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TRANSCRIPT
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© 2007 Pearson Education
Process Analysis
Chapter 3
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© 2007 Pearson Education
How Process Analysisfits the Operations Management
Philosophy
Operations As a Competitive Weapon
Operations StrategyProject Management Process Strategy
Process AnalysisProcess Performance and Quality
Constraint ManagementProcess LayoutLean Systems
Supply Chain StrategyLocation
Inventory ManagementForecasting
Sales and Operations PlanningResource Planning
Scheduling
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Omgeo
Omgeo is the leading provider of complete global trade management services, processing more than one million trades per day and servicing 6,000 broker-dealers, custodian banks and investment managers in more than 40 countries.
Through process analysis, it was able to reduce the typical trade expense from $10 or $12 down to between 20 cents and a dollar.
Trade processing time was reduced from 20 hours down to three hours.
These changes were the result of considerable customer contact and reflect more automation and process reengineering.
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Process Analysis
Process analysis is the documentation and detailed understanding of how work is performed and how it can be redesigned.
1Identify
Opportunity
1Identify
Opportunity
2Define Scope
2Define Scope
3DocumentProcess
3DocumentProcess
5RedesignProcess
5RedesignProcess
6ImplementChanges
6ImplementChanges
4Evaluate
Performance
4Evaluate
Performance
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A Systematic Approach to Process Analysis
Suggestion system: a voluntary system by which employees submit their ideas on process improvements.
Design team: A group of knowledgeable, team-oriented individuals who work at one or more steps in the process, do the process analysis and make the necessary changes.
Metrics: Performance measures that are established for a process and the steps within it.
Flowcharts: A diagram that traces the flow of information, customers, equipment, or materials through the various steps of a process. Service Blueprint: A special flowchart of a service
process that shows which steps have high customer contact (line of visibility).
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Standard Flowchart Symbols
A simple flowchart representing a process for dealing with a non-functioning lamp.
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Flowchart for the Sales Process of a Consulting Company
Service Blueprint
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Flowchart of aNested Subprocess
Client Agreement & Service Delivery Step
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Showing the Handoffs Between Departments
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Process Charts
Process chart: An organized way of documenting the activities performed by a person or group of people at a work station, with a customer, or on materials.
Five categories of process charts:1. Operations that change, create or add something.2. Transportation (materials handling): Moving something. 3. Inspection: Checking or verifying something.4. Delays: Time spent awaiting further action.5. Storage: When something is put away until a later time.
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Process Chart for an Emergency Room Admission
1 X Enter emergency room, approach patient window 2 X Sit down and fill out patient history3 X Nurse escorts patient to ER triage room4 X Nurse inspects injury5 X Return to waiting room6 X Wait for available bed 7 X Go to ER bed8 X Wait for doctor9 X Doctor inspects injury and questions patient
10 X Nurse takes patient to radiology11 X Technician x-rays patient12 X Return to bed in ER13 X Wait for doctor to return14 X Doctor provides diagnosis and advice15 X Return to emergency entrance area16 X Check out17 X Walk to pharmacy18 X Pick up prescription 19 X Leave the building
0.50 1510.0 -0.75 403.00 -0.75 40
1.00 -1.00 604.00 -5.00 -2.00 200
3.00 -2.00 2003.00 -2.00 -1.00 604.00 -2.00 1804.00 -1.00 20
Process: Emergency room admissionSubject: Ankle injury patientBeginning: Enter emergency roomEnding: Leave hospital
Step no.
Time (min)
Distance (ft)
SummaryNumber of stepsActivity
Time (min)
Distance (ft)
Step description
Insert Step
Append Step
Remove Step
Transport 9 11 815 Operation 5 23 —
Inspect 2 8 —
Store — — —Delay 3 8 —
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Evaluating Performance
Checklist: A form used to record the frequency of occurrence of certain process failures. Failures is any performance shortfall, such as error, delay…
Histogram: A summarization of data measured on a continuous scale, showing the frequency distribution of some quality characteristic (the central tendency and dispersion of the data).
Bar chart: A series of bars representing the frequency of occurrence of data characteristics measured on a yes-or-no basis.
Pareto Chart: A bar chart on which factors are plotted in decreasing order of frequency along the horizontal axis.
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Bar ChartExample 5.1
The manager of a neighborhood restaurant is concerned about rising customer complaints. He would like to present his findings in a way that his employees will understand.
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Pareto ChartExample 5.1
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So, in the example above, it can be seen that:• No Postcode is the most frequent result, with 98 items (out of the 240 sampled) being delayed for this reason. As the table on the Pareto Chart indicates, this is equivalent to 40.8%.• The second most frequent reason for delay is No Stamp, which represented 31.7% (76 out of the 240 sampled).• The Cumulative Frequency line (shown in blue) demonstrates that the first two categories account for 72.5% of the delayed post items.
