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Chapter 1
Introduction to Operations Management
Lecture Outline
What Operations and Supply Chain Operations Function Historical Evolution of Operations Management Transformation Process Value Added Productivity and Competitiveness
Managing inventories Assuring quality Motivating employees & training Facilities & location
As an educated guess, I would say there is about 1,700 to 2,200 parts in the average vehicle
Transformation Process
Physical:
as in manufacturing operations Locational: as in transportation or warehouse operations Exchange: as in retail operations Physiological: as in health care Psychological: as in entertainment Informational: as in communication
Operations Function
Finance
Operations Interfaces
Maintenance MIS
Providing management information it needs through hardware and software and preparing reports
Design
Distribution
Operations
Personnel Accounting
Cost of labour, materials and overheads and may provide reports on items such as scrap, downtime, and investments
Public Relations
Purchasing
Marketing
Operations
Flight Operations
Ground Support
Facility Maintenance
Catering
TRANSFORMATION PROCESS
Inputs are used to obtain finished good or services using one or more transformation processes (storing, transporting, cutting). To ensure that the desired outputs are obtained measurements are taken at various points in the transformation processes (feedback) and then compared with previously established standards to determine whether corrective action is needed (Control).
INPUTS
OUTPUTS Transformation
Transformation process
Manufacturing: At a Food Processor (canned vegetable)
Inputs Raw Vegetables Metal Sheets, Water, Energy, Labour, Building Equipment Process Cleaning, Making cans Cutting, Cooking Packing, Labelling Output Canned vegetables
Service: At a Hospital
Inputs Doctors, Nurses Building, Medical supplies, Equipment Labs Process Examination, Surgery Monitoring, Medication Therapy Output Healthy patients
Hospital
High Teachers, books, Imparting knowledge school classrooms and skills graduates (informational) Hungry customer Sheet steel, engine parts Food, chef waiters, staff, environment Tools, equipment, workers Well prepared, well served food Fabrication and assembly of cars (physical)
Automobile factory
Historical Development of OM
Scientific Management
Year 1910s Concept Scientific management based on observation, measurement, analysis and improvement of work methods and economic incentives Tool Formalized time study and work study concepts Motion study Activity scheduling chart EOQ applied to inventory control Originator Fredrick W. Taylor
Historical Development of OM
Decision Models
Year 1940s Concept Motivational theory Multidisciplinary team approaches to complex system problem Extensive development of operations research tools Tool Reward, increase in salaries, and breaks etc.. Simplex method of linear programming Originator Abraham Maslow
1950s -60s
Simulation, waiting line Many researchers in the theory, decision theory, US and Western Europe mathematical programming, project scheduling techniques of PERT and CPM
Historical Development of OM
Decision Models and Computers
Year 1970s Concept Widespread use of computer in business Service quality and productivity Tool Shop scheduling, inventory control, forecasting, project management, MRP Mass production in the service sector 1980s Manufacturing strategy paradigm JIT, TQC, FMS, and factory automation Synchronous manufacturing Manufacturing as a competitive weapon Originator Led by computer IBM;
McDonald Restaurants Harvard Business School faculty (US) Tai-Ichi Ohio of Toyota Motors (Japan), W. E. Deming and J.M. Juran, and engineering disciplines
Historical Development of OM
The Internet
Year 1990s Concept Total quality management Tool Baldrige quality award, IOS 9000, QFD, Originator National Institute of Standards and Technology American Society of Quality Control (ASQC) and ISO
Business process concurrent engineering, reengineering continuous improvement paradigm ERP, SCM, CRM Radical change paradigm Internet world wide web SAP/R3, client server software Internet world wide web
US government, Netscape Communication Corporation, and Microsoft Corporation SAP (Germany), Orcal (US) Amazon, E-bay, American on line, Yahoo
2000s
E-commerce
Value added
Added Value is the term used to describe the difference between the cost of inputs and the value or price of outputs. In non-profit organizations, the value of the outputs (e. g., highway construction, police, and fire protection) is their value to the society; the greater value added, the greater the efficiency of these operations. In for profit organizations, the value of the out puts is measured by the price that customers are willing to pay for those goods or services. Firms use the money generated by value added for research and development, investment on new facilities and equipment, paying workers and profits, Consequently, the greater value added, the greater the amount of funds available for these purposes.
1 2 3 4 5 6 7
Farmer produces and harvests wheat Wheat transported to mill Mill produces flour Flour transported to baker Baker produces bread Bread transported to grocery store Grocery store displays and sells bread Total Value-Added
The original cost of the product or service is $3.39. The price of outputs is $4.59. According to the definition added value is $4.59 - $3.30 = $1.29.
