When you hear the word “manufacturing,” you might think of a factory with an army of skilled workers surrounded by high-tech robots and fast-moving assembly lines. But the bustling factory that’s perfect for mass-producing automobiles or consumer electronics isn’t the right setup for customized, small-batch jobs.
For specialized products, job shop manufacturing is a better fit. A job shop might employ a few specialized employees who produce just a few units of a product before changing machine setups to manufacture something else. And, if the shop is small enough, the same people who do the hands-on manufacturing might also manage the production tasks that keep the operation running, like resource allocation, quality control, and packaging up the finished goods.
The key characteristics of job shop manufacturing
To help you understand what job shop manufacturing is and which settings it’s right for, let’s look at some of the characteristics typical of this manufacturing method.
Custom production runs
Job shops are great at creating highly customized products in small batches. Unlike large-scale manufacturing facilities that focus on mass production, job shops are designed to handle unique, one-off orders or small quantities of items tailored to specific customer needs.
Versatile equipment
The machinery in a job shop is often adaptable, multi-functional, and organized into work centers where certain tasks or operations are carried out. Instead of a dedicated line for each single product, the shop can reconfigure the same equipment to produce different items, adapting each setup to the job at hand so they can switch between projects with minimal downtime.
A skilled workforce
A job shop usually relies heavily on the skills of a workforce capable of handling a variety of tasks. These employees often wear many hats, switching between tasks like machine operation and quality control in the same shift.
High variation in workflow
Because job shops handle different products with each order, the workflow can vary greatly from day to day. Keeping operations efficient in this sort of dynamic environment requires careful planning and resource management to ensure different workflows all function equally well.
Low production volume
Mass production facilities manufacture large numbers of the same item, but that’s not the case in a job shop, which will typically produce items in limited quantities. Low volumes are perfect for custom orders, prototypes, or small-scale production runs that don’t require thousands of identical units.
Emphasis on quality over quantity
Smaller production runs mean a greater focus on precision and attention to detail. Well-run shops craft each product meticulously to meet specific standards, often going above and beyond their customers’ expectations.
Customization capabilities
One of the top things job shops are known for is their ability to accommodate custom specifications. Whether it’s a unique material, design alteration, or specific finish, most job shops can tailor their production processes to meet a client’s exact requirements.
Frequent changeovers
The average job shop is no stranger to changeovers — the process of switching a production line or machinery from making one product to another. Changeovers require machines to be reconfigured, settings to be adjusted, and machine tools or materials to be swapped out. The process can be time-consuming, but the ability to make it happen is what gives job shops the flexibility they need to manufacture these unique goods.
The pros and cons of job shop manufacturing
We’ve hinted at some of the perks and drawbacks of shops that handle small-job production, but here’s a more detailed look at the advantages and disadvantages.
Pros
High flexibility
A job shop’s flexibility allows the manufacturer to switch between different products and production processes, allowing them to handle custom orders and small-batch production that caters to specific customer requirements.
Customization
Whether it’s a unique material, specific design, or intricate detail that requires a special machine, a job shop can tailor their processes to meet precise specifications, delivering products that have no problem meeting a customer’s exacting standards.
Lower upfront costs
Since job shops manufacture items in smaller quantities, they often require a lower initial investment in materials. This advantage can make job shop manufacturing an appealing, cost-effective approach for businesses with limited budgets or those who want to test new products in the market before producing items on a larger scale.
Enhanced quality control
Smaller production runs mean a stronger emphasis on quality control. Inspectors can closely examine each product to ensure that it meets the necessary standards before leaving the shop, a perk that often results in higher-quality products.
Cons
Higher per-unit costs
Mass production is generally cheaper when the numbers are broken down into per-unit costs. The higher prices come from the specialized nature of the work, the need for frequent changeovers, and the lower economies of scale.
