1. Using Operations to Compete Chapter 1
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01-01

2. What is Operations Management?
The systematic design, direction, and control of processes that transform inputs into services and products for internal, as well as external, customers.
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3. What is Supply Chain Management?
The synchronization of a firm’s processes with those of its suppliers and customers to match the flow of materials, services, and information with customer demand.
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4. The Role of Operations in the Organization
Integration between Different Functional Areas of a Business
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A Process View
Process
Any activity or group of activities that takes one or more inputs, transforms them, and provides one or more outputs for its customers.
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6. Service and Manufacturing Processes
Differ Across Nature of Output and Degree of Customer Contact
More like a manufacturing process
More like a service process
Physical, durable output
Output can be inventoried
Low customer contact
Long response time
Capital intensive
Quality easily measured
Intangible, perishable output
Output cannot be inventoried
High customer contact
Short response time
Labor intensive
Quality not easily measured
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The Supply Chain View
Each activity in a process should add value to the preceding activities; waste and unnecessary cost should be eliminated.
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The Supply Chain View
Supplier relationship process – A process to select the suppliers of services, materials, and information and facilitate the flow of these into the firm.
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The Supply Chain View
New service/product development – A process to design and develop new services or products from customer or market inputs.
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The Supply Chain View
Order fulfillment process – A process to produce and deliver services or products to the external customer.
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The Supply Chain View
Customer relationship process – A process that identifies, attracts and builds relationships with external customers and facilitates the placement of orders.
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The Supply Chain View
Support Processes - Processes like Accounting, Human Resources, Engineering, and Information Systems that provides vital resources and inputs to the core processes
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13. Operations Strategy
Specifies the means by which operations implements corporate strategy and helps build a customer-driven firm
Corporate strategy provides an overall direction that serves as the framework for carrying out all the organization's functions
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14. Operations Strategy Corporate Strategy Environmental scanning
Core competencies
Core processes
Global strategies
Market Analysis
Market segmentation
Needs assessment
Competitive Priorities
Cost
Quality
Time
Flexibility
New Service/
Product Development
Design
Analysis
Development
Full launch
Operations Strategy
Decisions
Managing processes
Managing supply chains
Competitive Capabilities
Current
Needed
Planned
Performance Gap? No
Yes
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15. Competitive Priorities and Capabilities
The critical dimensions that a process or supply chain must possess to satisfy its internal or external customers, both now and in the future.
Competitive capabilities
The cost, quality, time, and flexibility dimensions that a process or supply chain actually possesses and is able to deliver.
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16. Order Winners and Qualifiers
The criterion customers use to differentiate the services or products of one firm from those of another.
Order Qualifiers
The minimum level required from a set of criteria for a firm to do business in a particular market segment.
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Examples
COST
Definition
Process Considerations
Example
Low-cost operations
Delivering a service or a product at the lowest possible cost
Processes must be designed and operated to make them efficient
Costco
QUALITY
Top quality
Delivering an outstanding service or product
May require a high level of customer contact and may require superior product features
Rolex
Consistent quality
Producing services or products that meet design specifications on a consistent basis
Processes designed and monitored to reduce errors and prevent defects
McDonald’s
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Examples
TIME
Definition
Process Considerations
Example
Delivery speed
Quickly filling a customer’s order
Design processes to reduce lead time
Dell
On-time delivery
Meeting delivery-time promises
Planning processes to increase percent of customer orders shipped when promised
United Parcel Service (UPS)
Development speed
Quickly introducing a new service or a product
Cross-functional integration and involvement of critical external suppliers
Zara
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Examples
FLEXIBILITY
Definition
Process Considerations
Example
Customization
Satisfying the unique needs of each customer by changing service or products designs
Low volume, close customer contact, and easily reconfigured
Ritz Carlton
Variety
Handling a wide assortment of services or products efficiently
Capable of larger volumes than processes supporting customization
Amazon.com
Volume flexibility
Accelerating or decelerating the rate of production of service or products quickly to handle large fluctuations in demand
Processes must be designed for excess capacity
The United States Postal Service (USPS)
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20. Relationship of Order Qualifiers to Competitive Priorities
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21. Relationship of Order Winners to Competitive Priorities
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22. OPERATIONS STRATEGY ASSESSMENT OF THE BILLING AND PAYMENT PROCESS
Competitive Priority
Measure
Capability
Gap
Action
Low-cost operations
Cost per billing statement
$0.0813
Target is $0.06
Eliminate microfilming and storage of billing statements
Weekly postage
$17,000
Target is $14,000
Develop Web-base process for posting bills
Consistent quality
Percent errors in bill information
0.90%
Acceptable
No action
Percent errors in posting payments
0.74%
Delivery speed
Lead time to process merchant payments
48 hours
Volume flexibility
Utilization
98%
Too high to support rapid increase in volumes
Acquire temporary employees
Improve work methods
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23. Trends in Operations Management
Productivity
The value of outputs (services and products) produced divided by the values of input resources (wages, costs of equipment, etc.)