3
Farmer produces and harvests wheat (0.15) Wheat transported to mil (0.08)
5
Bread transported to grocery store (0.08)
4
Grocery store displays and sells bread (0.21)
7 6
Chapter 2
Competitiveness, Strategy, and Productivity
Chapter 2 Outline
What is competitiveness? Order winners and Order qualifiers What is Mission, Vision, Strategy? Operations strategy (nine major decision making categories in Operations Management) Quality and time strategies Calculating productivity Productivity in the service sector Factors affecting productivity
Hourly Compensation Costs for Production Workers Source: U.S. Bureau of Labor Statistics, 2005.
Competitiveness
Companies must be competitive to sell their goods and services in the marketplace. Competitiveness is an important factor in determining whether a company prospers, barely gets by, or fails.
Competitiveness Cont..
Business organizations compete with one anther in variety of ways. Marketing influences competitiveness in several ways, including identifying customer wants and needs, pricing and advertising Identifying customer wants and needs is a basic input in an organizations decision making process, and influences competitiveness . The ideal is to achieve a perfect match between those needs and organizations goods and services. Competing on Price: is usually a key factor in consumer buying decision. It is important to understand the trade-off decision consumers make between price and aspects of product/service such as quality . Advertising and promotion are ways organizations can inform potential customers about features of their products\services and attract buyers. Product and service design: should reflect joint effort of many areas of the firm to achieve a match between financial resources, operations capabilities, supply chain capabilities, and consumers buying decision.
Competitiveness Cont..
Operations has a major influence on competitiveness through product and service design, cost, location, quality, response, flexibility, inventory and supply chain management, and service. Many of these are interrelated. Product and service design: should reflect joint effort of many areas of the firm to achieve a match between financial resources, operations capabilities, supply chain capabilities, and consumers buying decision. Cost of output is a key variable that effects pricing decisions and profits. Cost reduction efforts are generally ongoing in business organization. Productivity discussed later in the chapter is an important determinant of cost. Location: can be important in terms of cost and convenience for customers. Location near inputs can result in lower input cost. Competing on Quality: it relates to how well the product or service will serve its intended purpose. (ways to please customer not only to avoid problems) Flexibility: is the ability to respond to changes. Changes might relate to alterations in design features or service, or to the volume demanded.
Competitiveness Cont..
Competing on Time: refers to how quickly a product or service is delivered to the customers. Service organizations such as FedEx, McDonalds's have always competed on speed. Competing on variety: is the ability to produce a wide variety of products, to introduce new products and modify the existing one quickly and respond to customer needs. Inventory Management: can be competitive advantage by effectively matching supplies of goods with and demand Service: might involve after sale activities customer perceive as added value, such as setup, warranty, courtesy, keeping the customer informed, and attention to details. Managers and Workers: are the people are the heat and soul of the organization, and if they are competent and motivated, they can provide a distinct competitive advantage by their skills and the ideas they create.
Competitiveness Cont..
is the amount a customer must pay for a product or service.
Quality
Timeliness
Customer Service
Location
it relates to how well the product or service will serve its intended purpose.
Might involve after sales activities that perceived by customers as value added
Competitiveness Cont..
A firm is in trouble if the things it does best are not important to the customer. The key to successfully competing is to determine what customers want and then direct efforts toward meeting (or even exceeding) customer expectations. In formulating a successful strategy, organizations must take into account both order qualifiers and order winners. Order qualifiers: are the characteristics that customer perceive as minimum standard of acceptability to be considered as a potential for purchase. (what
qualifies an item to be considered for purchase).
Order winners: are the characteristics of an organizations good or services that cause it to be perceived as better than competition. (What wins the order).
For example, when purchasing a DVD player, customer may determine a price range (order qualifier) and then choose the product with most features (order winner) within that price range.
Source: Adapted from Nigel Slack, Stuart Chambers, Robert Johnston, and Alan Betts, Operations and Process Management, Prentice Hall, 2006, p. 47 Management,
Mission/Strategy/Tactics
Mission
Strategy
Tactics
(Mission vary from organization to organization, depending on the nature of their business. It is important that an organization have a clear and simple mission/vision statement, one that answers the questions what business are we in? The mission statement should serve to guide strategy formulation.)
Mission/Strategy/Tactics
Strategy: A plan for achieving organizational mission/goals. A strategy is a set of coordinated broad long term policies, objectives, and action programs to achieve goals. Organizations have overall strategies called organization or business strategies, which related to the entire organization, and they have functional strategies, which related to the functional areas of the organization. Tactics: The medium term objectives, method, and actions taken to accomplish strategies. (They are more specific in nature than strategies,
and they provide guidance and direction for carrying out actual operations, which need the most specific and details plans and decision making in an organization.
