Process Design Flashcards
What is process design?
Treat the two activities as interrelated
1.designing the product or service: designed in a way that they can be created efficiently
- designing the process: should be designed so they can create all products and services which the operation is likely to introduce
- both designs have an impact on the other
- the overlap is usually greater in operations which produces services
What are the different design processes?
- process types go by different names depending on whether they produce products or services
- process types are determined by volume and variety of items they process
- Manufacturing process types
- Service process types
What is the manufacturing process type, project processes?
Type: one off projects, discrete, highly customized products and complex
Time: long timescale between completion of each item (well defined start and finish)
Activities: ill defined and uncertain
Resources: low volume and high variety, taken to the location
Examples: software design, movie production and construction companies
What is the manufacturing process type, jobbing processes?
Type: one offs or only a few required, not as complex as projects since transportation is possible
Activities: specially made,
Skills: skill requirement is broad. Purpose built and hand made
Resources: low volume and high variety
Examples: made to measure tailors, furniture restorers
What is the manufacturing process type,batch processes?
Type: standard products, repeating demand, but can make specials.
Activities: products are produced in different stages, different people are responsible for different stages, often a WIP inventory for each stage
Skills: specialized narrower skills, set ups at each stage of production
Resources: higher volumes and lower variety than for jobbing
Examples: machine tool manufacturing, productions of special gourmet food,
What is the manufacturing process type, mass or line processes?
Type: standard repeat product runners, product range is narrower and difficult to customize
Activities: production process is split into a large number of steps and all products go through them sequentially
Skills: low and narrow skills, no set ups or change over or almost instantaneous ones
Resources: higher volumes than batch, narrow product range (little variety)
Examples: frozen food production, automatic packing lines, television factories
What is the manufacturing process type, continuous processes?
Type: standard repeat product runners, high capital intensive and automated
Activities: few changeover required set up costs are very high and therefore avoided, difficult to start and stop the process (operates 24 hours, 365 days)
Skills: labour normally monitor the system performance
Resources: extremely high volumes and low variety: often single product
Examples: water processing, steel making and paper making
How do these processes link with planning and scheduling? Make stock, assembly order, make to order, engineer to stock and engineer to order?)
- Make stock: producers make stock before receiving a customer order: typical mass production or continuous processing
- Assembly order: producers hold stock and WIP to quickly assemble order required by the customer: typical line or batch processes
- Make to order:material ordered and product made only after the buyer order is received: typical batch
- Engineer to stock: repeat business of low volume products allow generic engineering plants to be deployed: typical of jobbing
- Engineer to stock: customers specify requirements and operations manager delivers requested products: typical project
What service type is professional service?
Customer contact: high
Volume of customers: low, client spend considerable time in the service process
Resources: high variety/customization, flexibility/adaptability in services
Staff discretion: high
Base: people based not equipment
Example: doctors surgeries, architects
What service type is service shops?
Customer contact: medium or mixed level
Volume of customers: medium
Resources: medium level of variety/customization
Staff discretion: medium or mixed
Example: banks, high street shops, holiday tour operators and car rental companies
What service type is mass service?
Customer contact: low to medium level o Customer volume: high Resources: low variety/customization Staff discretion: low or mixed Example: supermarkets, national rail network and airport and call centers
What is e product process matrix?
- the most common method of illustrating the relationship between a process volume-variety position and its design characteristics
- the most important elements of process design are strongly related to volume variety position of the process
- moving off the natural diagonal of the product process matrix will incur excess costs
What is process mapping?
- describes the processes in terms of how the activities within the process relate to each other. Identify the different types of activities that take place during the process , shoe flow of material, people or info,still through process
What are the process mapping symbols?
Circle: operation (activity that directly adds value) Square: inspection/check Arrow: transport Round arrow: delay or wait Upside down triangle: storage Oval: beginning or end of process Rectangle: activity Tilted rectangle: Input or output of the process Thin arrow: direction of the flow Diamond: decision
Distinguish between throughout time, cycle time, work in progress and work content?
Throughput time: the elapsed time between an item entering the process and leaving it
Cycle time: the average time between the items being processed
Work in progress: the number of items within the process at any point in time
Work content: tots amount of work required to produce a unit of output
