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Chapter 1

 Production Systems
         And
Operations Management



                        C1 -
Why Should you study POM
• A business education is incomplete without an
  understanding of modern approaches to managing
  operations.
• Operations management provides a systematic
  way of looking at organizational processes.
• Operations management presents interesting career
  opportunities.
• The concepts and tools of OM are widely used in
  managing other functions of a business.

                                                      C1 -
Back office          Kitchen unit
    operation in        manufacturing
      a bank              operation




    They are all
    operations


                   Take-out /
 Retail            restaurant
operation          operation

                                        C1 -
The operations function is fashionable!

                     The consultancy services market
             % of world revenues of 40 largest firms

                            Financial         Marketing/sales
                                6                    2

          Organizational
             design
               11                                  Operations and process
                                                        management
                                                             31

Benefits/Actuarial
        16



              IT strategy                     Corporate strategy
                   17                                17



                                                                            C1 -
Introduction
• Plan, design and operate production system / subsystems
  that create and deliver the firm’s primary products and
  services and to achieve organizational goals
• Note that:
   –   Operations management deals with process
   –   Management in a broad, systems sense
   –   Subsystems are operations too
   –   Multiple goals: efficiency, productivity, cost minimization



                                                                     C1 -
Managers Need Knowledge Of

• Production processes
• Operations management processes
• Decision making tools




                                    C1 -
Analytical Tools Used In
              Operations
•   Forecasting methods
•   Optimization models
•   Queueing analysis
•   Decision analysis
•   Simulation



                                   C1 -
Introduction

• Operations management is the management of
  an organization’s productive resources or its
  production system.
• A production system takes inputs and converts
  them into outputs.
• The conversion process is the predominant
  activity of a production system.
• The primary concern of an operations manager
  is the activities of the conversion process.    C1 -
Organizational Model
              Finance
    Sales                HRM

               OM
                           QA
 Marketing


               MIS      Accounting
Engineering



                                     C1 -
Some inter-functional relationships between the
        operations function and other core and
                   support functions
          Engineering/                       Understanding of the    Product/service
           technical                            capabilities and      development
            function                           constraints of the       function
                                              operations process
                 Analysis of new
               technology options Understanding of
                                  process technology
Accounting                              needs        New product and
                       Provision                      service ideas
and finance           of relevant                                    Understanding of the
  function                data                                          capabilities and
                                       Operations                      constraints of the
           Financial analysis           function                      operations process
            for performance
             and decisions                                    Market
                                                          requirements
                                                                                Marketing
       Understanding of human
                                  Understanding Provision of systems for
                                                                                 function
          resource needs
                                  of infrastuctural design, planning and
                     Recruitment    and system control, and improvement
                     development        needs
                     and training
    Human                                 Information
   resources                              technology
    function                             (IT) function


                                                                                            C1 - 1
Operations Management as a
Function




Figure 1.3
                             C1 - 1
Operations Management As a
Function
                     Skill Areas
                 • Quantitative
                   methods
                 • Organizational
                   behavior
                 • General management
                 • Information systems
                 • Economics
                 • International
                   business
                 • Business ethics
                   and law
Figure 1.3
                                     C1 - 1
The position of the operations function



                              Accounting      Product
                Marketing                                 Operations
                              and finance   development

               Call on        Manage        Retranslate   Conduct
Church         newcomers      appeals       scriptures    weddings

Fast food      Advertise on   Pay           Design        Make
chain          television     suppliers     hamburgers    hamburgers

Furniture      Sell to                      Design new    Assemble
                              Pay staff
manufacturer   stores                       furniture     furniture



Process        Identify       Raise         Develop       Make and
perspective    needs          capital       product       distribute




                                                                       C1 - 1
(Input            Conversion / Transformation                         Output)
                  Environment :- *Customer * Competitors *Suppliers
                  *Government regulations * Technology * Economy
    Input
    Transformed
    Resources                    The Transformation
    Material                     Process                          Output
    Information
    Customer                     Physical Properties              Good or
                                 Informational Properties         Services
                                 Possession
                                 Location
 Input Transforming              Storage/Accommodation
 Resources                       Physiological State              Volume
                                 Psychological State              Variety
 Facilities                                                       Variation
 Staff                                                            Visibility

                                    Monitoring & Control



                                                                                C1 - 1
Continuum of Characteristics
            More like a                  More like
            manufacturing                a service
            organization              organization



