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material) and transform these inputs into outputs (services and goods) consumed by the public.
Operations Management is decision making involving the design, planning, and control of the
many factors that affect operations.
Goods (physical products) produced by organizations
For profit
Not-for-profit
Services (intangible products) produced by organizations
For profit
Not-for-profit
Operation Strategy: Operations should be linked to the organizations strategy to achieve the
greatest benefit
Operations Add Value:
1. Consumer
-willing to pay more for a product than the costs of the inputs
2. Private sector
3. Public sector
Relative advantage is the difference between the lowest cost producer and the next lowest cost
producer.
Relative advantage leads to the percentage of world production moving between nations, and
creating Global Markets.
A system is a group of items, events, or actions in which no item, event, or action occurs
independently.
Supply Chain Management
Supply Chain: The sequence of organizations - their facilities, functions, and activities - that are
involved in producing and delivering a product or service
Sometimes referred to as value chains
Facilities: The sequence of the supply chain begins with basic suppliers and extends all the way
to the final customer
Warehouses
Factories
Processing centers
Distribution centers
Retail outlets
Offices
Forecasting
Purchasing
Inventory management
Information management
Quality assurance
Scheduling
Production and delivery
Customer service
management.
Synchronize a firms functions and activities and those of its suppliers to match the flow
Supply chain management (SCM) represents one of the most significant paradigm shifts
of modern business management by recognizing that individual businesses no longer
compete as solely autonomous entities, but rather as supply chains (Chen and Paulraj,
JOM, 2004).
Every business organization is part of at least one supply chain, and many are part of
multiple supply chains.
SCM Managers:
People at various levels of the organization who are responsible for managing supply and
Outsourcing for the reasons of lower labor and materials costs, insufficient capacity, lack
of expertise/competency, etc.
Firms are realizing other costs such as transportation, inventory, duty costs, and the issues
of long lead time (lack of flexibility), intellectual property theft, which all should be
considered in outsourcing decisions.
Risk Management
Use Pull rather than Push systems to better match supply with demand.
Using a limited number of certified suppliers can eliminate the need for inspection and
strengthen relationships for continuous improvement.
Sustainability
Lower inventories
Higher productivity
Greater agility
Higher profits
Procurement
The purchasing department is responsible for obtaining the materials, parts, and supplies
and services needed to produce a product or provide a service.
Develop and implement purchasing plans for products and services that support
operations strategies
Duties of Purchasing
Negotiating contracts
Managing supplies
Purchasing Cycle
1. Requisition received
2. Supplier selected
3. Order is placed
4. Monitor orders
5. Receive orders
E-business: It is the use of electronic technology to facilitate business transactions
Applications include
Advantages of E-Business
Companies can:
Choosing Suppliers
Vendor analysis: refers to Evaluating the sources of supply in terms of price, quality,
reputation, and service
A supply chain initiative that focuses on information sharing among supply chain
trading partners in planning, forecasting, and inventory.
Inventory Management
Inventory location
Centralized inventories
Decentralized inventories
Inventory velocity
Variations in demand cause inventory fluctuations to fluctuate and get out of control
Periodic ordering
Reactions to shortages
Forecast inaccuracies
Order batching
Results in
Higher costs
Strategic buffering
Vendor-managed inventory
Vendors monitor goods and replenish retail inventories when supplies are low
Order fulfillment
Common approaches
Engineer-to-order (ETO)
Make-to-order (MTO)
Assemble-to-order (ATO)
Make-to-stock (MTS)
Logistics: refers to the movement of materials and information within a facility and to
incoming and outgoing shipments of goods and materials in a supply chain
Traffic management
Government regulations
A technology that uses radio waves to identify objects, such as goods in supply
chains
Types:
Active
Passive
Includes
Managing Returns
Reverse Logistics
Products are returned to companies or third party handlers for a variety of reasons and in
a variety of conditions
Gatekeeping
Avoidance
Analyzing the procurement process to lower costs by reducing waste and nonvalue-added activities, increase profits, reduce risks, and improve supplier
performance
There must be
Trust
Effective communication
Information velocity
Performance metrics
Challenges
Small businesses
Response time
Trade-Offs
Lot-size-inventory trade-off: Large lot sizes yield benefits in terms of quantity discounts and
lower annual setup costs, but it increases the amount of safety stock (and inventory carrying
costs) carried by suppliers
Inventory-transportation costs: Suppliers prefer to ship full truckloads instead of partial loads
to spread shipping costs over as many units as possible. This leads to greater holding costs for
customers
Cross-docking: A technique whereby goods arriving at a warehouse from a supplier are
unloaded from the suppliers truck and loaded onto outbound truck, thereby avoiding warehouse
storage.