Productivity = Output
Input
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24. (3 employees)(40 hours/employee)
Example 1.1
Calculate the Labor Productivity:
a. Three employees process 600 insurance policies in a week. They work 8 hours per day, 5 days per week.
Labor productivity =
Policies processed
Employee hours
= = 5 policies/hour
600 policies
(3 employees)(40 hours/employee)
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25. Labor cost + Materials cost
Example 1.1
Calculate the Multifactor Productivity:
A team of workers makes 400 units of a product, which is sold in the market for $10 each. The accounting department reports that for this job the actual costs are $400 for labor, $1,000 for materials, and $300 for overhead.
Multifactor productivity =
Value of output
Labor cost + Materials cost
+ Overhead cost
= = = 2.35
(400 units)($10/unit)
$400 + $1,000 + $300
$4,000
$1,700
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26. Application 1.1 Calculate the year-to-date labor productivity:
This Year
Last Year
Year Before Last
Factory unit sales
2,762,103
2,475,738
2,175,447
Employment (hrs)
112,000
113,000
115,00
Sales of manufactured products ($)
$49,363
$40,831 —
Total manufacturing cost of sales ($)
$39,000
$33,000
Calculate the year-to-date labor productivity:
factory unit sales
employment
This Year
2,762,103
= 24.66/hr
112,000
Last Year
2,475,738
= 21.91/hr
113,000
Year Before Last
2,175,447
= $18.91/hr
115,000
Calculate the multifactor productivity:
sales of mfg products
total mfg cost
This Year
$49,363
= 1.27
$39,000
Last Year
$40,831
= 1.24
$33,000
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27. Trends in Operations Management
Global Competition
Advantages:
Increased market penetration
Comparative cost advantages
Disadvantages:
Political risks
Lower skilled workers
Vulnerability to supply chain disruptions
Japanese Earthquake in March 2011
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28. Trends in Operations Management
Ethical, Workforce Diversity, and Environmental Issues
Ethical decision-making in different countries
Environmental concerns
Sustainability initiatives
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Solved Problem 1
Student tuition at Boehring University is $150 per semester credit hour. The state supplements school revenue by $100 per semester credit hour. Average class size for a typical 3-credit course is 50 students. Labor costs are $4,000 per class, material costs are $20 per student per class, and overhead costs are $25,000 per class.
What is the multifactor productivity ratio for this course process?
If instructors work an average of 14 hours per week for 16 weeks for each 3-credit class of 50 students, what is the labor productivity ratio?
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Solved Problem 1
SOLUTION
Multifactor productivity is the ratio of the value of output to the value of input resources.
Value of output =
50 student
class
$150 tuition +
$100 state support
credit hour
3 credit hours
student
= $37,500/class
Value of inputs = Labor + Materials + Overhead
= $4,000 + ($20/student  50 students/class) + $25,000
= $30,000/class
Multifactor productivity = = 1.25
$37,500/class
$30,000/class
Output
Input
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Solved Problem 1
SOLUTION
Labor productivity is the ratio of the value of output to labor hours. The value of output is the same as in part (a), or $37,500/class, so
Labor hours of input =
14 hours
week
16 weeks
class
= 224 hours/class
Labor productivity =
$37,500/class
224 hours/class
Output
Input
= $167.41/hour
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Solved Problem 2
Natalie Attire makes fashionable garments. During a particular week employees worked 360 hours to produce a batch of 132 garments, of which 52 were “seconds” (meaning that they were flawed). Seconds are sold for $90 each at Attire’s Factory Outlet Store. The remaining 80 garments are sold to retail distribution at $200 each. What is the labor productivity ratio of this manufacturing process?
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Solved Problem 2
SOLUTION
Value of output = (52 defective  90/defective)
+ (80 garments  200/garment)
= $20,680
Labor hours of input = 360 hours
Labor productivity =
$20,680
360 hours
Output
Input
= $57.44 in sales per hour
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