 • Physical, durable product   • Intangible, perishable
 • Output that can be            product
   inventoried                 • Output that cannot be
 • Low customer contact          inventoried
 • Long response time          • High customer contact
 • Regional, national, or      • Short response time
   international markets       • Local markets
 • Large facilities            • Small facilities
 • Capital intensive           • Labor intensive
 • Quality
Figure 1.4 easily measured
                               • Quality not easily measured
                                                               C1 - 1
Physical / Informational Output
• Physical Outputs          • Informational Outputs
• Seller no longer owns     • Seller continues to
  when sold                   possess after sale and
• Replication requires        can sell again
  manufacturing             • Replication at negligible
• Output exists in single     cost and without limit
  location                  • Output can exist in
• Wears Out                   multiple locations
                              simultaneously
                            • Does not wear out
                                                          C1 - 1
The output from most types of operation is a
                              mixture of goods and services
                                                                                                                                                     Pure goods
Crude oil production



                                                                                                                                                                  Tangible
                                                                                                                                                            Can be stored
                        Aluminium smelting

                                             Specialist machine tool                                                                                  Production precedes
                                                                                                                                                             consumption
                                                                                                                                                            Low customer
                                                 manufacturer

                                                                                                                                                                    contact
                                                                                                                                                       Can be transported
                                                                                                                                                         Quality is evident
                                                                       Restaurant

                                                                                    Computer systems
                                                                                       services

                                                                                                                                            Intangible
                                                                                                       Management


                                                                                                                     Psychotherapy clinic
                                                                                                       consultancy
                                                                                                                                            Cannot be stored
                                                                                                                                            Production and
                                                                                                                                            consumption are
                                                                                                                                            simultaneous
                                                                                                                                            High customer contact
                                                                                                                                            Cannot be transported
                                                                                                                                            Quality difficult to
                                                                                                                                            judge
                                                                                                                                                    Pure services

                                                                                                                                                                              C1 - 1
Facilitating Good Concept
• Often confusion in trying to classify
  organization as manufacturer or service
• Facilitating good concept avoids this
  ambiguity
• All organizations defined as service
• The tangible part of the service is defined as
  facilitating good
• Pure Services
                                                   C1 - 1
The Range From Services to
        Products




                             C1 - 1
Classification and Evolution of
     Economic Offerings




                                  C1 - 2
Comparison of Alternative
     Economic Offerings
  Economic
  Offering        Commodities       Goods        Services   Experiences
Value added       Extracting    Producing      Delivering   Staging
by

Form of           Fungible      Tangible       Intangible   Memorable
output

Key               Natural       Standardized   Customized   Personalized
characteristics

Buyer             Market        User           Client       Guest




                                                                           C1 - 2
A Typology of
    IMPLICATIONS              Operations                           IMPLICATIONS
Low repetition                                               High repeatability
Each staff member          Low        Volume          High   Specialization
performs more of job                                         Systemization
Less systemization                                           Capital intensive
High unit costs                                              Low unit cost

                                                             Well defined
Flexible
                                                             Routine
Complex                    High       Variety         Low    Standardized
Match customer needs
                                                             Regular
High unit cost                                               Low unit costs

Changing capacity                                            Stable
Anticipation                                                 Routine
Flexibility                High Variation in demand   Low    Predictable
In touch with demand                                         High utilization
High unit cost                                               Low unit costs

                                                             Time lag between
Short waiting tolerance                                      production and
Satisfaction governed by                                     consumption
customer perception                                          Standardized
Customer contact skills                                      Low contact skills
needed                     High      Visibility       Low
                                                             High staff utilization
Received variety is high
                                                             Centralization
High unit cost
                                                             Low unit costs


                                                                                      C1 - 2
Scope of POM

• A) GENERAL PHASE
 1Operations Management
   (Input Conversion / Transformation        Output)
 2Strategic Role ( Strategy and five performance
   objectives)




                                                       C1 - 2
Scope of POM Cont…
•   B) DESIGN PHASE
    3   Design of Products and Services
    4   Design of Operations Network
              a)    Capacity Decision
              b)    Layout Decision
              c)    Location Decision
              d)    Supply Chain Decision
    5   Process Technology
    6   Job Design & Work Organization
                                            C1 - 2
Scope of POM Cont…

• C) PLANNING & CONTROL
 7    Capacity Planning and Control
 8    Inventory Planning and Control
 9    Supply Chain Planning and Control
 10   MRP ( Material Requirement Planning )
 11   Quality Planning and Control
 12   Project Planning and Control
 13   JIT ( Just In Time) Planning and Control
                                                 C1 - 2
Scope of POM Cont…