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More Tools for Evaluating Performance
Cause-and-effect diagram: A diagram that relates a key performance problem to it’s potential causes.Sometimes called the fishbone diagram.
Graphs: Representation of data in a variety of pictorial forms, such as line charts and pie charts.
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Analysis of Flight Departure Delays
EXAMPLE The operations manager for Checker Board Airlines at Port Columbus International Airport noticed an increase in the number of delayed flight departures.SOLUTIONTo analyze all the possible causes of that problem, the manager constructed a cause-and-effect diagram, shown in Figure 4.11. The main problem, delayed flight departures, is the “head” of the diagram. He brainstormed all possible causes with his staff, and together they identified several major categories: equipment, personnel, materials, procedures, and “other factors” that are beyond managerial control. Several suspected causes were identified for each major category.
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Passenger processing at gate
Late cabin cleaners
Unavailable cockpit crew
Late cabin crew
Personnel
Aircraft late to gate
Mechanical failures
Equipment
Procedures
Waiting for late passengers
Weight/balance sheet late
Poor announcement of departures
Delayed check-in procedure
Delayed flight departures
Materials
Late food service
Late fuel
Late baggage to aircraft
Contractor not providedupdated schedule
Weather
Air traffic delays
Other
Analyzing Flight Delays Using a Cause-And-Effect Diagram
Analysis of Flight Departure Delays
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They decide to use the following tools:
The Wellington Fiber Board Company produces headliners, the fiberglass components that form the inner roof of passenger cars. Management wants to identify which defects were most prevalent and to find the cause.
Wellington Fiber Board Co.Example
Step 1. Checklist Step 2. Pareto chart
Step 3. Cause-and-effect diagram
Step 4. Bar chart
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Checklist
Headliner DefectsDefect type Tally Total
A. Tears in fabric //// 4B. Discolored fabric /// 3C. Broken fiber board //// //// //// ////
//// //// //// / 36D. Ragged edges //// // 7
Total 50
Wellington Fiber Board Co.
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C
DA B
Pareto Chart
100
80
60
40
20
0
Cum
ulat
ive
Perc
enta
ge
Num
ber o
f Def
ects
50
40
30
20
10
0Defect type
Wellington Fiber Board Co.72% of the quality defects broken fiber board
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Cause-and-Effect Diagram
Out of specificationNot available
Materials
HumiditySchedule changes
Other
Machine maintenanceMachine speed
Wrong setup
Process
TrainingAbsenteeism
Communication
People
Broken fiber
board
Wellington Fiber Board Co.
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Bar Chart20
15
10
5
0
Num
ber o
f Bro
ken
Fibe
r Boa
rds
First Second ThirdShift
Wellington Fiber Board Co.
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Redesigning the Process
Ideas for process redesign and improvement can be uncovered by asking six questions about each step in the process and about the process as a whole.
1. What is being done?2. When is it being done?3. Who is doing it?4. Where is it being done?5. How is it being done?6. How well does it do on the various metrics of
importance?
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Answers to the previous six questions are challenged by asking still another set of questions. Why is the process even being done? Why is it being done where it is being done? Why is it being done when it is being done?
Brainstorming is letting a group of people, knowledgeable about the process, propose ideas for change by saying whatever comes to mind.
Redesigning the Process
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Benchmarking
Benchmarking is a systematic procedure that measures a firm’s processes, services, and products against those of industry leaders. Benchmarking focuses on setting quantitative goals for
improvement. Competitive benchmarking is based on
comparisons with a direct industry competitor. Functional benchmarking compares functional
areas in the firm with those of outstanding firms in any industry.
Internal benchmarking involves using an internal unit with superior performance as the benchmark for other units.
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Benchmarking Steps
Planning: Identify the process, service or product to be benchmarked and the firm(s) to be used for comparison. Determine the performance metrics and collect the data.
Analysis: Determine the gap between the firm’s current performance and that of the benchmark firm(s).
Integration: Establish goals and obtain the support of managers who must provide the resources for accomplishing the goals.
Action: Develop cross-functional teams of those most affected by the changes, develop action plans, implement the plans and monitor progress.
