Week 2- Operations Process

Question 1

What are the five major process types?

Answer 1

1) Projects
2) Jobbing
3) Batch production
4) Line production
5 Continuous processing

Question 2

Describe project production

Answer 2

Large scale, complex products or services that can no be physically moved. Example: civil engineering projects - building a new runway

Question 3

Describe jobbing production:

Answer 3

• made for one-off (unique) products

- made by skilled people

Question 4

Describe batch production:

Answer 4

Used for previously provided products, hence have a higher sales volume

Repeat orders- reduces cost as can use same machines for products
Examples: Bakery, banking, hospitals

Question 5

Describe line production

Answer 5

Higher volume requires more investment. dedicated to customer requirements

• product range often narrower than batch production ( think Warburtons vs birds bakery)
• Production line split into more sequential steps eg. line processed bakery can only cook cookies on one line

Question 6

describe continuous processing

Answer 6

One or several basic materials are processed through successive stages and refined into one or more eg Gasoline production

Question 7

describe the difference between project and continuous processing in terms of variety and production volume

Answer 7

Project processing: High variety, low production volume

Continuous processing: low variety, high production volume

Job, batch and line production are in between these two extremes

Question 8

Describe make to stock production:

Answer 8

Producers make goods to be placed in stock prior to receiving an order. Typical of line production and continuous processing eg. milk manufacturer

Question 9

Describe assemble to order production:

Answer 9

Producer hold stock or raw materials and then work in progress to quickly assemble orders as required by customer. Typical of line and batch production. The customers order has penetrated the process somewhat

Question 10

Describe make to order production:

Answer 10

Material ordered and product or service made only after the buyer’s order is received. Typical of batch production. Eg customised name plates

Question 11

Describe engineer to stock:

Answer 11

Repeat business of low volume products allows generic engineering plans to be developed. Typical of jobbing. Eg. the firm has several kitchen designs and the customer picks one of them

Question 12

Describe engineer to order:

Answer 12

The customer specifies the requirements and the operations manager delivers the requested product eg. custom made kitchen

Question 13

what is a product focussed business?

Answer 13

When a firm bases its strategies, operations and admin systems around the products

higher volume products are usually product focused

Question 14

what is a process focused business?

Answer 14

When a firm bases its strategies, operations and admin systems around the processes eg . a small baker is dependant on his machines

Question 15

what is process mapping?

Answer 15

the process of identifying which processes add value and which do not. Any process that does not add value is a waste so should be got rid of to develop a simpler/ more efficient system

Question 16

What are the seven lean wastes?

Answer 16

1) transportation
2) inventory
3) motion
4 Waiting
5) overproduction
6) over processing
7) defects

Question 17

Describe the lean waste of transportaion:

Answer 17

anywhere we need to move a product from one place to another is a time waste

Question 18

Describe the lean waste of inventory

Answer 18

Holding any more than is needed to do the job

Question 19

Describe the lean waste of motion

Answer 19

Any motion of a worker that does not add value

Question 20

Describe the lean waste of waiting

Answer 20

the time spent waiting for parts, people and machines

Question 21

Describe the lean waste of overproduction

Answer 21

Producing too much or too soon so you have to inventory it ( worst waste as it causes other wastes)

Question 22

Describe the lean waste of over processing

Answer 22

having excess capacity, excess quality standards

Question 23

Describe the lean waste of defects

Answer 23

Having to do any repairs, rework on products takes time away from producing new products

Question 24

what other wastes can you have?

Answer 24

Peoples talent and energy

Question 25

what are the catorgies of waste?

Answer 25

1) Value adding activities: anything customer is willing to pay for eg. Delivery
2) non- value adding activities: Costs money but doesn’t add value
3) Necessary non- value adding activities: Necessary to included in the product but doesn’t add value: seatbelts i a car are a requirement by law

Question 26

what is a value-adding activity?

Answer 26

The customer must be willing to pay for it

Must be done right, the first time to avoid spoilage waste

Must enhance the product or service

Question 27

What does a circle mean on a process map?

Answer 27

Operation- where a change of state occurs

Question 28

what does an arrow mean on a process map?

Answer 28

Transport

Question 29

what does a triangle mean on a process map?

Answer 29

store- controlled delay

Question 30

What does a D satnd for on a process map?

Answer 30

Delay- uncontrolled delay (queue)

Question 31

What does a square stand for?

Answer 31

Inspection

Question 32

what is a swim line on a process map?

Answer 32

Another process map for when multiple routes can be taken

Question 33

What is the primary examination of a process? what 10 questions do we need to ask to reduce wastes?

Answer 33

Purpose; what is being achieved? And Is it necessary?
Place: Where is it done? And Why there?
Sequence: when is it done? Why then?
Person: Who does it? Why that person
Means: How is it done? Why is it done in that way?

Question 34

What is the secondary examination of a process? what 10 questions do we need to ask to reduce wastes?

Answer 34

Purpose: What else could/should be done?
Place: Where else could/should it be done?
Sequence: When else could/should it be done?
Person: Who else could/should do it?
Means: How else could/should it be done?

Question 35

If an activity cannot be eliminated could it be…

Answer 35

Changed? 
Combined with another activity?
Done in a different place? 
Done in a different order?
Done by different people? 
Done by a different means?

Question 36

what is the iron triangle of project management?

Answer 36

Is it the project ONTIME?
Is the project On BUDGET?
Is the project ON QUALITY?

Question 37

Do different projects have different focuses?

Answer 37

Yes eg. a music festival is more focused on keeping ON TIME than on budget and on quality