• D) IMPROVEMENT
  14 Failure Prevention & Recovery
  15 TQM ( Total Quality Management)




                                       C1 - 2
Scope of POM Cont…

•    E)      OPERATION CHALLENGES
b)   Globalization and Environmental Protection
c)   Social Responsibility
d)   Technology Awareness
e)   Knowledge Management
f)   Industrial Safety and Security


                                                  C1 - 2
Japanese Production System

• Quality comes first
• Continuous improvement of products &
  processes
• Eliminate all forms of waste




                                         C1 - 2
Operations Management Today

• Service economy
• Environmental awareness




                                C1 - 2
D. Operations Management,
  Productivity & Competitiveness
          (1990-93)      (1982-93)
          Productivity   Labor cost
          growth (%)     increase (%)
U.S.       2.5            16.1
Canada     2.4            16.2
Japan      1.8            123.9
Germany    1.2            100.8
Sweden     4.2            26.3
U.K.       4.5            27.0
                                        C1 - 3
Operations Management Uses

•   apply quality tools to tax work
•   project management used on merger
•   inventory theory for personal purchases
•   job design improves home chores
•   flexible spending accounts analyzed as
    inventory models


                                              C1 - 3

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What is pom

  • 1. Chapter 1 Production Systems And Operations Management C1 -
  • 2. Why Should you study POM • A business education is incomplete without an understanding of modern approaches to managing operations. • Operations management provides a systematic way of looking at organizational processes. • Operations management presents interesting career opportunities. • The concepts and tools of OM are widely used in managing other functions of a business. C1 -
  • 3. Back office Kitchen unit operation in manufacturing a bank operation They are all operations Take-out / Retail restaurant operation operation C1 -
  • 4. The operations function is fashionable! The consultancy services market % of world revenues of 40 largest firms Financial Marketing/sales 6 2 Organizational design 11 Operations and process management 31 Benefits/Actuarial 16 IT strategy Corporate strategy 17 17 C1 -
  • 5. Introduction • Plan, design and operate production system / subsystems that create and deliver the firm’s primary products and services and to achieve organizational goals • Note that: – Operations management deals with process – Management in a broad, systems sense – Subsystems are operations too – Multiple goals: efficiency, productivity, cost minimization C1 -
  • 6. Managers Need Knowledge Of • Production processes • Operations management processes • Decision making tools C1 -
  • 7. Analytical Tools Used In Operations • Forecasting methods • Optimization models • Queueing analysis • Decision analysis • Simulation C1 -
  • 8. Introduction • Operations management is the management of an organization’s productive resources or its production system. • A production system takes inputs and converts them into outputs. • The conversion process is the predominant activity of a production system. • The primary concern of an operations manager is the activities of the conversion process. C1 -
  • 9. Organizational Model Finance Sales HRM OM QA Marketing MIS Accounting Engineering C1 -
  • 10. Some inter-functional relationships between the operations function and other core and support functions Engineering/ Understanding of the Product/service technical capabilities and development function constraints of the function operations process Analysis of new technology options Understanding of process technology Accounting needs New product and Provision service ideas and finance of relevant Understanding of the function data capabilities and Operations constraints of the Financial analysis function operations process for performance and decisions Market requirements Marketing Understanding of human Understanding Provision of systems for function resource needs of infrastuctural design, planning and Recruitment and system control, and improvement development needs and training Human Information resources technology function (IT) function C1 - 1
  • 11. Operations Management as a Function Figure 1.3 C1 - 1
  • 12. Operations Management As a Function Skill Areas • Quantitative methods • Organizational behavior • General management • Information systems • Economics • International business • Business ethics and law Figure 1.3 C1 - 1
  • 13. The position of the operations function Accounting Product Marketing Operations and finance development Call on Manage Retranslate Conduct Church newcomers appeals scriptures weddings Fast food Advertise on Pay Design Make chain television suppliers hamburgers hamburgers Furniture Sell to Design new Assemble Pay staff manufacturer stores furniture furniture Process Identify Raise Develop Make and perspective needs capital product distribute C1 - 1