Lead time-transportation costs: Suppliers like to ship in full loads, but waiting for sufficient
orders and/or production to achieve a full load may increase lead time
Product variety-inventory: Greater product variety usually means smaller lot sizes and higher
setup costs, as well as higher transportation and inventory management costs
Delayed differentiation: Production of standard components and subassemblies which are held
until late in the process to add differentiating features
Cost-customer service: Producing and shipping in large lots reduces costs, but increases lead
time
Disintermediation: Reducing one or more steps in a supply chain by cutting out one or more
intermediaries
3. Psychological components
4. Self-directed teams
5. Motivation and incentive systems
Labor Specialization: it is the division of labor into unique tasks
First suggested by Adam Smith in 1776
1. Development of dexterity and faster learning
2. Less loss of time
3. Development of specialized tools
Later Charles Babbage (1832) added another consideration
4. Wages exactly fit the required skill
Job Expansion: Adding more variety to jobs
Intended to reduce boredom associated with labor specialization
Job enlargement
Job rotation
Job enrichment
Employee empowerment
Psychological Components of Job Design: Human resource strategy requires consideration of
the psychological components of job design
Core Job Characteristics:
Jobs should include the following characteristics
Skill variety
Job identity
Job significance
Autonomy
Feedback
Self-Directed Teams: it is a group of empowered individuals working together to reach a
common goal
May be organized for long-term or short-term objectives
Effective because
Provide employee empowerment
Ensure core job characteristics
Meet individual psychological needs
To maximize effectiveness, managers should:
Ensure those who have legitimate contributions are on the team
Provide management support
Ensure the necessary training
Endorse clear objectives and goals
Financial and non-financial rewards
Supervisors must release control
Benefits of Teams and Expanded Job Designs:
Improved quality of work life
Improved job satisfaction
Increased motivation
Allows employees to accept more responsibility
Capacity decisions must be integrated into the organizations mission and strategy
Capacity Considerations:
Forecast demand accurately
Understand the technology and capacity increments
Find the optimum
operating level
(volume)
Build for change
Managing Demand
Demand exceeds capacity
Curtail demand by raising prices, scheduling longer lead time
Long term solution is to increase capacity
Capacity exceeds demand
Stimulate market
Product changes
Adjusting to seasonal demands
Produce products with complementary demand patterns
Tactics for Matching Capacity to Demand:
1. Making staffing changes
2. Adjusting equipment
Purchasing additional machinery
Selling or leasing out existing equipment
3. Improving processes to increase throughput
4. Redesigning products to facilitate more throughput
5. Adding process flexibility to meet changing product preferences
6. Closing facilities
Break-Even Analysis: It is a technique for evaluating process and equipment alternatives
Objective is to find the point in dollars and units at which cost equals revenue
Requires estimation of fixed costs, variable costs, and revenue
Product design is concerned with the efficient and effective generation and development of
ideas through a process that leads to new products.
Product Designers conceptualize and evaluate ideas, making them tangible through
products in a more systematic approach.
Their role is to combine art, science and technology to create tangible three-dimensional
goods.
This evolving role has been facilitated by digital tools that allow designers to
communicate, visualize and analyze ideas in a way that would have taken greater
manpower in the past.
Product design is conceptualization of an idea about a product and transformation of the idea
into a reality. To transform the idea into reality a specification about the product is prepared. This
specification is prepared by considering different constraints such as production process,
customer expectation, etc. In product design stage every aspects of the product are analyzed.
