© Sistema Universitario Ana G. Méndez, 2011. Derechos Reservados.

Process StrategyProcess Strategy

W4 4.4

1© Ana G. Méndez University System, 2012. All rights reserved.

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Outline for Workshop 4 Four Process Strategies

Process Focus

Repetitive Focus

Product Focus

Mass Customization Focus Process Analysis and Design

Flow Diagrams Time-Function Mapping Value-Stream Mapping Process Charts Service Blueprinting

Service Process Design Customer Interaction and Process Design More Opportunities to Improve Service Processes

Production Technology Machine technology Automatic identification Systems

(AISs) Process control Vision system Robot Automated storage and retrieval

systems (ASRSs) Automated guided vehicles (AGVs) Flexible manufacturing systems

(FMSs) Computer-integrated

manufacturing (CIM)

Redesign process

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Specific Objectives for Workshop 4

At the end of the workshop, you will be able to:1. Describe the four production processes 2. Use the tools of process analysis3. Describe customer interaction in process design.4. Identify advances in production technology and

redesign process.

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Production Process: Volume and Variety

Low Volume

High VolumeVolume

High Variety, one or few products

Low Variety,long runs

only

Repetitive FocusVariety

Process Focusprojects, job shops

(machine, print, carpentry) Mass Customization

(difficult to achieve, but huge rewards)

Product Focus(commercial baked goods, steel, glass)

Changes in attributes

Changes in runs

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Process Strategies

Four basic strategies

Process focus Repetitive focus Product focus Mass customization

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Process Focus

FoundryMilling

machines

LathesGrinding

Painting Drills

Office

Welding

Forging

Many departments and

many routingsJob Shop or Intermittent Process

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Process Flow Diagram

This is a process flow diagram for a high quality product and service in the industry.

Shows the flow of material or service

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Repetitive Focus

Raw materials

and module inputs

Modules combined for many output options

Few modules

Assembly Line

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Product Focus

Station 1 Station 2 Station 3 Station 4

Continuous Work Flow

Output variations

in size, shape, and packaging

Few inputs

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Mass Customization

Mass CustomizationEffective scheduling techniques

Rapid throughput techniques

Repetitive FocusFlexible peopleand equipment

Process-FocusedHigh variety, low volume

Low utilization (5% to 25%)General-purpose equipment

Product-FocusedLow variety, high volume

High utilization (70% to 90%)Specialized equipment

Modular techniquesSupportive

supply chains

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Process Analysis and Design

Flow Diagrams - Show the movement of

materials

Time-Function Mapping - Shows flow and time

frame

Value-Stream Mapping - Shows flow, time. and

value added beyond the immediate organization

Process Charts - Use symbols to show key

activities

Service Blueprinting - focuses on

customer/provider interaction

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Flow Diagrams

Time-Function MappingCustomer

Sales

Production control

Plant A

Warehouse

Plant B

Transport Move

Receive product

Extrude

Wait

Move

Wait

Print

Wait

Order product

Process order

Wait

12 days 13 days 1 day 4 days 1 day 10 days 1 day 0 day 1 day52 days

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Value Stream Mapping

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Process Charts

Process Charts Symbols

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Service Blueprints

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Service Process Design

Service Factory Service Shop

Degree of CustomizationLow High

Deg

ree

of L

abor

Low

High

Mass Service Professional Service

Commercial banking

Private banking

General-purpose law firms

Law clinics

Specialized hospitals

Hospitals

Full-service stockbroker

Limited-service stockbroker

Retailing Boutiques

Warehouse and catalog stores Fast-food

restaurants Fine-dining restaurants

AirlinesNo-frills airlines

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Production Technology

Machine technology Automatic identification Systems (AISs) Process control Vision system Robot Automated storage and retrieval systems

(ASRSs) Automated guided vehicles (AGVs) Flexible manufacturing systems (FMSs) Computer-integrated manufacturing (CIM)

19Prepared by María Vázquez

Machine Technology Automatic Identification Systems (AIS) and Radio Frequency Identification

(RFID)

Increased precision Increased productivity Increased flexibility Improved environmental impact Reduced changeover time Decreased size Reduced power requirements

Improved data acquisition Reduced data entry errors Increased speed Increased scope of process

automation

Bar Codes RFID

20Prepared by María Vázquez

Process Control Vision Systems

Increased process stability Increased process precision Real-time provision of

information for process evaluation

Data available in many forms

Particular aid to inspection Consistently accurate Never bored Modest cost Superior to individuals

performing the same tasks

21Prepared by María Vázquez

Robot Automated Storage and Retrieval System (ASRS)

Perform monotonous or dangerous tasks

Perform tasks requiring significant strength or endurance

Generally enhanced consistency and accuracy

Automated placement and withdrawal of parts and products

Reduced errors and labor Particularly useful in inventory and

test areas of manufacturing firms

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Automated Guided Vehicles (AGV)

Flexible Manufacturing System

(FMS)

Electronically guided and controlled carts

Used for movement of products and/or individuals

Computer controls both the workstation and the material handling equipment

Enhance flexibility and reduced waste Can economically produce low volume at

high quality Reduced changeover time and increased

utilization Stringent communication requirement

between components

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Computer-integrated Manufacturing (CIM)

Extension of flexible manufacturing systems

Backwards to engineering and inventory control

Forward into warehousing and shipping

Can also include financial and customer service areas

Reducing the distinction between low-volume/high-variety, and high-volume/low-variety production

© Sistema Universitario Ana G. Méndez, 2011. Derechos Reservados.

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Process Redesign The fundamental rethinking of

business processes to bring about dramatic improvements in performance

Relies on reevaluating the purpose of the process and questioning both the purpose and the underlying assumptions

Requires reexamination of the basic process and its objectives

Focuses on activities that cross functional lines

Any process is a candidate for redesign

End

After studying the content, please complete the assigned activities.

© Ana G. Méndez University System, 2012. All rights reserved.25