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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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-m"ro*ement
!rocess technolog#
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Layout in!ol!es the relati!e positioning of transfor#ed resources within operations and the allocation of tas$s% which together dictate the flow of transfor#ed resources
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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'hat is a layout(
0 1he ?la#out> o. an o"eration or "rocess means ho$ its trans.ormed resources are "ositioned relati*e to each other and ho$ its *arious tasks are allocated to these trans.orming resources 0 1ogether these t$o decisions $ill dictate the "attern o. .lo$ .or trans.ormed resources as the# "rogress through the o"eration or "rocess
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1 &i2ed@"osition la#out
0 -n .i2ed@"osition la#out the trans.ormed resources do not mo*e bet$een the trans.orming resources -nstead o. materials, in.ormation or customers .lo$ing through an o"eration, the reci"ient o. the "rocessing is stationar# and the e5ui"ment, machiner#, "lant and "eo"le $ho do the "rocessing mo*e as necessar# 0 1his could be because the "roduct or the reci"ient o. the ser*ice is too large to be mo*ed con*enientl#, or it might be too delicate to mo*e, or "erha"s it could ob'ect to being mo*edF .or e2am"le6
Motorway construction the "roduct is too large to mo*e. Open-heart surgery "atients are too delicate to mo*e. High-class service restaurant customers $ould ob'ect to being mo*ed to $here .ood is "re"ared Shipbuilding the "roduct is too large to mo*e. Mainframe computer maintenance the "roduct is too big and "robabl# also too delicate to mo*e, and the customer might ob'ect to bringing it in .or re"air
Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Stud# desks
Com"an# re"orts En5uiries
1o 'ournal stack
Re.erence section
Store room Counter sta..
Co"#ing area
Entrance
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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S"orts sho"
Eens$ear
Entrance
Entrance
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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=oth Cadbur#>s chocolate .actor# and its ?Cadbur# 7orld> *isitor attraction use ?"roduct> la#out =ut $hat $ill be di..erent about the la#outs and $h#8
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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%ecture theatre
7aiting area
7aiting area
+octor
=lood test H@ra# =lood test H@ra# =lood test H@ra# Records6 "ersonal histor# and medical details
+octor
Gni.orm store
+octor
+octor
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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/i0ed layout1 . restaurant co#ple0 with all four basic layout types
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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2electing a layout
0 1he im"ortance o. .lo$ to an o"eration $ill de"end on its !olu#e and !ariety characteristics. 0 7hen *olume is *er# lo$ and *ariet# is relati*el# high, ?.lo$> is not a ma'or issue and a .i2ed@"osition man# be suitable 0 7ith higher *olume and lo$er *ariet#, .lo$ becomes an issue 0 -. the *ariet# is still high, ho$e*er, an entirel# .lo$@dominated arrangement is di..icult because there $ill be di..erent .lo$ "atterns 0 7hen the *ariet# o. "roducts or ser*ices reduces to the "oint $here a distinct ?categor#> $ith similar re5uirements becomes e*ident but *ariet# is still not small, cell la#out could become a""ro"riate 0 7hen *ariet# is relati*el# small and *olume is high, .lo$ can become regulari(ed and a "roduct@based la#out is likel# to be a""ro"riate, as in an assembl# "lant 0 1he *olume4*ariet# characteristics o. the o"eration $ill, to a large e2tent, narro$ the choice do$n to one or t$o la#out o"tions 0 1he decision as to $hich la#out t#"e to ado"t $ill be in.luenced b# an understanding o. their relati*e ad*antages and disad*antages
Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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!roduct la#out
Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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&i2ed@"osition la#out
Ier# high "roduct and mi2 .le2ibilit#
Ad*antages
!roduct)customer not mo*ed 9igh *ariet# o. tasks .or sta.. Ier# high unit costs Scheduling s"ace and acti*ities can be di..icult
+isad*antages
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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&unctional la#out
9igh "roduct and mi2 .le2ibilit#
Ad*antages
