials, WIP, and finished goods
to optimize inventory levels and prevent shortages.By understanding these key stages,
challenges, and optimization tools, job shops can effectively manage their production
 CHAPTER 4

SUMMARY OF RESULTS AND FINDINGS

A job shop production process is a type of manufacturing in which small batches of custom
or bespoke products are made to order. The process is characterized by its flexibility, as
machines and workers are not dedicated to producing a single product. This allows job shops
to produce a wide variety of products, often with short lead times.

The results and findings of job shop production process are the outcomes and
insights that can be derived from analyzing the performance, efficiency, quality, and
cost of the job shop manufacturing system. Some possible results and findings are:

● The job shop production process can produce a wide range of products with
different specifications and requirements, which can increase customer
satisfaction and market competitiveness.

● The job shop production process can also adapt to changing customer
demands and market conditions, which can enhance flexibility and
responsiveness.

However, the job shop production process also faces some challenges and
limitations, such as:

The high variability and uncertainty of the jobs, which can affect the planning,
scheduling, and control of the production system.

The high complexity and variety of the products, which can increase the labor and
material costs.

The low economies of scale and scope, which can reduce the profitability and
efficiency of the production system.
 CHAPTER 5

SUGGESTIONS

Here are some suggestions for improving the job shop production process:

1. Improve workflow and scheduling:

Implement a scheduling system: A good scheduling system will help you to track the
progress of jobs, identify bottlenecks, and optimize the flow of work through the shop. There
are many different scheduling systems available, so you can choose one that is right for your

Job shop scheduling system

● Use Kanban boards: Kanban boards are a visual tool that can help you to
track the progress of jobs and identify bottlenecks. They are simple to use and
can be very effective in improving workflow
 ● Cross-train employees: Cross-training your employees will make them more
flexible and adaptable, which will help you to cope with changes in demand
and unexpected events..

2. Improve inventory management:

Implement a just-in-time (JIT) inventory system: A JIT inventory system will help
you to reduce the amount of inventory that you need to carry, which can save you
money and improve your overall efficiency.

Just in time inventory management

● Use a bill of materials (BOM): A BOM is a list of all the parts and materials that are
required to make a product. Using a BOM can help you to ensure that you have all of
the necessary materials on hand before you start a job.

● Track your inventory levels closely: It is important to track your inventory levels
closely so that you can avoid running out of materials. You can use a variety of
methods to track your inventory, such as barcodes or RFID tags.
 3. Improve quality control :

● Implement a quality control program: A quality control program will help

you to identify and correct defects before they reach the customer. There are
many different quality control programs available, so you can choose one that
is right for your needs.

● Inspect your products at each stage of the production process: This will
help you to catch defects early and prevent them from being passed on to the
next stage of production.

● Train your employees on quality control procedures: Your employees need

to understand the importance of quality control and how to identify defects.

4. Use technology to your advantage:

● There are a number of technologies that can be used to improve the job shop
production process, such as:
● Computer-aided design (CAD) and computer-aided manufacturing (CAM):
These technologies can help you to design and manufacture products more
efficiently.
● Enterprise resource planning (ERP) systems: ERP systems can help you to
manage all of your business operations in one place, including your
production, inventory, and finances.
● Manufacturing execution systems (MES): MES systems can help you to track
the progress of jobs in real time and identify bottlenecks.

By implementing these suggestions, you can improve the efficiency and effectiveness of
your job shop production process.
 CHAPTER 6

CONCLUSIONS AND DIRECTIONS FOR FUTURE

Conclusions and Directions for the Future of Job Shop Production:

1. Strengths :

● Flexibility and agility: Job shops excel at handling diverse, custom projects and
adapting to changing market demands quickly.

● Skilled workforce: Job shops often cultivate highly skilled, specialized craftsmen
with deep knowledge of their craft.

● Innovation and customization: The ability to personalize products and processes

sets job shops apart from mass production.

● Community and relationships: Close-knit teams and local connections can foster
strong customer relationships and build trust.

2. Challenges :

● Competition: Globalization and automation put pressure on job shops to compete on

price and efficiency.

● Technology adoption: Embracing advanced technologies like automation and data

analytics is crucial for staying competitive.
● Skilled labor shortage: Attracting and retaining skilled workers requires competitive
wages, benefits, and opportunities for growth.

● Lean management: Optimizing workflow, minimizing waste, and improving

efficiency are key to cost-effectiveness.

3. Future directions :

● Embrace advanced technologies: Implement machine learning, AI, and digital twins
to optimize production, predict outcomes, and improve decision-making.

● Invest in automation: Integrate robotics and automated processes for repetitive tasks
while focusing human expertise on high-value activities.

● Develop skills and training: Offer continuous training programs and invest in
apprenticeship programs to attract and retain skilled workers.

● Build strategic partnerships: Collaborate with other manufacturers, suppliers, and

research institutions to share knowledge, resources, and expertise.

● Focus on niche markets: Specialize in unique products or services with high margins
and cater to specific customer needs.

● Sustainability and green practices: Implement eco-friendly technologies and

materials to reduce environmental impact and appeal to environmentally conscious
customers.

● Data-driven decision making: Leverage real-time data to analyze production,

identify bottlenecks, and make informed decisions for improvement
 .

● Customer focus and relationship building: Build strong relationships with

customers, offer personalized services, and understand their evolving needs.

Conclusion:

While job shops face challenges, the future holds immense potential. By embracing
technology, upskilling the workforce, focusing on value and niche markets, and adopting
sustainable practices, job shops can thrive in the years to come. The key is to remain agile,
adaptable, and prioritize continuous improvement while leveraging their unique strengths to
excel in a changing manufacturing landscape. Job shop conclusions in BHEL Company:

Successful Completion:

The finished product meets all specifications and quality standards. This satisfies the
customer's needs and ensures their satisfaction.

The job was completed on time and within budget. This demonstrates efficiency and
adherence to schedule.

All safety protocols were followed, and no injuries occurred. This highlights the importance
of a safe working environment.

Lessons were learned and improvements identified for future jobs. This promotes continuous
improvement and adaptability.

Additional Considerations:

If the job faced challenges, you can mention how they were overcome and the lessons
learned. This showcases resilience and problem-solving skills.

Highlight any innovative techniques or approaches used during production. This showcases
creativity and a commitment to progress.
Express gratitude to the team and collaborators who contributed to the success. This fosters
teamwork and morale.

Connect the completed job to the larger goals of the shop. This emphasizes the job's
significance and contribution to the bigger picture.
 BIBLIOGRAPHY

BOOKS : "Production and Operations Management" by R.K. Jain and S.L. Chhabra

"Job Shop Scheduling with Genetic Algorithms" by D.T. Pham and D.A. Karabagla

RESEARCH ARTICLES : "A review of research on scheduling in the job-shop

environment" by J.J. López-Pérez and M. Vela-Pacheco (International Journal of Production
Research, 2019)

Recent advances in job shop scheduling" by M. Pinedo (Annals of Operations Research,

2022)

WEBSITES :

www.bhelindia.com

www.jobshop.com

www.wikipedia.com