Complex scheduling
Since projects and processes change frequently in a job shop, scheduling can be tricky. A production manager might need to juggle multiple orders with different deadlines and resource requirements, so they’ll often require an advanced scheduling software solution to stay on top of it all.
Longer lead times
For clients looking for quick turnaround times, job shops usually aren’t the way to go. The need for customization, complex setups, and frequent changeovers often results in longer lead times compared to other manufacturing methods.
Resource-intensive operations
It takes a lot of preparation to set up a job shop for a new project, and the setup process can be resource-intensive — the shop has to source the right materials, ensure the right tools are available, and make sure they have the right people for the job. Higher operational costs are one of the side effects, and the shop needs people and systems in place to oversee production.
Limited scalability
Unlike flow shops that streamline operations for high volume, job shops are meant for small-scale production. If a client suddenly requires a large order, a shop might struggle to meet the demand without making significant adjustments or investments in additional resources, ultimately causing them to lose business.
The job shop manufacturing process
Let’s look at a breakdown of the typical stages of the job shop process.
1. Customer order and design specification
A customer places an order with detailed design specifications, which might include technical drawings, material requirements, and any special instructions the manufacturer needs to follow. The job shop then works closely with the customer to ensure they’ve fully understood and documented every detail before moving on to the next stage.
2. Planning and scheduling
Next comes planning and scheduling the production, which involves mapping out the workflow, allocating resources, and setting deadlines. Taking the shop’s current workflow into account, the production manager will prioritize tasks to ensure the order is delivered on time.
3. Material procurement
With a plan in place, the job shop will procure the items it needs for production, sourcing high-quality raw materials that meet the customer’s specifications. To avoid delays in the production process, the procurement team also has to ensure that the suppliers it chooses to work with actually have all the necessary materials in stock.
4. Job routing
The process of determining the most efficient path across the shop floor is called job routing — deciding which machines the shop needs to use and in what order, then assigning the right personnel to each task.
5. Production and fabrication
Once the job is all mapped out and set up, it’s time for production and fabrication. Skilled workers operate industrial machines, carefully following the design specifications agreed upon in step one. Depending on the complexity of the order, this stage might involve several different processes, like cutting, shaping, assembling, and welding.
6. Quality control and inspection
Throughout the production process, inspectors check the product to catch defects and ensure the items meet the required standards. They’ll use the most appropriate inspection method for that stage of the job, whether it’s a dimensional check, material testing, or a visual inspection.
7. Finishing and packaging
After the product passes quality control, it moves to the finishing stage, which could involve polishing, painting, or applying protective coatings. Once the finishing touches are complete, the product is carefully packaged to prevent damage during transit.
8. Delivery and feedback
When the finished product is ready to go, the job shop arranges for secure and timely transportation. After delivery, many shops will ask the customer for feedback to gauge how well the product met their expectations.
4 job shop manufacturing examples
There are many different types of job shop manufacturers. Here are four of the most common:
- Custom metal fabrication: A job shop specializing in metalwork might produce custom parts for machinery, like brackets, enclosures, or components.
- Specialty woodworking: A woodworking job shop might craft custom furniture pieces, cabinets, or architectural elements that meet a client’s unique specifications.
- Medical device components: Job shops often handle the manufacturing of surgical instruments, custom prosthetics, or other specialized medical device components.
- Custom automotive parts: Car enthusiasts or restorers might commission a job shop for custom car parts like bespoke exhaust systems or unique body panels.
Fishbowl: The perfect management solution for job shop inventory
Fishbowl is the all-in-one inventory management solution designed to help you control stock, warehouse operations, manufacturing workflows, and more, even integrating with QuickBooks for financial visibility. And with Fishbowl Manufacturing, your job shop can seamlessly track materials and enhance custom processes to ensure every job is completed with precision and efficiency.
Are you ready to gain control and end-to-end visibility over your manufacturing operations? Schedule a demo of Fishbowl, the intuitive, scalable, and user-friendly inventory management platform.