report in production operation management by mitch g

8/13/2019 Report in Production Operation Management by Mitch g.

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PRODUCTION OPERATION

MANAGEMENT

Process Selection andFacility Layout


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Process Selection

Refers to deciding on the way

production of goods or services

will be organized. It has majorimplications for capacity

planning, layout of facilities,

equipment, and design of work

system.


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System Design

Inputs Outputs

Forecasting

Technological

change

Facilities

and

Equipment

Work

Design

Product

and

Service

design

Layout

Capacity

Planning

Process

Selection


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TECHNOLOGY

TechnologyRefers to applications of

scientific discoveries to the development and

improvement of goods and services and/or

the processes that produce or provide them.

Technology InnovationRefers to the

discovery and development of new or

improved products, services, or processes

for producing or providing them.


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Three Kinds of Technology

Product and Service technologyis the

discovery and development of new products

and services.

Process technology

includes methods,procedures, and equipment used to produce

goods and provide services.

Information technology (IT)

is the scienceand use of computers and other electronic

equipment to store, process, and send

information.


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Technology as a Competitive Advantage

Technology innovation in products andservices, and in processing technology can

produce tremendous benefits fororganizations.

Technology Acquisition

While process technology can have

enormous benefits, it also substantial riskunless a significant effort is made to fullyunderstand both the downside as well theupside of a particular technology.


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Process Selection

Process Types - There are five basic types of Process Types :

Job shopA job shop usually operates on a relatively

small scale. It is used when a low volume of high-

variety goods or services will be needed.

Batch

Batch processing is used when a moderatevolume of goods or services is desired, and it can

handle a moderate variety in products or services.

Repetitivewhen higher volumes of more standardized

goods or services are needed, repetitive processing isused.

Continuouswhen a very high volume of non discrete,

highly standardized output is desired, a continuous

system is used.


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Projectis used for work that is non routine,

with a unique set of objectives to be

accomplished in a limited time frame.

Product and Service Profiling

can be used toavoid any inconsistencies by identifying key

product or service dimensions and then

selecting appropriate process.

Automationis machinery that has sensing and

control devices that enable it to operate

automatically.


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Computer

aided manufacturing (CAM)

refersto the use of computers in process control,

ranging from robots to automated quality

control.

Numerically controlled (N/C)are programmed

to follow a set of processing instructions based

on mathematically relationship that tell the

machine the details of the operations to beperformed

RobotA machine consisting of a mechanical

arm, a power supply, and a controller.


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Facilities Layout

LayoutRefers to the configuration of departments,

work centers, and equipment, with particular emphasis

on movement of work (customer or materials) through

the system.

Layout decisions are important for three basis reasons:

a. they require substantial investments of money and

efforts.

b. they involved long-term commitments, which makes

mistakes difficult to overcome.

c. they have a significant impact on the cost and

efficiency of operations.


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Objective of Layout Design

To facilitate attainment of product orservice quality.

To use workers and space efficiently.

To avoid bottlenecks. To minimize material handling costs.

To eliminate unnecessary movements ofworkers or materials.

To minimize production time orcustomer service time.

To design for safety.


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Repetitive Processing: Product

Layout

Product Layoutlayout that uses standardized

processing operations to achieve smooth,

rapid, high-volume flow.

Production Line

standardized layout arrangedaccording to a fixed sequence of production

task.

Assembly Linestandardized layout arranged

according to a fixed sequence of assembly

tasks.


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Process Layout

Dept. A

Dept. B Dept. D

Dept. C

Dept. F

Dept. E

Used for Intermittent processing

Job Shop or Batch

Process Layout

(functional)


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Process Layout

Work

Station 1

Work

Station 2

Work

Station 3

Product Layout

(sequential)

Used for Repetitive Processing

Repetitive or Continuous


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Cellular Production

Layout in which machines are

grouped into a cell that can process

items that have similar processing

requirements.

Group Technology

The grouping into part families of

items with similar design or

manufacturing characteristics.


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Warehouse and storage layouts

Retail layouts

Office layouts

Other Service Layout


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Line Balancing

Line Balancing is the process of

assigning tasks to workstationsin such a way that the

workstations have approximately

equal time requirements.


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Cycle Time

Cycle timeis the maximum timeallowed at each workstation to

complete its set of tasks on a unit.


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Design of Work System


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Job design involves specifying the content

and methods of job.

What will be done.

Who will do the job.

How the job will be done.

Where the job will be done.


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Specialization

Behavioral Approaches to

Job Design

Motivation

Teams

Methods Analysis

Motions Study

Working conditions


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Specialization


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Specialization in Business:

Advantages

ForManagement:

1. Simplifies training

2. High productivity

3. Low wage costs

ForLabor:

1.Low education and

skill requirements

2.Minimum

responsibilities

3.Little mental effort

needed


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Disadvantages

For Management:

1. Difficult to motivate

quality

2. Worker dissatisfaction,

possibly resulting in

absenteeism, high

turnover, disruptive

tactics, poor attention

to quality

For Labor :

1. Monotonous work

2. Limited opportunitiesfor advancement

3. Little control over work

4. Little opportunity forself-fulfillment


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Job Enlargement

Giving a worker a larger portion ofthe total task by horizontal loading

Job Rotation

Workers periodically exchange jobs

Job Enrichment Increasing responsibility for planning

and coordination tasks, by verticalloading

Behavioral Approaches to Job

Design


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Motivation and Trust

Motivation

Influences quality and

productivity.Contributes to work environment.

Trust

Influences productivity and

employee-management relations.


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Teams


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Teams

Benefits of teams

Higher quality

Higher productivity

Greater worker satisfaction

Self-directed teams

Groups of empowered to makecertain changes in their work process


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Methods Analysis

Methods analysis

Analyzing how a job gets done

Begins with overall analysis

Moves to specific details


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Changes in tools and equipment

Changes in product design

or new products

Changes in materials or procedures

Other factors (e.g. accidents, quality

problems)

The need for methods analysis can come

from a number of different sources:


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Methods Analysis Procedure

1.Identify the operation to be studied

2.Get employee input

3.Study and document current method4.Analyze the job

5.Propose new methods

6.Install new methods7.Follow-up to ensure improvements

have been achieved


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Motion Study

Motion study - is the

systematic

study of the human

motions used

to perform an

operation.


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Motion Study Techniques

Motion study principles - guidelines for

designing motion-efficient work procedures

Analysis of therbligs - basic elemental

motions into which a job can be broken down

M icromotion study - use of motion pictures

and slow motion to study motions that otherwise

would be too rapid to analyzeCharts


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Working Conditions

Working conditions are an important

aspect of job design. Physical factorssuch as temperature, humidity,

ventilation, illumination, and noise can

have significant impact on worker

performance in terms of productivity,

quality of output, and accidents.


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Compensation

Compensation is asignificant issue for the

design work system.

T B i f


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Two Basic system for

Compensation

Timebased system

also known as hourly and measured day work

system,

Compensate employees for the time theemployee has worked during a pay period.

Outputbased (incentive) system

Compensation based on amount of output an

employee produced during a pay period.


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Thats All

hank You

report in production operation management by mitch g

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