Você está na página 1de 47

OperationsManagement 19Apr17

Process Strategy

The Four Vs of Operations Management

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
2

Dr.Yash 1
OperationsManagement 19Apr17

Examples

Production Process Classification by position of Customer Order

Make to Stock (MTS)


Serve customers from finished goods inventory

Assemble to Order (ATO)


Combine a number of preassembled modules to meet a customers
specifications

Make to Order (MTO)


Make the customers product from raw materials, parts, and components

Engineer to Order (ETO)


Work with the customer to design and then make the product

Dr.Yash 2
OperationsManagement 19Apr17

Customer Order Decoupling Point

Process Strategy

How to produce a product or provide a service that -


Meets or exceeds customer requirements
Meets cost and managerial goals

Process Strategy has long term effects on -


Efficiency and production flexibility
Costs and quality

Process selection is based on


4Vs
Position of Customer Order Decoupling Point (or Order to delivery strategy)
Range of Technology Choices: Manual, Mechanized or Automated

Dr.Yash 3
OperationsManagement 19Apr17

Process, Volume, and Variety


Volume
Low Repetitive High
Volume Process Volume
High Variety Process Focus
one or few units Mass Customization
Projects, job shops (difficult to achieve,
per run, (machine, print,
(allows but huge rewards)
hospitals, restaurants) Dell Computer
customization) General Hospital
Variety (Flexibility)

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)

Comparison between characteristics of the four processes


ProcessFocus RepetitiveFocus ProductFocus MassCustomization

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)

Dr.Yash 4
OperationsManagement 19Apr17

Process Flow Structures

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)

The Product-Process Matrix: Hayes and Wheelright matrix

Flexibility (High)
Unit Cost (High)

Flexibility (Low)
Unit Cost (Low)

10

Dr.Yash 5
OperationsManagement 19Apr17

Relationship of product design, process design and inventory policy

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

11

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

12

Dr.Yash 6
OperationsManagement 19Apr17

Crossover Chart Example

Software A is most economical


from 0 to 2,857 reports

Software B is most economical


from 2,857 to 6,666 reports
13

Service Process Strategy

14

Dr.Yash 7
OperationsManagement 19Apr17

Designing Service Processes

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
15

The Customer Contact Approach to Designing Service Processes

High Degree Low Degree


of Customer of Customer
Contact Contact

Percentage of customer contact


High Low
(customer influence on the system)
Difficulty in managing system

In high contact service systems, the customer can affect the time of demand,
the exact nature of service, and the quality of the service

16

Dr.Yash 8
OperationsManagement 19Apr17

Major Differences between High and Low Contact Service Systems

17

Major Differences between High and Low Contact Service Systems

18

Dr.Yash 9
OperationsManagement 19Apr17

Service Design and Delivery Approaches

Three schemes for producing and delivering services

1. The Production Line Approach


Orientation is toward the efficient production of resultsprecisely controlled
execution of the central function

2. The Customer Involvement Approach


Having the customer take a greater participatory role in the production of the
service

3. The Personal Attention Approach


The central focus is complete customer attention and satisfaction at all times

19

The Production Line Approach

Also known as - Quasi-Manufacturing Approach

Pioneered by McDonalds

Physical goods are dominant over intangible service

Production of goods takes place along a production line

Operations can be highly automated

Almost no customer interaction

Overcomes many of the problems inherent in the concept of service itself

Example banks checking encoding operation

20

Dr.Yash 10
OperationsManagement 19Apr17

The Customer Involvement Approach

Also known as - Customer-as-Participant Approach

Physical goods may be a significant part of the service

Services may be either standardized or custom

High degree of customer involvement in the process

Need to convince consumers that this is beneficial for them

Promote the benefits of cost, speed and convenience

Examples: ATM, self-service gas station, in-room coffee equipment,

McDonalds

21

The Personal Attention Approach

Also known as - Customer-as-Product Approach

Concept of mass-customization applied to services

Service is provided through personal attention to the customer

Customized service on the customer

Often maintains a database of customers likes and dislikes

High degree of customer contact, customer becomes the central focus

There is a perception of high quality

Examples: medical clinic, hair salon

22

Dr.Yash 11
OperationsManagement 19Apr17

Common Characteristics of Well-Designed Service Systems

1. Consistency with the operating focus of the firm

2. User-friendly customers can interact easily

3. Robust capable to deal with variations in demand & resources availability

4. Consistent performance

5. Effective linkage between the back office and the front office

6. Evidence of service quality - customers see the value in the service

7. Cost-effective minimum waste of time and resources

23

Strategic Capacity Management

Dr.Yash 12
OperationsManagement 19Apr17

Capacity Management

Capacity - The throughput, or the number of units a facility can hold,


receive, store, or produce in a period of time

Output that a system is capable of delivering over a specific period of time

Often determines capital requirements (large fixed costs)