Also final decision regarding the product is taken on the basis of the analysis. This decision can
be any aspect related to the product, e.g. dimension and tolerances, type of material for every
components, etc.
Product design is one of the most important and sensitive factor for an organization. Success or
failure of the product decides companys business, market share and reputation. So during design
stage various factors related to the product needs to be addressed.
Objectives of product design:
To ensure growth of the organization
To utilize the surplus capacity of the organization, such as physical facility, man power,
etc.
To utilize the surplus fund of the organization
To meet new requirement of the customers
To increase companys market share and to target new market segment
To ensure complete product range in companys portfolio
Cost effectiveness: The product must be cost effective. The must be manufactured in the
most cost effective environment.
Concepts of product design:
1. Research & development:
Basic research is a search for new knowledge. It does not have any immediate application, but
based on the basic research new product can be developed in future. Applied research has
objective of developing commercial products.
2. Reverse engineering:
Reverse engineering is the process of carefully dismantling a product, understanding its design
and developing a product which is better than the existing one.
3. CAD-CAM:
By using 3D modeling software system, designers develop a computerized model of a new
product and analyze its design parameters. After computer aided design (CAD), computer aided
manufacturing (CAM) system produce the product by using CNC facility.
4. Concurrent engineering (CE):
CE is different than conventional approach of design. In CE, different co-related teams are
formed, which perform different activities for developing a product. For example, development
of market concept, design of product, development of manufacturing process, selection and
arrangement of material for new design is performed by different teams at the same time. It
reduces considerable amount of time to develop a new product.
In practice different concepts are combined and applied together to design a new product
Steps of product design:
Synthesis: Try to develop different alternatives
Sketching: Draw sketches in exact scale for different alternatives
Analysis: Analysis different alternatives with respect to operability, maintainability, inspection,
assembling and dismantling issues, cost parameters, production methods, etc.
Selection: Select the best alternative
Basic engineering: Prepare layout in exact scale, calculate strength of components, select proper
cost effective material.
Detail design: Prepare detail engineering drawing for each component
Prototype: If option is there, then prepare prototype and test it
Manufacturing: If prototype is not made, then follow manufacturing steps and solve
manufacturing problems and assembly problems, if any.
Operation: collect feedback during actual operation of the new product. If any problem exists,
try to provide design based solution. Also, implement lessons in the future design.
Product development: If any modification can be done, implement the same in the next
generation product.
Concurrent Engineering:
is defined as the simultaneous development of project design functions, with open and
interactive communication existing among all team members for the purposes of reducing
time to market, decreasing cost, and improving quality and reliability.
Technical Team
Design-Build Teams
House of Quality
Achieve equivalent or better performance at a lower cost while maintaining all functional
requirements defined by the customer
Does the item have any design features that are not necessary?
Types of Processes:
Break-Even Analysis:
Model seeks to determine the point in units produced (and sold) where we will start
making profit on the process or equipment
Model seeks to determine the point in units produced (and sold) where total revenue and
total cost are equal
Example: Suppose you want to purchase a new computer that will cost $5,000. It will be
used to process written orders from customers who will pay $25 each for the service. The
cost of labor, electricity and the form used to place the order is $5 per customer. How
many customers will we need to serve to permit the total revenue to break-even with our
costs?
Break-even Demand:
The most common tools to conduct a process flow design include assembly drawings,
assembly charts, and operation and route sheets
Just imagine another example: you head a food catering company which provides schools with
meals. A TV journalist announces that three children have been transported to the Hospital and
that the cause seems to be food poisoning. He calls you for a hot interview: What would you say,
what would you do?
Difference between the two
Books only describe how to deal with proactive decisions such as starting a business,
partnering or merging. These decisions allow time for studying the options.
On the contrary, the reactive decisions that you have to make facing a disaster do not
allow any time. You have to act under the pressure of time and circumstances and of
course such decisions are both the most important and difficult.
Reactive Decision:
automatically when the event occurs. A bad event with either a high or either a low probability is
a risk. The first step is to carefully study the risks which could strike your business.
