chapter 3: process planning and design1 chapter 3 process planning and design
TRANSCRIPT
Chapter 3: Process Planning and Design 1
Chapter 3
Process Planning and Design
Chapter 3: Process Planning and Design 2
Process Planning and Design
Chapter 2 identified the critical factors in providing value to the customer. This chapter discusses the selection and design of the transformation process that can deliver those factors—low cost, high quality, enhanced functionality, speed, and so on—in an efficient and effective manner.
Chapter 3: Process Planning and Design 3
Introduction
Fender's Custom Shop Assembly line at IBM's plant in Charlotte,
North Carolina Rickard Associates, an editorial production
company Martin Marietta's aerospace electronics
manufacturing facility in Denver, Colorado Nynex
Chapter 3: Process Planning and Design 4
Examples Examples illustrate several transformation systems.
The Fender Custom Shop is a job shop that has specialized departments for routing, lathe operations, inlaying, paint and finishing, and final assembly. Because work is organized by the task performed, Rickard Associates is also a job shop - even though the work is not performed in one location. Companies like Rickard that rely on information technology to bring separated workers together are referred to as virtual organizations. Martin Marietta converted into focused factories. And assembly lines like the one IBM uses are referred to as flow shops.
Chapter 3: Process Planning and Design 5
Fender’s Custom Shop
Customers include Eric Clapton, John Deacon (Queen), David Gilmour, Yngwie Malmsteen and Stevie Ray Vaughn
Production Steps: computer controlled routers and lathes
shape guitar bodies and necks also have Neck Duplicator necks and bodies hand and machine
sanded
Chapter 3: Process Planning and Design 6
Fender’s Custom Shop continued
detailed inlay work done with Hegner precision scroll saw
paint and finishing operations in special room where air is re-circulated 10 times/minute
buffed hung up and seasoned for two weeks final assembly by actual musicians
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IBM’s Charlotte, NC Plant
Assembly line produces 27 significantly different products
Products include hand-held bar-code scanners, portable medical computers, fiber-optic connectors, and satellite communications devices
“Kits” of parts delivered to workers Computer screen displays assembly
instructions
Chapter 3: Process Planning and Design 8
Rickard Associates
Produces magazines and marketing materials Only two of editorial production company’s
employees work at headquarters in NJ Art director works in AZ Editors are located in FL, GA, MI, and D.C. Freelancers even more scattered Internet and AOL used to coordinate work
Chapter 3: Process Planning and Design 9
Martin Marietta Aerospace Plant
Originally set up as job shop with numerous functional departments high WIP levels long lead times long travel distances departmental barriers inhibited
communication Plant subsequently arranged into three
focused factories
Chapter 3: Process Planning and Design 10
Martin Marietta continued
Each focused factory completed entire electronic assembly for particular application
Each focused factory treated as separate business enterprise
Factory manager assigned to each focused factory
“NFL draft” used to select worker teams
Chapter 3: Process Planning and Design 11
Martin Marietta continued Within focused factories part families identified
based on technology and processes Standard routings identified for each part
family Improvements
seven months of consecutive production with no scrap
50% reduction in WIP 21% reduction in lead times 90% reduction in overtime
Chapter 3: Process Planning and Design 12
Nynex
Analyzed company in terms of four core processes customer operations customer support customer contact customer provisioning
Chapter 3: Process Planning and Design 13
Nynex continued
Obtained services of Boston Consulting Group
Visited 152 companies to document best practices
Estimated savings are $1.5 to $1.7 billion
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Variety of Transformation Systems
Fender Custom Shop is job shop Rickard Associates is job shop and is
also a virtual organization Martin Marietta converted from a job
shop to focused factories IBM uses a flow shop
Chapter 3: Process Planning and Design 15
Transformation System Design and Layout Analysis
Transformation system design considers alternative transformation forms and selects best one given characteristics of desired outputs.
Layout analysis seeks to maximize the efficiency or effectiveness of operations.