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
25

Capacity Decisions over Different Time Horizons

Long term decisions include (>3 years)


When, how much, and in what form to alter capacity

Medium term decisions include (318 months):


Also known as aggregate planning
How much inventory to hold
Level of manpower required
Whether to sub-contract or not?
To buy new equipment or not

Short term decisions include (<3 months):


Scheduling specific orders, allocating resources (manpower, equipment)

26

Dr.Yash 13
OperationsManagement 19Apr17

Considerations for Capacity Decisions

Forecast demand with reasonable accuracy

Understand the technology and capacity increments

Find the optimum operating level (volume)

Build for change

27

How can companies manage demand?

Demand exceeds capacity


Curtail demand by raising prices, scheduling longer lead time
Catering to only specific segment
Long term solution is to increase capacity

Capacity exceeds demand


Stimulate market through product launches, advertising etc
Product changes and upgrades

Adjusting to seasonal demands


Produce products with complementary demand patterns, if possible

28

Dr.Yash 14
OperationsManagement 19Apr17

Complementary Demand Patterns

Combining the
two demand
patterns reduces
the variation
4,000
Sales in units

Snowmobile
3,000 motor sales

2,000

1,000 Jet ski


engine
sales

JFMAMJJASONDJFMAMJJASONDJ
Time (months)

29

How can companies match capacity with demand?

Making staffing changes

Adjusting equipment
Purchasing additional machinery
Selling or leasing out existing equipment

Closing facilities

Improving processes to increase throughput

Redesigning products to facilitate more throughput

Adding process flexibility to meet changing product preferences

30

Dr.Yash 15
OperationsManagement 19Apr17

Companies should also account for lifecycle stages

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

31

Capacity Issues in Service Industry

Need of responsiveness- customers may not wait for long

Managing demand volatility- no option of inventory

Manage both peak hour and non-peak hour demand

Trade off between utilization and performance measures like waiting time

Location

Layout

32

Dr.Yash 16
OperationsManagement 19Apr17

Demand and Capacity Management in the Service Sector

Demand management
Appointment, reservations, FCFS rule

Capacity management
Full time, temporary, part-time staff

Revenue management
Airlines, hotels etc.

33

Dr.Yash 17
OperationsManagement 19Apr17

Facility Location

The Strategic Importance of Facility Location

Affects both fixed and variable costs

Affects various functions i.e. operations, marketing etc.


Motivating Factors
Major impact on overall risk and profit Growing demand
Shift in demand
Relatively infrequent but long term decisions To remain Competitive
Cost changes
Can make (or break) a companys business strategy New products
Facility Location Options
Expanding existing facilities
Maintaining current sites while adding another facilities elsewhere
Closing the existing facility and moving to another location
2

Dr.Yash 1
OperationsManagement 19Apr17

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

Determining optimal facility location is a good investment

Globalization adds to complexity


Market economics
Communication
Rapid, reliable transportation
Ease of capital flow
Differing labor costs
3

Location Decisions

Country Decision Key Success Factors

1. Political risks, government rules, attitudes,


incentives
2. Corruption
3. Cultural and economic issues
4. Location of markets
5. Labor talent, attitudes, productivity, costs
6. Availability of supplies, communications, energy
7. Exchange rates and currency risks

Dr.Yash 2
OperationsManagement 19Apr17

Location Decisions

Region Decision Key Success Factors


1. Corporate desires
2. Attractiveness of region
MN 3. Labor availability and costs
WI 4. Costs and availability of utilities
MI 5. Environmental regulations
IL IN
OH 6. Government incentives and fiscal policies
7. Proximity to raw materials and customers
8. Proximity to competitors (Clustering)
9. Transportation and infrastructure

Location Decisions

Site Decision Key Success Factors

1. Site size and cost


2. Air, rail, highway, and waterway transport systems
3. Zoning restrictions
4. Proximity of services/ supplies needed
5. Environmental impact issues
6. Customer base
7. Utilities
8. Competition
9. Safety
6

Dr.Yash 3
OperationsManagement 19Apr17

International Location Factors

Government stability Number and proximity of suppliers


Government regulations Transportation & distribution system
Political & economic systems Labor cost & education
Economic stability & growth Available technology
Exchange rates Commercial travel
Culture Technical expertise
Climate Cross--border trade regulations
Export import regulations Group trade agreements
Duties & tariffs Labor productivity
Raw material availability Competition