Risk Assessment Matrix
Each business is exposed to specific risks connected with its main activity.
For example, Banks, currency traders and jewelers are currently exposed to difficulty. It's not
only a matter of insurance. It's a matter of life or death according how you react.
Businesses connected to chemicals, foods and drugs are currently exposed to poisoning risks,
ecological threats and food diseases. Travel agencies can be exposed to terrorism in some
countries. All businesses are exposed to labor accidents, fire, earthquake, volcanic eruption,
fraud and so on. In some countries, you must take in account civil wars, revolution and riots in
urban areas.
All these events can never be planned. It is quite impossible to identify or to predict their
chances: They occur suddenly and you have to decide suddenly too.
List your risks:
In any preparation, the first step is to list your risks and their probability. To simplify, just
identify high probability and low probability.
For example, with growing insecurity, a criminal attack must be graded as a high
possibility for any business involved in money business or gem trade. On the contrary, a
travel agency has a low probability to be confronted with a hitch.
The second task is to estimate the impact of the event. You can distinguish the accident,
the disaster and the catastrophe. With an accident, your business will go on as usual. A
disaster implies a long recovery and a catastrophe means that your business is terminated.
When you have finished this analysis, you draw up your risk assessment matrix.
You write in each square, the risks you have listed according to their probabilities and
their impacts.
Whatever their low or high probabilities, all the risks that are fully insured could be put in
the left part of the drawing: low impact. However, you have to analyze: For example a
your internet site and so on. It does not prevent the risk but just reduces its probability.
Secondly, according to your risk assessment matrix, establish the best emergency plans.
Thirdly, you must be aware that once the event occurs, most people are in panic. In this
case, the best plan becomes ineffective because people are emotionally unable to apply it.
It means that you have to prepare for a chain of automatic decisions that everybody can
follow up without having to think.
Proactive Decision Making: Fortunately, proactive decisions are more frequent than reactive
decisions. We bear in mind that daily business decisions and solutions rely on well-known tools.
Decision making implies a phase of preparation and a phase of execution
Unfortunately, most often there are different possible solutions such as A, B, and C. What
is more, you do not know the chances of success of A, B, or C!
3. Collect information: One way for reducing uncertainty is to collect information. For
example: Will you partner with company A? This company can be good, medium or bad. In
order to reduce this uncertainty, you can collect information from your bank or other sources.
Unfortunately, sensible information is not on the market place and requires that you enter in
the domain of intelligence.
4. Assess the consequences of each option: You must also intensively investigate all the
consequences of your decision: Let's suppose that your decision could have three outcomes: one
very good (A), one good (B) and one bad (C) with equal probabilities. In this case, your decision
should have 66% of chance to be a good decision.
Now examine more carefully the possible consequences: With A, you win 100, with B you win
30 and with C you get a death penalty! In this case the consequences of C are out of proportion
with the benefit that you can expect. It's why most criminal activities are risked!
5. Define your options and the best alternative: Be careful about the idea to multiply the
options. It could be a poor excuse for never taking any decisions. Too much option kills the
decisions and risk inducing an infinite process of brainstorming
6. Execution: After passing through all the above stages the one can make an appropriate
decision, and later carryout a decision Tree.
A Decision tree is a way for visualizing a complex chain of decisions. A decision leads to a new
choice and therefore to a new decision that in turn faces with a new choice and so on.
Decision Trees are excellent tools for helping you to choose between several courses of action.
They provide a highly effective structure within which you can lay out options and investigate
the possible outcomes of choosing those options. They also help you to form a balanced picture
of the risks and rewards associated with each possible course of action.
Starting from the new decision squares on your diagram, draw out lines representing the options
that you could select. From the circles draw lines representing possible outcomes. Again make a
brief note on the line saying what it means. Keep on doing this until you have drawn out as many
of the possible outcomes and decisions as you can see leading on from the original decisions.
a) Define decision making
b) Distinguish between Proactive & Re active decision making.
c) Identify & explain the rationale for decision making in operations management.
d) Describe the stages of decision making in operations management.
e) What challenges are faced in decision making
f) As an operational manager how would overcome such challenges above