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Managing Processes
Failure to manage processes is failure to manage the business
Seven common mistakes1. Not connecting with strategic issues2. Not involving the right people in the right way3. Not giving the design teams and process
analysts a clear charter and then holding them accountable
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Managing Processes
Seven common mistakes
4. Not being satisfied unless fundamental “reengineering” changes are made
5. Not considering the impact on people6. Not giving attention to implementation7. Not creating an infrastructure for continuous
process improvement
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Solved Problem 1
Create a flowchart for the following telephone-ordering process at a retail chain that specializes in selling books and music CDs. It provides an ordering system via the telephone to its time-sensitive customers besides its regular store sales.The automated system greets customers, asks them to choose a tone or pulse phone, and routes them accordingly.The system checks to see whether customers have an existing account. They can wait for the service representative to open a new account.Customers choose between order options and are routed accordingly.Customers can cancel the order. Finally, the system asks whether the customer has additional requests; if not, the process terminates.
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© 2007 Pearson Education Figure 4.15 – Flowchart of Telephone Ordering Process
Solved Problem 1SOLUTION
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Solved Problem 1SOLUTION
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Solved Problem 2
An automobile service is having difficulty providing oil changes in the 29 minutes or less mentioned in its advertising. You are to analyze the process of changing automobile engine oil. The subject of the study is the service mechanic. The process begins when the mechanic directs the customer’s arrival and ends when the customer pays for the services.SOLUTIONFigure 4.15 shows the completed process chart. The process is broken into 21 steps. A summary of the times and distances traveled is shown in the upper right-hand corner of the process chart.The times add up to 28 minutes, which does not allow much room for error if the 29-minute guarantee is to be met and the mechanic travels a total of 420 feet.
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Solved Problem 2Step No.
Time (min)
Distance (ft) Step Description
1 0.80 50.0 X Direct customer into service bay2 1.80 X Record name and desired service3 2.30 X Open hood, verify engine type, inspect hoses, check fluids4 0.80 0.30 X Walk to customer in waiting area5 0.60 X Recommend additional services6 0.70 X Wait for customer decision7 0.90 70.0 X Walk to storeroom8 1.90 X Look up filter number(s)9 0.40 X Check filter number(s)
10 0.60 50.0 X Carry filter(s) to service pit11 4.20 X Perform under-car services12 0.70 40.0 X Climb from pit, walk to automobile13 2.70 X Fill engine with oil, start engine14 1.30 X Inspect for leaks15 0.50 40.0 X Walk to pit16 1.00 X Inspect for leaks17 3.00 X Clean and organize work area18 0.70 80.0 X Return to auto, drive from bay19 0.30 X Park the car20 0.50 60.0 X Walk to customer waiting area21 2.30 X Total charges, receive payment
Summary
Activity Number of StepsTime (min)
Distance (ft)
Operation Transport Inspect Delay
Store
Figure 4.16– Process Chart for Changing Engine Oil
7 16.50
8 5.50 420
4 5.00
1 0.70
1 0.30
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Solved Problem 3
What improvement can you make in the process shown in Figure 4.16?
SOLUTIONYour analysis should verify the following three ideas for improvement. You may also be able to come up with others.
a. Move Step 17 to Step 21. Customers should not have to wait while the mechanic cleans the work area.
b. Store small inventories of frequently used filters in the pit. Steps 7 and 10 involve travel to the storeroom.
c. Use two mechanics. Steps 10, 12, 15, and 17 involve running up and down the steps to the pit. Much of this travel could be eliminated.
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Vanishing Cream AnalysisSolved Problem 4
Vera Johnson and Merris Williams manufacture vanishing cream. Their packaging process has four steps: mix, fill, cap, and label. They have had the reported defects analyzed, which shows the following.
Draw a Pareto chart to identify the vital defects.
Defect Frequency
Incorrect mixture (mix) 7
Over- or underfilled (fill) 18
Jar lids did not seal (seal) 6
Labels smudged (label) 29
Total 60
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2960
× 100% = 48.33%
Defective labels account for 48.33 percent of the total number of defects:
Vanishing Cream Analysis
Improperly filled jars account for 30 percent of the total number of defects:
1860
× 100% = 30.00%
The cumulative percent for the two most frequent defects is
48.33% + 30.00% = 78.33%
Lumps represent of defects; the cumulative percentage is
760 × 100% = 11.67%
78.33% + 11.67% = 90.00%
Solution:
Defect FrequencyIncorrect mixture (mix) 7Over- or underfilled (fill) 18Jar lids did not seal (seal) 6Labels smudged (label) 29Total 60
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Vanishing Cream AnalysisPareto Chart
Freq
uenc
y of
Def
ects
100
90
80
70
60
50
40
30
20
10
0
40
36
32
28
24
20
16
12
8
4
0
Cum
ulat
ive
Perc
enta
ge o
f Def
ects
Label Fill Mix Seal
48%
78%100%90%