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UCL ESPO/IAG/POMS PROD 2800 PRODUCTION AND OPERATIONS MANAGEMENT Gestion de la production et des opérations Per AGRELL Lecture 2Process.

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Presentation on theme: "UCL ESPO/IAG/POMS PROD 2800 PRODUCTION AND OPERATIONS MANAGEMENT Gestion de la production et des opérations Per AGRELL Lecture 2Process."— Presentation transcript:

1 UCL ESPO/IAG/POMS PROD 2800 PRODUCTION AND OPERATIONS MANAGEMENT Gestion de la production et des opérations Per AGRELL agrell@poms.ucl.ac.be Lecture 2Process analysis UCL

2 PROD 28002 Outline Processes – Terminology – Definitions Flowcharting (PFA) Process improvement

3 PROD 28003 Process flow classification Project Jobbing Batch Line Continuous processing

4 PROD 28004 Production order regimes Design to order (DTO) – Specific design and manufacture for all customers Engineer to order (ETO) – Changes to standard products are offered and produced Make to order (MTO) – Production of standard product on receipt of order/call-off Assemble to order (ATO) – Components MTS. Assembly made on receipt of order. Make to stock (MTS) – Production to forecast. Order met from inventory.

5 PROD 28005 Process choice Product Structure Process Structure Process focus Product focus Intermediate focus Job shop Batch process Line process Continouos process

6 PROD 28006 Implications of process choice Products and Markets – Type of product – Product range – Customer order size – Rate of product introductions – Order winners? – Order qualifiers? Manufacturing – Nature of process technology – Focus Investment and Cost – Level of capital investment – Level of inventory – Level of WIP – Cost drivers Infrastructure – Organizational control – Organizational style – Required support expertise

7 PROD 28007 Process analysis PROCESS Resources (Inputs) Products (Outputs) Control

8 PROD 28008 Process flowcharting Abstraction of process interdependencies Uniform process terminology Methodology to analyze – Tasks/operations – Flows – Storages/inventories – Decision making

9 PROD 28009 PFA symbols Tasks or operations Decision Points Storage areas / queue Material flow

10 PROD 280010 Example 1 Exam passed? Yes No Drive on! Revise material Attend reexam

11 PROD 280011 Buffers Exam passed? Yes No Drive on! Revise material Attend reexam Buffer

12 PROD 280012 Parallel activities Drive to UCL Park car Wait Listen to radio

13 PROD 280013 Time concepts Wait Cycle timeThroughput time Run time Setup Operation 1 Operation 2 Operation 1 Operation time

14 PROD 280014 Performance measures Cycle time = Ave. time between completion of units Throughput time = Ave. time in process per unit Throughput rate = 1. Cycle time Velocity = Throughput time Value-added time

15 PROD 280015 Productivity measures Productivity =Output Input Efficiency = Actual output Potential Output Utilization = Time Activated Time Available

16 PROD 280016 Process improvement Process choice Vertical integration Resource flexibility Flow time reduction

17 PROD 280017 Vertical integration

18 PROD 280018 Resource flexibility Workforce flexibility – Training, certification – Buffer against uncertainty – Capacity – Job satisfaction Equipment flexibility – Fixed automation – High demand volume, stable market, long PLC – Flexible automation – Quick setups, FMS

19 PROD 280019 Flow time reduction Parallel activities – On-line and off-line work Reorganizing sequences Reduction of non-value added work Outsourcing Process focus

20 PROD 280020 Summary Bottleneck WIP Buffer Throughput time


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