Process Configuration

Question 1

Process configuration of an operation results from 2 things. Name them.

Answer 1

1) how it’s transforming resources are positioned relative to each other in terms of layout
2) how it’s various tasks are allocated to these transforming resources

Question 2

Why is the layout of an operation important?

Answer 2

It is important because the layout of the facilities determines the way in which resources (materials, information and customers) flow through an operation. Relatively small changes can affect the flow through the operation which in turn affects the costs and the general effectiveness of the operation.

Question 3

What does layout reflect?

Answer 3

Reflects the overall ethos and vision of the organisation. Ryan Air for example - layout is driven by cost effectiveness

Question 4

What makes a good layout?

Answer 4

Objectives of any layout will depend on the strategic objectives of the operation but there are general objectives that apply to all layouts:

• Need to be safe
• Need to minimise the length of flow through the operation and make the flow clear
• Staff should be located away from the unpleasant parts of the operation
• Equipment should be accessible
• Should allow for flexibility over the long term

Question 5

Define process configuration

Answer 5

The overall design and configuration of a process that determines the sequence of activities and flow of transformed resources b/w them

Question 6

Define fixed position layout

Answer 6

Locating the position of a product/service such that it remains largely stationary while transforming resources are moved to and from it

Question 7

Define functional or process layout

Answer 7

Layout where similar resources or processes are located together.

Question 8

Define cell layout

Answer 8

Layout where transforming resources with a common purpose (such as processing the same type of product, serving similar types of customer etc) are located in close proximity (i.e. the cell)

Question 9

Define product or line layout

Answer 9

Locating transforming resources in a sequence defined by the processing needs of a product or service

Question 10

Define process types

Answer 10

Terms used to describe a particular general approach to managing processes.

Question 11

What are the 5 process types in manufacturing/production operations?

Answer 11

These are:

1) Project
2) Jobbing
3) Batch
4) Mass production
5) Continuous production

Question 12

What are the 3 process types in service operations?

Answer 12

These include:

1) Professional services
2) Service shops
3) Mass services

Question 13

What are transformed resources?

Answer 13

These are the resources that are treated, transformed or converted in a process. Usually a mix of materials, information and customers.

Question 14

What are transforming resources?

Answer 14

The resources that act upon the transformed resources - usually classified as the facilities (buildings, plant and equipment) and staff (people who operate, maintain and manage the operation).

Question 15

Draw the diagram that illustrates the four different types of layout.

Answer 15

Refer to the diagram in the notes

Question 16

When is a fixed position layout used?

Answer 16

When the transformed resource is too large or delicate to move or when it is not possible to move the transformed resource. Used for low volume and high variety products and services. Demolition sites, events and operating theatres are examples of fixed position layouts.

Question 17

When do you use functional layout?

Answer 17

Similar transforming resources are located together - according to their function - to meet the demand of the transformed resources. Hospitals, libraries and supermarkets are examples of functional layouts

Question 18

Give three examples of functional layouts.

Answer 18

Supermarkets, Libraries and Hospitals.

Question 19

When do you use cell layouts?

Answer 19

This involves locating in close proximity transforming resources with a common purpose such as processing the same types of product or serving similar types of customer. Good example is a maternity ward in a hospital that provides all maternity related care within a cell within the hospital. All customers are pregnant.

Question 20

What is the main difference between functional layout and cell layout?

Answer 20

Functional layout produces one type of output whilst a cell layout can produce multiple types of end results.

Question 21

When are product or line layouts used?

Answer 21

This is used when the flow of the transformed resources is continuous and the operation has high volume and low variety. Transforming resources are located in a sequence defined by the processing needs of the transformed resource(s) or product/service. Assembly line manufacturing is a good example of product or line layout.

Question 22

What are the 2 primary influences on the type of layout for an operation?

Answer 22

Volume and variety characteristics.

Question 23

Do operations typically function in single or mixed layouts?

Answer 23

Many operations function in mixed layouts.

Question 24

What are the 3 advantages of fixed position layouts?

Answer 24

1) Very high variety and mix flexibility
2) Product and customer not moved
3) High variety of tasks for staff

Question 25

What are the three disadvantages of fixed position layouts?

Answer 25

1) Expensive - very high unit costs
2) Scheduling space and activities can be difficult
3) High variety of tasks

Question 26

What are the three advantages of functional layout?

Answer 26

1) High variety and mix flexibility
2) Relatively robust in case of disruptions
3) Easy to supervise

Question 27

What are the 3 disadvantages of functional layout?

Answer 27

1) Low utilisation
2) Can have very high WIP
3) Complex flow

Question 28

What are the advantages of cell layout?

Answer 28

1) Good variety and mix compromise
2) Group work can result in good motivation
3) Fast through put

Question 29

What are the 2 disadvantages of cell layout?

Answer 29

1) can require more equipment

2) Can be costly to rearrange existing layout

Question 30

What are the 2 advantages of product layout?

Answer 30

1) Low unit costs for high volume

2) Opportunities for specialisation of equipment

Question 31

What are the 3 disadvantages of product layout?

Answer 31

1) Can have low mix flexibility
2) Not very robust when facing disruption
3) Work can be very repetitive