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Process Strategy
Volume of demand
How many the organization makes: one / a few / a large no.
Variety in outputs
The ability to adapt the transformation process to meet needs of the
heterogeneous customer base
Variation in demand
Adapting to changing demand
Visibility of transformation
Customers ability to see, track their experience or order through the
operations process
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Examples
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Process Strategy
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Changes in Repetitive
Modules (autos, motorcycles,
modest runs, home appliances)
standardized Harley-Davidson
modules
Changes in
Attributes Product Focus
(such as grade, Poor Strategy (commercial baked goods,
quality, size, (Both fixed and steel, glass, beer)
thickness, etc.) variable costs Frito-Lay
long runs only are high)
Equipment General purpose Mix of general and special Special purpose Flexible equipment with
equipment purpose rapid changeover
Skill of labor With broad set of skills Moderately skilled Less broadly skilled Skilled with training for
customization
Product flow High with slow material Moderate from start to finish in Moderate Low with fast material
time movement days with assembly in minutes movement
Costs Low fixed costs and high Costs are dependent on flexibility High fixed costs and low High fixed costs and low
variable costs of facility variable costs variable costs
Raw material High relative to value of Low with JIT procurement Low relative to value of Low relative to value of
inventory product techniques product product
Work-in-process High Low with lean and JIT techniques Low compared to output Low and driven by lean
inventory production
Finished goods Made to order Assemble to order based on Made to stock Made to order
delivery frequent forecasts (postponement
technique used)
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Job shop
(ex. A shop producing dies, jigs/fixtures etc, auto repair shop)
Batch shop
(ex. A factory production setting)
Assembly Line
(ex. Assembly of various models of cars)
Continuous Flow
(ex. Petroleum manufacturer)
Flexibility (High)
Unit Cost (High)
Flexibility (Low)
Unit Cost (Low)
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Standard product
Product focused process design
Make to stock finished goods
inventory
Customized product
Process focused
Make to order
Can be assemble to order also
Components kept in inventory
Assembled after receipt of
customer order
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Crossover Chart
Variable
costs
Variable Variable
$ costs $ costs $
Fixed costs Fixed costs
Fixed costs
Low volume, high variety Repetitive High volume, low variety
Process A Process B Process C
Example
Evaluate three different accounting software products
Calculate crossover points b/w software A and B and b/w software B and C
TOTAL FIXED COST DOLLARS REQUIRED PER ACCOUNTING REPORT
Software A $200,000 $60
Software B $300,000 $25
Software C $400,000 $10
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Service systems are generally classified along industry lines, e.g. financial
services, banking services, health services, transportation services etc.
Customer Contact
The presence of the customer in the system
Some interaction with customer is necessary, but this often affects
performance adversely
The better these interactions are accommodated in the process design, the
more efficient and effective the process
Extent of Contact
The percent of time the customer is involved relative to the total time required
to deliver the service
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In high contact service systems, the customer can affect the time of demand,
the exact nature of service, and the quality of the service
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Pioneered by McDonalds
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McDonalds
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4. Consistent performance
5. Effective linkage between the back office and the front office
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Capacity Management
Too much (idle capacity) vs. Too little (opportunity cost of losing customers)
Some measures
Number of units / week
Total work time available
Numbers of bed
Billable hours
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Combining the
two demand
patterns reduces
the variation
4,000
Sales in units
Snowmobile
3,000 motor sales
2,000
JFMAMJJASONDJFMAMJJASONDJ
Time (months)
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Adjusting equipment
Purchasing additional machinery
Selling or leasing out existing equipment
Closing facilities
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Should be careful in making Systematically build capacity Focus on efficient utilization Need of flexibility of
large, irreversible without overshooting by of existing capacity equipment and manpower
investments, need more large extent increases
flexibility
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Trade off between utilization and performance measures like waiting time
Location
Layout
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Demand management
Appointment, reservations, FCFS rule
Capacity management
Full time, temporary, part-time staff
Revenue management
Airlines, hotels etc.
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Facility Location
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Location Strategy
The objective of location strategy is to maximize the benefit of location to the
firm
Once in place, location-related costs are fixed in place and difficult to reduce
Location Decisions
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Location Decisions
Location Decisions
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Location Analysis
Solution Techniques
Factor Rating Method
Cross-over Charts, Break-even Analysis
Load-distance Method, Centroid Method
Transportation Method (special case of Linear Programming modeling)
Cross-over Charts
Single Facility, Absolute Location, Shortlisted sites, Single Factor (Cost)
Centroid Method
Single Facility, Relative Location, Anywhere (No Shortlisted sites), Single
Factor (Load-distance)
Transportation Method
Single Facility, Relative Location, Shortlisted sites, Single Factor (Cost)
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Factor-Rating Method
Highly popular: Wide variety of qualitative factors are considered during the
analysis
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Cross-over Charts
Steps
Determine fixed and variable costs for each location
Plot the cost for each location
Select location with lowest total cost for expected production volume
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Transportation Model
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Applications
Assumptions
The items to be shipped are homogeneous regardless of the source or destination
Shipping cost per unit is the same regardless of the number of units shipped
Only one route or mode of transportation is used between each origin and each
destination
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An Example
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Formulation
Objective Function
Constraints
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Solution Methods
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Where,
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Example : LD Method
Management has
limited the search for
the new plant to
these five locations
The following
information has been
collected. Which is
best, assuming
rectilinear distance?
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Service
Facilities
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Dominating Factors
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Techniques
Factor-rating method
Traffic counts
Center-of-gravity method
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Burger Doodle wants to evaluate three different sites it has identified for its
new distribution center relative to its four suppliers. The coordinates of the
three sites under consideration are as follows
Which site would be best for Burgle Doodle? Assume Euclidean distance.
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Distance Calculations
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Load-Distance Calculations
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Layout Strategies
Innovations at McDonalds
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world
advantage
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Types of Layout
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Process Layout
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Scheduling can be difficult and setup, material handling, and labor costs can
be high
Services: Minimize customer and worker travel time through the process
Departments with large flows of material or people in close proximity
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The diversity of the task offers a more interesting and satisfying occupation
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Since longer flow lines usually result, material handling is more expensive
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Computer Software
CRAFT
ALDEP
CORELAP
Factory Flow
Proplanner
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CRAFT Example
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One of the problems is to identify a family parts that require the same group
of machines
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Limitations
Depends on balanced material flow through the cell; otherwise, buffers and
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Product Layout
When product demand is sufficiently high and sustainable over a long period
of time, it is usually cost effective to rearrange resources from a process
layout to product layout
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Assumptions
Volume is adequate for high equipment utilization
Product demand is stable enough to justify high investment in specialized
equipment
Product is standardized or approaching a phase of its life cycle that justifies
investment in specialized equipment
Supplies of raw materials and components are adequate and of uniform
quality ensure they will work with specialized equipment
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A breakdown of one machine may lead to complete stoppage of the line that
follows that machine
Since the layout is determined by the product, a change in product design
may require major alterations in the layout
The pace of production is determined by the slowest machine
Comparatively high investment is required, as identical machines (a few not
fully utilized) are sometimes distributed along the line
Lack of flexibility in product or production rates
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Design issues?
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Servicescape
The aspects of the physical surroundings in a service operation that can affect a
customers perception of the service received
Ambient conditions
Noise, lighting, and temperature
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