at Washburn Guitars
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| In Chapter 5, a variety of ways to organize processes, known as general layout types, are discussed. One of the most common is the process-oriented layout, also known as a functional or jobshop layout. Washburn Guitars, manufacturers of over 150,000 guitars, banjos, and mandolins, annually, provides an excellent example of a process-oriented operation or job shop. | (VIDEOps1) |
| A very traditional departmentalized layout is used at Washburn and it allows them to produce guitars ranging from one-of-a-kind custom instruments to batches of standard products. This approach is a great example of a classic intermittent flow | (VIDEOps2) |
| The functional departments at Washburn provide excellent examples of the result of this type of layout. Each is quite specific in what it is capable of doing. The departments perform those specific tasks, however, on a variety of products. Washburn’s painting department, for example, is capable of painting and finishing any of its products. | (VIDEOps8) |
| Likewise, it’s assembly and testing department can assemble and test any of its broad range of products | (VIDEOps9) |
| Like many process-oriented businesses, Washburn sometimes must deal with queues of products that build up in front of its work centers. Part of Washburn management's challenge is to schedule the orders in front of Washburn’s various functional departments. Different priority rules are used to maintain order due date performance and to provide guidance to employees managing the queues. The task of identifying priorities, and occasionally interrupting them because of emergencies and rush orders, is a critical part of managing the flow of orders in a job shop. | (VIDEOps3) |
| Many job shops have incorporated technology as a means of achieving a balance between volume and flexibility. Washburn utilizes a very expensive Computerized Numerically Controlled (CNC) machine to drill holes for the fret boards, bodies, and electronic for all of the guitars. This machine, a workcenter all by itself, is like any expensive asset in that it needs to produce high quantities in order to spread out its cost and maintain an economical cost per unit produced. | (VIDEOps4) |
| Many job shops strive to gain the type of flexibility and speed that can be achieved through the use of a CNC machine. This type of manufacturing is often referred to as a flexible manufacturing system. | (VIDEOps5) |