Chapter 3: Process Planning and Design 16
Forms of Transformation Systems
Continuous Process
Chapter 3: Process Planning and Design 17
Continuous Process
Highly standardized products in large volumes
Often these products have become commodities
Typically these processes operate 24 hours/day seven days/week
Objective is to spread fixed cost over as large a volume as possible
Chapter 3: Process Planning and Design 18
Continuous Process continued
Starting and stopping a continuous process can be prohibitively expensive
Highly automated and specialized equipment used
Layout follows the processing stages Output rate controlled through
equipment capacity and flow mixture rates
Chapter 3: Process Planning and Design 19
Continuous Process continued
Low labor requirements
Often one primary input
Initial setup of equipment and procedures very complex
Chapter 3: Process Planning and Design 20
Forms of Transformation Systems
Flow Shop
Chapter 3: Process Planning and Design 21
Flow Shop
Similar to continuous process except discrete product is produced
Heavily automated special purpose equipment
High volume - low variety Both services and products can use flow
shop form of processing
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A Generalized Flow Shop Operation
Chapter 3: Process Planning and Design 23
Advantages of the Flow Shop
Low unit cost specialized high volume equipment bulk purchasing lower labor rates low in-process inventories simplified managerial control
Chapter 3: Process Planning and Design 24
Disadvantages of Flow Shop
Variety of output difficult to obtain Difficult to change rate of output Minor design changes may require
substantial changes to the equipment Worker boredom and absenteeism Work not very challenging Vulnerable to equipment breakdowns
Chapter 3: Process Planning and Design 25
Disadvantages of Flow Shop continued
Line balanced to slowest element Large support staff required Planning, design, and installation very
complex task Difficult to dispose of or modify special
purpose equipment
Chapter 3: Process Planning and Design 26
Flow Shop Layout
Objective is to assign tasks to groups The work assigned to each group should
take about the same amount of time to complete
Final assembly operations with more labor input often subdivided easier
Paced versus unpaced lines
Chapter 3: Process Planning and Design 27
Line Balancing
number of theoretical workstations, task times / cycle timeTN
efficiency = output
input
total task time
N stations) cycle timeA
(
demand
work timeavailable timeCycle
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Line Balancing Example
Task Time Required PrecedesA 2.2 min. B, C, DB 3.4 EC 1.7 ED 4.1 FE 2.7 FF 3.3 GG 2.6 --
Chapter 3: Process Planning and Design 29
Line Balancing Example continued
Company operates one shift per day Available time per shift is 450 minutes Demand is 100 units/day
Chapter 3: Process Planning and Design 30
Precedence Diagram
A
B
C
D
E
F G
Chapter 3: Process Planning and Design 31
Calculations
cycle time = 450/75 = 6 minutes/part
NT = 20/6 = 3.33 = 4 stations
Chapter 3: Process Planning and Design 32
Task Assignment
StationTimeAvail.
Elig.Tasks
WillFit?
TaskAssign.
IdleTime
1 6.0 A A
3.8 B,C,D B,C B
0.4 C,D -- -- 0.4
2 6.0 C,D C,D D
1.9 C C C
0.2 E -- -- 0.2
Chapter 3: Process Planning and Design 33
Task Assignment continued
StationTimeAvail.
Elig.Tasks
WillFit?
TaskAssign.
IdleTime
3 6.0 E E E
3.3 F F F 0.0
4 6.0 G G G 3.4
Chapter 3: Process Planning and Design 34
Line Balancing Solution
A
B
C
D
E
F G
Station 1
Station 2
Station 3
Station 4
Chapter 3: Process Planning and Design 35
Efficiency
efficiency = 20/(4*6) = 83.3%
Chapter 3: Process Planning and Design 36
Precedence Graph for Credit Applications
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Stations Assignments for Credit Application
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Forms of Transformation Systems
Job Shop
Chapter 3: Process Planning and Design 39
Job Shop
High variety - low volume Equipment and staff grouped based on
function Each output processed differently
Chapter 3: Process Planning and Design 40
A Generalized Job Shop Operation
Chapter 3: Process Planning and Design 41
Advantages of the Job Shop
Flexibility to respond to individual demands
Less expensive general purpose equipment used
Maintenance and installation of general purpose equipment easier
General purpose equipment easier to modify and therefore less susceptible to becoming obsolete
Chapter 3: Process Planning and Design 42
Advantages of the Job Shop continued
Dangerous activities can be segregated from other operations
Higher skilled work leading to pride of workmanship
Experience and expertise concentrated Pace of work not dictated by moving line Less vulnerable to equipment
breakdowns
Chapter 3: Process Planning and Design 43
Disadvantages of the Job Shop
General purpose equipment is slower Higher direct labor cost High WIP inventories High material handling costs Management control very difficult
Chapter 3: Process Planning and Design 44
Directly Specified Closeness Preferences
A = absolutely necessary E = especially important I = important O = ordinary closeness OK U = unimportant X = undesirable
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Cost-Volume-Distance Model
TC = C V Di=1
N
ij ij ijj=1
N
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Office Layout
Chapter 3: Process Planning and Design 47
Forms of Transformation Systems
Cellular Production
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The Cell Form
Combines flexibility of job shop with low costs and short response times of flow shop
Based on group technology First identify part families Then form machine cells to produce part
families
Chapter 3: Process Planning and Design 49
Conversion of a Job Shop Layout to a Cellular Layout
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Organization of Miscellaneous Parts into Families
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Advantages of Cellular Production
Reduced machine setup times increased capacity economical to produce in smaller batch
sizes smaller batch sizes result in less WIP less WIP leads to shorter lead times shorter lead times increase forecast
accuracy and provide a competitive advantage
Chapter 3: Process Planning and Design 52
Advantages of Cellular Production continued
Parts produced in one cell Capitalize on benefits of using worker
teams Minimal cost to move from job shop to
cellular production (e.g. EHC) Can move from cellular production to
