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PRODUCTION
AND SERVICE
OPERATIONS
Worker-Paced Assembly Line
An assembly line refers to a production layout arranged in sequence to
accommodate processing of large volumes of standardized products or
services. Shown in the figure is a diagram of the work flow in an assembly
line
MANUFACTURING PROCESSES
The worker-paced assembly line is characterized by the
following:
1. The products manufactured are mostly standardized
2. There is a clear process pattern
3. Specialized equipment is used
4. The size of operation is variable.
5. The process is worker paced.
6. The type of Layout used is the line flow
7. Labor is still a big cost item.
Station 1 Station 1 Station 1 Station 1
Raw Materials Materials Materials Materials
Materials and/or and/or and/or and/or
labor labor labor labor
MANUFACTURING PROCESSES
Examples of machine-paced assembly line are automobile
manufacturers like General Motors and Ford Motors. Shown
in the Figure is an example of Machine-paced assembly line
process.
The Body Line
Body Assembly Paint Shop
*floor pan, body side, *primer (ELPO BATH)
roof panel positioning *finish coat
and welding
*door hanging
*engine enclosure
positioning and
welding
Miscellaneous Chassis
*front-end assembly
Operations
(e.g., fenders hood)
*gas tank and fuel lines
*metal finishing
*break lines assembled
Various Trim Line Sub-assemblies *front-end alignment
*rear axle mounted
Hard Trim line *wheel mounting
*bumpers and other
chrome
*glass The Motor Cradle Line
*vinyl tops *dressing of basic motor
*air conditioning with various parts, hoses
*instrument panel and harnesses
MANUFACTURING PROCESSES
Its other characteristics are as follows:
1. There is economy of scale in production resulting to low
percent unit cost of production
2. The process is clear and very rigid
3. Specialized equipment are used.
4. The line flow layout is used.
5. Operations are highly capital intensive
6. The size of operations is very large.
7. Processing is fast.
Diagram of the Continuous Flow Process of a Paper-Making
Company
Temporary
storage Cleaning Wet end: headbox, wire Inventory of Rewinding, sitting
additives and Rollers, drying drums parent logs Shipping
added blending Dry end: winders slitting
Broke added
MANUFACTURING PROCESSES
Examples of companies using the batch/continuous hybrid are
breweries, gelatin procedures and tobacco manufacturers. A simplified
process using the batch/continuous flow hybrid is shown in the figure.
A Simplified Production Process of a Gelatin Manufacturing Company Using the
Batch/Continuous Flow Hybrid
Packaging
Service Process
Service processes are those that refer to the provision of
services to persons by hand or with machinery.
MANUFACTURING PROCESSES
1. Service Factory
A service factory offers a limited mix of services which
results to some economies of scale in operations. This also
affords the company to compete in terms of price and
speed of producing the service.
The process layout preferred by the service factory is the
rigid pattern of line flow processing. McDonalds and
Shakeys are also examples of service factories.
Service Process
2. Service Shop
A service shop provides a diverse mix of services. The layout used
are those for job shops or fixed position and are adaptable to
various requirements.
Service shops abound throughout the Philippines. Examples are
Servitek and Megashell. Among the services provided by these
shops are car engine tune-ups, wheel balancing, wheel alignment,
change oil, etc.
Service Process
Process Flow of a Car Repair Service Shop
Withdrawal of
Parts parts from parts
inventory department
Road test
If car fails
by mgmt.
test
Shown in the figure is a diagram
of the process flow of a car Car returned
and customer Papers gathered
repair service shop. payment on car and sent to
processed cashier
3. Mass Service
A mass service company provides service to a large number of
people simultaneously. A unique processing method is therefore
necessary to satisfy this requirement. To be able to serve many
people, mass service companies offer limited mix of services.
The process layout used is typically fixed position where customers
move through the layout.
Service Process
Process Flow for Material Receipt and Sales Transactions in a Mass Service
Retailing Institution
I. Material Receipt
Any
problem
reports filed
II. Sales Transactions
Presenting
Register merchandise to Sale entry Sale Register
opened customer and on register made closed and
closing sale balanced
Credit not
approved
4. Professional Services
These are companies that provide specialized services to other firms or
individuals. Examples of such firms are as follows:
a. Engineering management consulting services which help in improving
the plant layout of the efficiency of a company.
b. Design services which supply designs for a physical plant, products,
and promotion materials.
Service Process
c. Advertising agencies which help promote a firms products.
d. Accounting services
e. Legal services
f. Data processing services
g. Health services
Service Process
Professional service firms offer a diverse mix of services. There is
a lower utilization of capital equipment compared to the service
factory and the service shop. The process pattern used is very
loose. The process layout used is identical to the job shop.
Service Process
Professional service firms are oftentimes, face with
delivery problems brought about by non-uniform
demand. Strategies that may be used depending on the
situations are as follows:
a.The use of staggered work-shift schedules
b. The hiring of part-time staff
c. Providing the customer with the opportunity to select
the level of service.
Service Process
1. Product Design
2. Production planning and scheduling
3. Purchasing and materials management
4. Inventory control
5. Work flow layout
6. Quality control
1. Product Design
Refers
to the process of creating a set of product specifications
appropriate to the demands of the situation.
Companies wanting to maintain or improve its market share
keeps a product design team composed of engineers,
manufacturing and marketing specialists.
Product Design
May be defined as forecasting the future sales of a give
product, translating this forecast into the demand it generates
for various production facilities, and arranging the
procurement of these facilities.
Production planning is a very important activity because it
helps management to make decisions regarding capacity. When
the right decisions are made, there will be less opportunities
for wastages.
4. Inventory Control
There are ways of achieving proper inventory control, they are as
follows:
a. Determining reorder point and reorder quantity.
b. Determining the economic order quantity.
c. The use of just-in-time method (JIT) of inventory control
d. The use of material requirement planning method (MRP) of planning
and controlling inventories.
4. Inventory Control
Work-flow layout is the process of determining the
Physical arrangement of the production system. In the
transformation process, the flow of work may be done
wither haphazardly or orderly.
5. Work-Flow layout
The job of the operations manager is to assure that a cost-
effective work-flow layout is installed. A good work-flow layout
will have the following benefits.
a. Minimize investment in equipment.
b. Minimize overall production times
c. Use existing space most effectively.
d. Provide for employee convenience, safety and comfort.
5. Work-Flow layout
e. Maintain flexibility of arrangement and operation.
f. Minimize material handling cost.
g. Minimize variation in types of material-handling equipment.
h. Facilitate the manufacturing (or service) process.
i. Facilitate the organizational structure.
5. Work-Flow layout
Quality control refers to the measurement of products or
services against standards set by the company. Certain
standard requirements are maintained by the management to
facilitate production and to keep customers satisfied.
Poor quality control breeds customer complaints, returned
merchandise, expensive lawsuits, and huge promotional
expenditures.
6. Quality Control
The management of operations is very crucial to the survival of
firms. Operations refer to the changing of inputs into useful
outputs. In the effort to manufacture products (or services),
operations management must contribute its share in the
accomplishment of the companys objectives.
The function of the operations manager is to plan, organize.
And control operations in order to achieve objectives
efficiently and effectively. The engineer manager is, oftentimes
assigned to perform the task of the operations manager.
Summary
The transformation process may be classified generally as
manufacturing of service processes. These two are sub-
classified into various types, each with built in advantages
depending on certain conditions.
Production systems consists of various parts that complement
one another in the production task. The engineer manager
needs to be familiar with these various parts.
Summary