Perspective towards Facility Location

Manufacturing Industry Total Cost Minimization

Service Industry Revenue Maximization

Warehouse & Distribution Transportation costs


Proximity to markets

Non-Competitive Services Accessibility


Response time

Competitive Services and Retail Proximity to customers


Location is everything

There are three important things in retailing- location, location, location

Dr.Yash 4
OperationsManagement 19Apr17

Location Analysis

Types of Location Problem


Single Factor or Multiple Factors
Single Facility or Multiple Facilities
Absolute Location or Relative Location
Anywhere or from shortlisted sites

Solution Techniques
Factor Rating Method
Cross-over Charts, Break-even Analysis
Load-distance Method, Centroid Method
Transportation Method (special case of Linear Programming modeling)

Location Analysis Techniques

Factor Rating Method


Single Facility, Absolute Location, Shortlisted sites, Multiple Factors

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)

10

Dr.Yash 5
OperationsManagement 19Apr17

Factor-Rating Method

Single Facility, Absolute Location, Shortlisted sites, Multiple Factors

Highly popular: Wide variety of qualitative factors are considered during the
analysis

Subjective opinion, can be highly sensitive in dynamic environment

11

Example: Factor-Rating Method (Service / Manufacturing)

Management is considering three potential locations for a new cookie factory

They have assigned scores shown below to the relevant factors on a 0 to 10


basis (10 is best)

Using the preference matrix, which location would be preferred?

12

Dr.Yash 6
OperationsManagement 19Apr17

Cross-over Charts

Single Facility, Absolute Location, Shortlisted sites, Single Factor (Cost)

Compare location alternatives on the basis of quantitative factors

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

City Fixed Cost Variable Cost


Athens $30,000 $75
Brussels $60,000 $45
Lisbon $110,000 $25
13

Example: Cross-over Charts

Crossover point Athens/Brussels


30,000 + 75(x) = 60,000 + 45(x)
30(x) = 30,000
(x) = 1,000

Crossover point Brussels/Lisbon

60,000 + 45(x) = 110,000 + 25(x)


20(x) = 50,000
(x) = 2,500

14

Dr.Yash 7
OperationsManagement 19Apr17

Worldwide Distribution of Volkswagens and Parts

15

Transportation Model

Single Facility, Relative Location, Shortlisted sites, Single Factor (Cost)

Involves finding the lowest-cost plan for distributing stocks of goods or


supplies from multiple origins to multiple destinations that demand the goods

Minimize costs of shipping n units to m destinations, or


Maximize profit of shipping n units to m destinations

A special class of linear programming problem

Min 5xA1 + 7xA2 + 9xA3 +


8xB1 + 6xB2 + 4xB3

16

Dr.Yash 8
OperationsManagement 19Apr17

Applications

Minimize shipping costs


Determine low cost location
Find minimum cost production schedule
Military distribution system

Type: Balanced vs. Unbalanced

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

17

An Example

18

Dr.Yash 9
OperationsManagement 19Apr17

Formulation

Objective Function

Constraints

19

Solution Methods

Stepping stone method

Modified Distribution (MODI) method

Excel based approach

20

Dr.Yash 10
OperationsManagement 19Apr17

Load-Distance (ld) Method (Manufacturing / Distribution)


Identify and compare candidate locations
Weighted-distance method
Minimizes the sum of the loads multiplied by the distance the load travels
Proximity to customers / market
Proximity to suppliers / resources
Time may be used instead of distance

Calculating a load-distance (LD) score


Varies by industry
Use the actual distance to calculate LD score
Use Actual or Euclidean (straight line) or Rectilinear (city-block) distances
Find one acceptable facility location that minimizes the LD score

21

Formula for the LD Score

Where,

LD = the load-distance value

= the load expressed as a weight, number of trips or units being shipped


from the proposed site and location I

= the distance between the proposed site and location i

22

Dr.Yash 11
OperationsManagement 19Apr17

Formulae for calculating Distance

Euclidean (straight line) Distance dAB = (xA xB)2 + (yA yB)2

Rectilinear (city-block) Distance dAB = |xA xB| + |yA yB|

What is the distance between (20, 10) and (80, 60)?