  • 14. (Input Conversion / Transformation Output) Environment :- *Customer * Competitors *Suppliers *Government regulations * Technology * Economy Input Transformed Resources The Transformation Material Process Output Information Customer Physical Properties Good or Informational Properties Services Possession Location Input Transforming Storage/Accommodation Resources Physiological State Volume Psychological State Variety Facilities Variation Staff Visibility Monitoring & Control C1 - 1
  • 15. Continuum of Characteristics More like a More like manufacturing a service organization organization • Physical, durable product • Intangible, perishable • Output that can be product inventoried • Output that cannot be • Low customer contact inventoried • Long response time • High customer contact • Regional, national, or • Short response time international markets • Local markets • Large facilities • Small facilities • Capital intensive • Labor intensive • Quality Figure 1.4 easily measured • Quality not easily measured C1 - 1
  • 16. Physical / Informational Output • Physical Outputs • Informational Outputs • Seller no longer owns • Seller continues to when sold possess after sale and • Replication requires can sell again manufacturing • Replication at negligible • Output exists in single cost and without limit location • Output can exist in • Wears Out multiple locations simultaneously • Does not wear out C1 - 1
  • 17. The output from most types of operation is a mixture of goods and services Pure goods Crude oil production Tangible Can be stored Aluminium smelting Specialist machine tool Production precedes consumption Low customer manufacturer contact Can be transported Quality is evident Restaurant Computer systems services Intangible Management Psychotherapy clinic consultancy Cannot be stored Production and consumption are simultaneous High customer contact Cannot be transported Quality difficult to judge Pure services C1 - 1
  • 18. Facilitating Good Concept • Often confusion in trying to classify organization as manufacturer or service • Facilitating good concept avoids this ambiguity • All organizations defined as service • The tangible part of the service is defined as facilitating good • Pure Services C1 - 1
  • 19. The Range From Services to Products C1 - 1
  • 20. Classification and Evolution of Economic Offerings C1 - 2
  • 21. Comparison of Alternative Economic Offerings Economic Offering Commodities Goods Services Experiences Value added Extracting Producing Delivering Staging by Form of Fungible Tangible Intangible Memorable output Key Natural Standardized Customized Personalized characteristics Buyer Market User Client Guest C1 - 2
  • 22. A Typology of IMPLICATIONS Operations IMPLICATIONS Low repetition High repeatability Each staff member Low Volume High Specialization performs more of job Systemization Less systemization Capital intensive High unit costs Low unit cost Well defined Flexible Routine Complex High Variety Low Standardized Match customer needs Regular High unit cost Low unit costs Changing capacity Stable Anticipation Routine Flexibility High Variation in demand Low Predictable In touch with demand High utilization High unit cost Low unit costs Time lag between Short waiting tolerance production and Satisfaction governed by consumption customer perception Standardized Customer contact skills Low contact skills needed High Visibility Low High staff utilization Received variety is high Centralization High unit cost Low unit costs C1 - 2
  • 23. Scope of POM • A) GENERAL PHASE 1Operations Management (Input Conversion / Transformation Output) 2Strategic Role ( Strategy and five performance objectives) C1 - 2
  • 24. Scope of POM Cont… • B) DESIGN PHASE 3 Design of Products and Services 4 Design of Operations Network a) Capacity Decision b) Layout Decision c) Location Decision d) Supply Chain Decision 5 Process Technology 6 Job Design & Work Organization C1 - 2
  • 25. Scope of POM Cont… • C) PLANNING & CONTROL 7 Capacity Planning and Control 8 Inventory Planning and Control 9 Supply Chain Planning and Control 10 MRP ( Material Requirement Planning ) 11 Quality Planning and Control 12 Project Planning and Control 13 JIT ( Just In Time) Planning and Control C1 - 2
  • 26. Scope of POM Cont… • D) IMPROVEMENT 14 Failure Prevention & Recovery 15 TQM ( Total Quality Management) C1 - 2
  • 27. Scope of POM Cont… • E) OPERATION CHALLENGES b) Globalization and Environmental Protection c) Social Responsibility d) Technology Awareness e) Knowledge Management f) Industrial Safety and Security C1 - 2
  • 28. Japanese Production System • Quality comes first • Continuous improvement of products & processes • Eliminate all forms of waste C1 - 2
  • 29. Operations Management Today • Service economy • Environmental awareness C1 - 2
  • 30. D. Operations Management, Productivity & Competitiveness (1990-93) (1982-93) Productivity Labor cost growth (%) increase (%) U.S. 2.5 16.1 Canada 2.4 16.2 Japan 1.8 123.9 Germany 1.2 100.8 Sweden 4.2 26.3 U.K. 4.5 27.0 C1 - 3
  • 31. Operations Management Uses • apply quality tools to tax work • project management used on merger • inventory theory for personal purchases • job design improves home chores • flexible spending accounts analyzed as inventory models C1 - 3