Mission
Goals A set of coordinated broad long-term policies, objectives and action program
Tactics
Tactics
Tactics
Capacity utilization Quality of delivery Work in progress Cost per operation hour Information carrying cost Total inventory cost
Operating procedure
Operating procedure
Operating procedure
Operations Strategy
Operations strategy is narrow in scope, dealing guiding the operations aspect of
the organization, but aligned with organization strategy and goals. Operations strategy comprises a set of well-coordinated policies, objectives, and action programs, which provides advantage over the competitors. In order to formulate an operations strategy, the operations function has to cooperate with all other functions of the business, marketing, R&D, and finance. The creation of operations strategy occurs both at the company level and at the functional level. At the company level, the role of operations should be identified. Usually, operations objectives/performance measure are given in terms of competitive attribute (cost, quality, flexibility). Usually the operations policies, objectives, and action programs are classified into nine major decision making categories:
Environmental Scanning
Internal Factors Human Resources Farcicalities and Equipment Financial Resources Customer Product and Services Technology Suppliers External Factors Economic Conditions Political Conditions Legal Environment Technology Competition Markets
New Strategies
Quality-based strategies Focuses on maintaining or improving the quality of an organization s products or services Quality at the source Time-based strategies Focuses on reduction of time needed to accomplish tasks
Time-based Strategies
JAN
FEB
MAR
APR
MAY
JUN
Planning
Productivity
Productivity: A measure of efficient use of resources usually expressed as the ratio of output to input.
Partial measures: output/(single input) Multi-factor measures: output/(multiple inputs) Total measure: output/(total inputs)
Outputs Productivity = Inputs
Productivity Growth =
Current Period Productivity Previous Period Productivity Previous Period Productivity
Increased globalization
results from the Internet and falling trade barriers
Average Annual Growth Rates in Output and Input, 1995-2005 Source: Bureau of Labor Statistics. A Chartbook of International Labor Comparisons, January 2007, p. 26.
Measures of Productivity
Partial or single measures Output Labor Output Machine Output Capital Output Energy
Multifactor Measures
Total measure
Units of output per labor hour Units of output per shift Units of output per dollar input Units of output per kilowatt-hour
Example-1-Labour Productivity
A company that processes fruits and vegetable is able to produce 400 cases of canned peaches in one-half hour with four workers. What is labor hour productivity?
A wrapping paper company produced 2,000 rolls of paper in one day. Labor cost was $160, material cost $50 and overhead was $320. Determine the multifactor productivity.
Example-2-Labour Productivity
At a local Lumber small business. Steve the owner and producer of apple boxes sold to growers, has been able, with his current equipment, to produce 240 boxes per 100 logs. He currently purchase 100 logs per day and each log requires 3 labor hours to process. He believes that he can hire a professional buyer who can buy a better quality log at the same cost. If this is the case, he can increase his production to 260 boxes per 100 log. His labor hour will increase by 8 hours per day. What will be the impact on productivity (measured in boxes per labor-hour) if the buyer is hired.
b. New labor productivity = 260 100 logs (3 hours/log) + 8 hours = 0.844 boxes per labor-hour
Using current productivity (0.8 from [a].) as a base, the increase will be 5.5% (0.844/0.8 = 1.055, or a 5.5% increase)
Sold for $10/unit Labor rate: $9/hr Cost of purchased material: $25,000
Output 10,000 units ! ! 20 Labour hours 500 L - hour Output 10,000 10,000 units ! ! ! 0.29 $ All inputs 500 v 9 5,000 25,000 34,500
Example 4-Productivity
Calculate the multifactor productivity measure for each of the weeks shown below. What do the productivity figures suggest? Assume 40-hour weeks and an hourly wage of $12. Overhead is 1.5 times weekly labour cost. Material cost is $6 per kilogram. Selling price is $140 per unit.
Output = 300 units Material = 45kg Number of workers = 6 Sales = 300 X 140 = $42,000 Cost of material = 45 X 6 = $270 Cost of labour = 6 X 40 X 12 = $2880 Cost of overhead = 2880 X 1.5 = $4320 Total cost = $270 + 2880 + 4320 = $7470 Multifactor productivity for week 1 = $42,000/$7470 = $5.62
Multifactor productivity is dropping steadily from a high of 5.62 to 5.01 $ output per $ input.
About Productivity
Productivity growth is a key factor in a country s standard of living. Labour productivity is still the main measure used to gauge the performance of individuals and plants. Wage and price increases not accompanied by productivity increases tend to create inflationary pressure on economy. Because of the large amount of trade with US, it is very important not to lose ground on productivity.
Sometimes the measures of output result in misleading conclusions (measure the productivity of a hospital by the number of patient-days of care provided).
Quality
Technology
Management
Improving Productivity
Develop productivity measures Determine critical (bottleneck) operations Develop methods for productivity improvements Establish reasonable goals Get management support Measure and publicize improvements Don t confuse productivity with efficiency
Bottleneck Operation
Look at the system as a whole in deciding which operations are most critical; it is overall productivity that is important. Figure above which shows several operations feeding their output into a bottleneck operation. The capacity of the bottleneck operation is less than the combined capacities of the operations that provide input, so units queue up waiting to be processed: hence the term bottleneck.
Operation 10/hr
Operation
Operation
10/hr
Operation
10/hr
End of Lecture # 1
Thank You