Euclidean distance (20 80)2 + (10 60)2 = 78.1

Rectilinear distance |20 80| + |10 60| = 110

23

Example : LD Method

Management is investigating which location would be best to position its new


plant relative to two suppliers (located in Cleveland and Toledo) and Three
market areas (represented by Cincinnati, Dayton, and Lima)

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?
24

Dr.Yash 12
OperationsManagement 19Apr17

Example Solution: LD Method

Cincinnati = 15(0) + 20(9) + 30(9) + 25(8) + 40(4) = 810


Dayton = 15(9) + 20(0) + 30(10) + 25(5) + 40(9) = 920
Cleveland = 15(9) + 20(10) + 30(0) + 25(5) + 40(5) = 660
Toledo = 15(8) + 20(5) + 30(5) + 25(0) + 40(8) = 690
Lima = 15(4) + 20(9) + 30(5) + 25(8) + 40(0) = 590

25

Service Facility Location

New service facilities far Multiple sites close to


more common than new customers
factories and warehouses
Much less expensive
Clustering?

Service
Facilities

Location decision closely Decision more about


tied to the market selection maximizing profits than
decision minimizing costs

26

Dr.Yash 13
OperationsManagement 19Apr17

Dominating Factors

1. Impact of location on sales and customer satisfaction


2. Purchasing power of customer-drawing area
3. Service and image compatibility with demographics (employment, income,
population, education etc.) of the customer-drawing area
4. Competition in the area
5. Safety, Parking, Rent, Accessibility, Traffic etc.
6. Uniqueness of the firms and competitors locations
7. Physical qualities of facilities and neighboring businesses
8. Operating policies of the firm
9. Quality of management

27

Techniques

Regression models to determine importance of various factors

Factor-rating method

Traffic counts

Demographic analysis of drawing area

Purchasing power analysis of area

Center-of-gravity method

Geographic information systems (GIS)

28

Dr.Yash 14
OperationsManagement 19Apr17

Geographic information systems (GIS)

Important tool to help in


location analysis

Enables more complex


demographic analysis

Available data bases include


Detailed census data
Detailed maps
Utilities
Geographic features
Locations of major services

29

Practice Problem: LD Method

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.

Load Trips from Suppliers


A 75, B 105, C 135, D 60

30

Dr.Yash 15
OperationsManagement 19Apr17

Distance Calculations

31

Load-Distance Calculations

32

Dr.Yash 16
OperationsManagement 19Apr17

Layout Strategies

Innovations at McDonalds

Indoor seating (1950s)

Drive-through window (1970s)

Adding breakfast to the menu (1980s)

Adding play areas (late 1980s)

Redesign of the kitchens (1990s)

Self-service kiosk (2004)

Now three separate dining sections

Six out of the seven are layout decisions !


34

Dr.Yash 17
OperationsManagement 19Apr17

McDonalds New Layout

Seventh major innovation

Redesigning all 30,000 outlets around the

world

Three separate dining areas


Linger zone with comfortable chairs and
Wi-Fi connections
Grab and go zone with tall counters
Flexible zone for kids and families
Facility layout is a source of competitive

advantage
35

What is Facility Layout?

Location or arrangement of everything within & around buildings

Layout Design Considerations


Higher utilization of space, equipment, and people
Improved flow of information, materials, or people
Improved employee morale and safer working conditions
Improved customer/client interaction
Flexibility

Strategic Importance of Layout Decisions Its Dynamic


The objective of layout strategy is to develop an effective and efficient
layout that will meet the firms competitive requirements
36

Dr.Yash 18
OperationsManagement 19Apr17

Objectives of Facility Layout

A facility layout problem may have many objectives. In the context of


manufacturing plants, minimizing material handling costs is the most
common one. Other objectives include -
Utilize Facilitate
space organization structure
labor communication and interaction between
workers
Eliminate
manufacturing process
bottlenecks
visual control
waste or redundant movement
Provide
Minimize
convenience, safety and comfort of the
manufacturing cycle time or
employees
customer flow time
flexibility to adapt to changing conditions
investment
37

Characteristics of a Good Layout

38

Dr.Yash 19
OperationsManagement 19Apr17

Types of Layout

1. Office layout - positions workers, their equipment, and spaces/offices to


provide for movement of information
2. Retail layout - allocates shelf space and responds to customer behavior
3. Warehouse layout - addresses trade-off between space and material
handling
4. Fixed-position layout - Used in projects for large products e.g., airplanes,
ships and rockets
5. Process layout - Used in a job shop for low volume, customized (high
variety) products
6. Group Technology / Cellular Layout focus on product families
7. Product layout - Used in a flow shop for high volume, standard (low variety)
products
39

Types of Layouts (continued)

40

Dr.Yash 20
OperationsManagement 19Apr17

Process Layout

41

Process Layout (continued)