“mini-plants”
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Disadvantages of Cellular Production
Volumes too low to justify highly efficient high volume equipment
Vulnerable to equipment breakdowns Balancing work across cells Does not offer the same high degree of
customization as the job shop
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Cellular Layout
Teams of workers and equipment to produce families of outputs
Workers cross-trained Nominal cells versus physical cells. Remainder cell Cell formation methods
production flow analysis
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Original Machine-Component Matrix
A B C D E
1 1 1 1
2 1 1
3 1 1 1
4 1 1
5 1 1
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Reordered Machine-Component Matrix
A C E B D
1 1 1 1
3 1 1 1
5 1 1
2 1 1
4 1 1
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Forms of Transformation Systems
Project Operations
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Project Operations
Large scale Finite duration Nonrepetitive Multiple
interdependent activities
Offers extremely short reaction times
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Selection of the Process
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Volume/Variety Considerations
High volume indicate automated mass production
High variety implies use of skilled labor and general purpose equipment
Make-to-stock versus make-to-order
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Effect of Output Characteristics on Transformation Systems
Chapter 3: Process Planning and Design 62
Product/Process Life Cycles
In R&D stage, product made in small volumes
At peak of life cycle, demand may justify high volume special purpose equipment
System should evolve as market evolves Whether an organization moves with a
product through its life cycle depends on the organization’s focus
Chapter 3: Process Planning and Design 63
Selection of Transformation System by Stage of Life Cycle
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Service Processes Often implemented with little
development or pretesting Need to consider amount of customer
contact Customers may not arrive at smooth and
even increments Including customer in service process
provides opportunities to improve service
Chapter 3: Process Planning and Design 65
New Transformational Technologies and Reengineering
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Information Technology
World Wide Web Federal Express
Web server set up in late 1994 By 1996 12,000 customers using service each
day to access package-tracking database provides higher customer service saves FedEx $2 million per year
Intranets
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Information Technology continued
Decision support systems Artificial intelligence Expert systems
Chapter 3: Process Planning and Design 68
The Office of the Future Focus of 1980s was on improving
individual productivity Focus 1990s is enhancing way teams
work together Groupware
communications (e-mail) collaboration (access to shared data) coordination (jointly accomplishing
activities)
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Manufacturing Technologies
Numerical Control (NC) computer numerical control direct numerical control
Robotics Flexible Manufacturing Systems (FMS)
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Business Process Design (Reengineering)
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Division of Labor Concept
Work broken down into its simplest most basic tasks Performing same task facilitates attaining
greater skill No time lost switching to another task Workers well positioned to improve tools
and techniques
Chapter 3: Process Planning and Design 72
Division of Labor Concept continued
Division of labor concept not challenged until recently despite dramatic changes in technology
Quality, innovation, service, and value more important than cost, growth, and control
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Process
Set of activities that taken together produce a result of value to the customer
Organizing on basis of processes Eliminate delays and errors when work is
handed off Capture information once and at source When people closest to process perform
work, there is little need for management overhead
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Business Process Design (BPD)
The fundamental rethinking and radical redesign of business processes to bring about dramatic improvements in performance
Hammer, M. and Stanton, S. The Reengineering Revolution, Harper Business, 1995.
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Radical
Profoundly change the way work performed
Not concerned with making superficial changes
Get to root Get rid of old Reinventing, not improving
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Redesign
BPD is about designing how work is done
Smart, capable, well trained, highly motivated employees mean little if the way work is performed is poorly designed
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Process
All organizations perform processes Customers not interested in individual
activities but rather overall results Few of them are organized on the basis
of processes Thus, processes tend to go unmanaged Team approach one way this addressed
Chapter 3: Process Planning and Design 78
Dramatic
Quantum leaps in performance, not marginal or incremental improvements
Breakthroughs in performance
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IBM Credit Example
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IBM Credit Example continued
Order logged by 1 of 14 people in conference room
Carted upstairs to credit department Information entered into computer to
check borrower’s creditworthiness Results written on piece of paper
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IBM Credit Example continued
Business practices department modified standard loan covenant in response to customer requests
Used its own computer system Pricer keyed data into PC to determine
appropriate interest rate Administrator converted to quote letter
and Fedexed to field sales rep.
Chapter 3: Process Planning and Design 82
IBM Credit Example continued
Average time to process a request was 6 days
Could take as long as 2 weeks Actual processing time 90 minutes Deal Structurer
Turnaround time 4 hours Number of deals processed increased 100
times with small reduction in head count
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