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Ad*antages
&ast through"ut Jrou" $ork can result in good moti*ation Can be costl# to rearrange e2isting la#out Can need more "lant
+isad*antages
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Ad*antages
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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!ro.essional ser*ices
Ser*ice sho"s
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4asic layout types ha!e different fi0ed and !ariable costs that see# to deter#ine which one to use
Costs
&i2ed@ "osition &unctional
Cell !roduct
Gse cell
Gse "roduct
Iolume
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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4ut uncertainty about e0act fi0ed and !ariable costs #eans the decision can rarely be #ade on cost alone
Costs
&i2ed@"osition &unctional Cell !roduct
( Gse "roduct
Iolume
Gse .unctional or cell or "roduct Gse .unctional or cell
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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&unctional la#out 4 .lo$ charts and relationshi" charts Cell la#out 4 "roduct .lo$ anal#sis !roduct la#out 4 assembl# line balancing techni5ues
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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;a<
1o &rom
%,A+S)+AK
;b<
%,A+S)+AK
= 17
E A =
-. direction is not im"ortant, colla"ses to
= /0
A = C + E /0 1/
20
/0 10 20
/0
60 20
10
70 /0
C + E
/0 B0 30
- -
10 10 10 10
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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;b<
%,A+S)+AK
A A = C + E
= /0
%,A+S)+AK
/0
60 20
/0
/0 B0 30
@ /0 60 @ 20 @ /0 B0 30
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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%,A+S)+AK
;d<
= 17
&rom
= 2
C 2 /
+ 2 / 2
E 2 3 2 10
A = C + E /0 1/
20
/0 10 20
A =
-. cost o. .lo$ di..ers bet$een $ork centres, combine $ith
/ 2 2
10
70 /0
C + E
- -
10 10 10 2 2 2 2
10 10 10 10
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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= 2
C 2 /
+ 2 / 2
E 2 3 2 10
1o gi*e
= /3
A = C + E / 2
A = /D C + /00
60 20 60 60 130 /00
20
10 10 10 2 2 2 2
E 20 20 20 20
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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= /3
E A =
im"ortant, colla"ses to
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A = /D C + /00
B0
/60 30 B0
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C + E
160 /20
E 20 20 20 20
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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. relationship chart
C,+E A E , G H C%,SENESS Absolutel# necessar# Es"eciall# im"ortant -m"ortant ,rdinar# closeness Gnim"ortant Gndesirable
+E!AR1EEN1
Eetrolog# Electronic testing Anal#sis Gltrasonic testing &atigue testing -m"act testing
E E
A G , ,
, G G
H G
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Eachines
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+etailed design of product layout 0 Rather than ?$here to "lace $hat>, "roduct la#out is concerned more $ith ?$hat to "lace $here> 0 %ocations are .re5uentl# decided u"on and then $ork tasks are allocated to each location 0 &or e2am"le, it ma# ha*e been decided that .our stations are needed to make com"uter cases 0 1he decision then is $hich o. the tasks that go into making the cases should be allocated to each station 0 1he main "roduct la#out decisions are as .ollo$s6
C 7hat c#cle time is needed8 C 9o$ man# stages are needed ;number o. $orkstations<8 C 9o$ should the task@time *ariation be dealt $ith8 C 9o$ should the la#out be balanced8
Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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'or$ed E0a#ple
Su""ose the regional back@o..ice o"eration o. a large bank is designing an o"eration $hich $ill "rocess its mortgage a""lications 1he number o. a""lications to be "rocessed is 160 "er $eek and the time a*ailable to "rocess the a""lications is 30 hours "er $eek
C#cle time .or the la#out L 1ime A*ailable L No 1o be "rocessed 30 L 160 1 3 L 1: minutes
So the bank>s la#out must be ca"able o. "rocessing a com"leted a""lication once e*er# 1: minutes
Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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'or$ed E0a#ple
-n &igure o*erlea. the $ork allocations in a .our@stage line are illustrated 1he total amount o. time in*ested in "roducing each "roduct or ser*ice is .our times the c#cle time because, .or e*er# unit "roduced, all .our stages ha*e been $orking .or the c#cle time 7hen the $ork is e5uall# allocated bet$een the stages, the total time in*ested in each "roduct or ser*ice "roduced is 3 N 2 : L 10 minutes 9o$e*er, $hen $ork is une5uall# allocated, as illustrated, the time in*ested is / 0 N 3 L 12 minutes, i e 2 0 minutes o. time, 16 67 "er cent o. the total, is $asted
Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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4alancing loss is that proportion of the ti#e in!ested in processing the product or ser!ice which is not used producti!ely
Stage
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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4alancing loss is that proportion of the ti#e in!ested in processing the product or ser!ice which is not used producti!ely 6Continued7
=ut i. $ork is not e5uall# allocated, the c#cle time $ill increase and ?balancing losses> $ill occur
/: / 2: 2 %oad 1: 1 0: 0
-dle time
6 2 2< s s 4 o l 0 O ;/ ncing < a : l a 2 b ting /04 ; a l u O c < l Ca 42/ 0 / ; L e m i t e l mins -d 0 2 e l L c#c 20 e*er# /0 L g N n i 3 c =alan 67 6 1 0 L loss 67P 6 1 L
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
Stage
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4alancing techni"ues
0 . precedence diagra# is used to assist in balancing wor$ti#e allocation. 0 This is a representation of the ordering of the elements which compose the total $ork content o. the "roduct or ser*ice 0 1his general a""roach is to allocate elements .rom the "recedence diagram to the .irst stage, starting .rom the le.t, in order o. the columns until the $ork allocated to the stage is as close to, but less than, the c#cle time 7hen that stage is as .ull o. $ork as is "ossible $ithout e2ceeding the c#cle time, mo*e on to the ne2t stage, and so on, until all the $ork elements are allocated, taking into account "recedence re5uirements 0 9euristic rules are used to decide $hich task to select .or allocation6
C Sim"l# choose the largest that $ill ?.it> into the time remaining at the stage C Choose the element $ith the most ?.ollo$ers>6 that is the highest number o. elements $hich can onl# be allocated $hen that element has been allocated
Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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4alancing techni"ues
'or$ed E0a#ple Qarlstad Qakes ;QQ< is a manu.acturer o. s"ecialit# cakes, $hich has recentl# obtained a contract to su""l# a ma'or su"ermarket chain $ith a s"ecialit# cake in the sha"e o. a s"ace rocket -t has been decided that the *olumes re5uired b# the su"ermarket $arrant a s"ecial "roduction line to "er.orm the .inishing, decorating and "acking o. the cake 1his line $ould ha*e to carr# out the elements sho$n in .igure o*erlea., $hich also sho$s the "recedence diagram .or the total 'ob 1he initial order .rom the su"ermarket is .or :,000 cakes a $eek and the number o. hours $orked b# the .actor# is 30 "er $eek &rom this6
1he re5uired c#cle time L 30 hrs N 60 mins :,000 L 0 3B minutes
1he re5uired number o. stages L 1 6B min ;the total $ork content< L / : stages 0 3B min ;the re5uired c#cle time<
Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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0 17 mins
0 /0 mins
0 2: mins
0 0: mins
0 2: mins
a
0 12 mins
c
0 /6 mins
g
0 10 mins
h
0 0B mins
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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a b c d e . g h i
+e@tin and trim Resha"e $ith o..@cuts Clad in almond .ondant Clad in $hite .ondant +ecorate, red icing +ecorate, green icing +ecorate, blue icing A..i2 trans.ers 1rans.er to base and "ack
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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<.B <.A C#cle time L 0 3B mins <.@ <.? <.> <.= < = > ? @
-dle time L ;0 3B 4 0 32< O ;0 3B 4 0 /6< O ;0 3B 4 0 32< e*er# L 0 23 mins c#cle !ro"ortion o. 0 23 idle time "er L 3 N 0 3B c#cle
L 12 :P
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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1 e*er# 1: minutes
60 ?< ?<
1 e*er# 1: minutes
60
?<
?<
1 e*er# 1: minutes
60
60
at . @ t r Sho
es c o r "
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Ad*antages o. long@thin "rocesses controlled .lo$ sim"le materials handling lo$er ca"ital re5uirement ;no du"lication< greater e..icienc# higher s"ace utili(ation
Ad*antages o. short@.at "rocesses higher mi2 .le2ibilit# higher *olume .le2ibilit# greater robustness less monotonous higher o$nershi"
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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&orecast +emands +uring the !eriod ;A< A*ailabilit# o. !roducti*e 1ime ;=< C#cle 1ime ;CL=)A<
7ork Content o. the 1ask ;+< C#cle 1ime Re5uired ;C< Number o. Sta.. ;+)C<
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010