42

Dr.Yash 21
OperationsManagement 19Apr17

Process Layout (continued)

Like machines and equipment are grouped together

Arrange departments consisting of similar or identical processes in a way that


optimizes their relative placement

Flexible and capable of handling a wide variety of products or services

Scheduling can be difficult and setup, material handling, and labor costs can
be high

Manufacturing: Arrange work centers so as to minimize the material


handling cost

Services: Minimize customer and worker travel time through the process
Departments with large flows of material or people in close proximity
43

Process Layout - Advantages

Better utilization of machines

Fewer machines required

High degree of flexibility relative to equipment or manpower allocation for


specific tasks

Comparatively low investment in machines is required

The diversity of the task offers a more interesting and satisfying occupation

for the operator

Specialized supervision is possible

44

Dr.Yash 22
OperationsManagement 19Apr17

Process Layout - Limitations

Since longer flow lines usually result, material handling is more expensive

Production planning and control systems are more involved

Total production time is usually longer

Comparatively large amounts of in-process inventory results

Space and capital are tied up by work-in-process

Because of the diversity of the jobs in specialized departments, higher

grades of skill are required

45

Computer Software

Graphical approach only works for small problems

Computer programs are available to solve bigger problems

Three dimensional visualization software allows managers to view possible


layouts and assess process, material handling, efficiency, and safety issues

CRAFT
ALDEP
CORELAP
Factory Flow
Proplanner

46

Dr.Yash 23
OperationsManagement 19Apr17

CRAFT Example

47

Group Technology / Cellular Layout

Group technology identifies products that have similar characteristics for

particular work cells

Volume must justify work cells

Work cells can be reconfigured as designs or volume changes


48

Dr.Yash 24
OperationsManagement 19Apr17

Group Technology / Cellular Layout (continued)

Every cell contains a group of machines which are dedicated to the


production of a family of parts

One of the problems is to identify a family parts that require the same group
of machines

49

Advantages of Work Cells

1. Reduced work-in-process inventory

2. Less floor space required

3. Reduced raw material and finished goods inventories

4. Reduced direct labor cost

5. Heightened sense of employee participation

6. Increased equipment and machinery utilization

7. Reduced investment in machinery and equipment

50

Dr.Yash 25
OperationsManagement 19Apr17

Limitations

General supervision is required

Higher skill levels required of employees than for product layout

Compromise between product and process layout, with associated limitations

Depends on balanced material flow through the cell; otherwise, buffers and

work-in-process storage are required

Lower machine utilization than for process layout

51

Improving Layouts Using Work Cells

Flexible Line Layouts

U-shaped line may


reduce employee
movement and space
requirements while
enhancing
communication,
reducing the number
of workers, and
facilitating inspection

52

Dr.Yash 26
OperationsManagement 19Apr17

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

53

Product Layout (continued)

Facility organized around products or families of similar high-volume, low-


variety products

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

54

Dr.Yash 27
OperationsManagement 19Apr17

Product Layout - Advantages

Since the layout corresponds to the sequence of operations, smooth and


logical flow lines result
Since the work from one process is fed directly into the next, small in-process
inventories result
Total production time per unit is short
Since the machines are located as to minimize distances between
consecutive operations, material handling is reduced
Little skill is usually required by operators at the production line; hence,
training is simple, short and inexpensive
Simple production planning and control systems are possible
Less space is occupied by work in transit and for temporary storage
Lower variable cost per unit

55

Product Layout - Limitations

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

56

Dr.Yash 28
OperationsManagement 19Apr17

Product Layout Types

Fabrication Line builds components, such as automobile tires or metal parts


for a refrigerator, on a series of machines

Assembly Line puts the fabricated parts together at a series of workstations

Fabrication Line Assembly Line


Builds components Assembles fabricated parts
Uses series of machines Uses workstation
Repetitive process Repetitive process
Machine paced Paced by tasks
Balanced by physical redesign Balanced by moving tasks

57

Example: McDonalds Assembly Line

Design issues?

58

Dr.Yash 29
OperationsManagement 19Apr17

Facility Layout for Services

Goals of Service Facility Layouts

Minimize travel time for workers and customers

Maximize revenues from customers

Types of Service Layouts

Process layoutemergency rooms

Product layoutcafeteria line

Fixed-position layoutautomobile repair shop

59

Facility Layout for Services (continued)

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

Spatial layout and functionality


Minimizing employee travel time and maximizing revenue opportunities
from customers

Signs, symbols, and artifacts


Objects that create positive images of the firm
60

Dr.Yash 30

Você também pode gostar