Chapter 4 Process design Source: Joe Schwarz, www.joyrides.com Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Process design Process design Operations strategy Supply network design Layout and flow Process technology Design Job design Product/service design Operations management Improvement Planning and control Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Nature and purpose of the design activity Products, services and the processes which produce them all have to be designed Decisions taken during the design of a product or service will have an impact on the decisions taken during the design of the process which produces those products or services, and vice versa Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Design of products / services and design of processes are interrelated and should be treated together Designing the product or service Products and services should be designed in such a way that they can be created effectively Designing the process Product / service design has an impact on the process design and vice versa Processes should be designed so they can create all products and services which the operation is likely to introduce Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Design of the Product Design of the Process In manufacturing operations overlapping the activities of product and process design is beneficial Design of the Service Design of the Process In most service operations the overlap between service and process design is implicit in the nature of service Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Designing processes There are different ‘process types’ Process types are defined by the volume and variety of ‘items’ they process Process types go by different names depending on whether they produce products or services Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Process flow Diverse/ complex Intermittent High Repeated/ divided Continuous Variety Process tasks Low Manufacturing process types Low Volume High Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Project processes One-off, complex, large-scale ‘products’ with high work content Specially made, every one ‘customized’ Defined start and finish: time, quality and cost objectives Many different skills have to be coordinated Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 A project process describes the whole process Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Jobbing processes Very small quantities: ‘one-offs’, or only a few required Specially made: high variety, low repetition, ‘strangers’, every one ‘customized’ Skill requirements are usually very broad Skilled jobber, or team, completes whole product Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Preparing photolithography materials on a jobbing basis with a typical process map Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Batch processes Higher volumes and lower variety than for jobbing Standard products, repeating demand. But can make specials Specialized, narrower skills Set-ups (changeovers) at each stage of production Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 A batch process in a kitchen Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Mass (line) processes Higher volumes than batch Standard, repeat products (‘runners’) Low and/or narrow skills No set-ups, or almost instantaneous ones Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 A mass process – a packing process Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Continuous processes Extremely high volumes and low variety: often single product Standard, repeat products (‘runners’) Highly capital-intensive and automated Few changeovers required Difficult and expensive to start and stop the process Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Part of a continuous process Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Process flow Diverse/ complex Intermittent High Repeated/ divided Continuous Variety Process tasks Low Service process types Low Volume High Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 A professional service – Consultants planning how best to help their client Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 A service shop – This health club offers some variety within a standard set of facilities and processes Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 A mass service – This call centre can handle a very high volume of customer enquiries because it standardizes its process Source: Royal Bank of Scotland Group Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Deviating from the ‘natural’ diagonal on the product–process matrix has consequences for cost and flexibility Manufacturing operations process types Variety None Project Jobbing Batch Service operations process types Volume Less process flexibility than is needed so high cost More process flexibility than is needed so high cost Professional service Service shop Mass Continuous Mass service None The ‘natural’ line of fit of process to volume/variety characteristics Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Deviating from the ‘natural’ diagonal on the product–process matrix has consequences for cost and flexibility Volume Variety None Old process Old process, new product New process, new product None Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Flow (layout), technology and job design are all influenced by process positioning Flow Technology Volume Jobs Variety Unorganized Little / general Varied / high discretion None Custom furniture maker Machine tool maker Automobile factory Predictable Specialist Routine / low discretion None Petrochemical refinery Manufacturing Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Flow (layout), technology and job design are all influenced by process positioning Flow Technology Volume Jobs Variety Unorganized Little / general Varied / high discretion None Investment banking Customer service branch Bank call centre Predictable Specialist Routine / low discretion None Credit card processing Services Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 The Service Package (or Bundle) is a concept used to alayse and design services and consists of the following 4 features: 1 Supporting Facility. 2 Facilitating goods. 3 Sensual benefits or Explicit services 4 Psychological benefits or Implicit services Service Management th Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Fitzsimmonds and Fitzsimmonds, Service Management 4 Edition, 2004, McGraw Hill. (p22) Supporting Facility Architectural appropriateness Interior decorating Facility layout Supporting equipment Service Management th Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Fitzsimmonds and Fitzsimmonds, Service Management 4 Edition, 2004, McGraw Hill. (p22) Facilitating goods Consistency Quantity Selection Service Management th Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Fitzsimmonds and Fitzsimmonds, Service Management 4 Edition, 2004, McGraw Hill. (p22) Explicit services Training of service personnel Comprehensiveness Consistency Availability Service Management th Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Fitzsimmonds and Fitzsimmonds, Service Management 4 Edition, 2004, McGraw Hill. (p22) Implicit services Attitude of service personnel Privacy and security convenience Atmosphere Waiting Status Sense of well-being Service Management th Slack, Chambers and Johnston, Operations Management 5th Edition © Nigel Slack, Stuart Chambers, and Robert Johnston 2007 Fitzsimmonds and Fitzsimmonds, Service Management 4 Edition, 2004, McGraw Hill. (p22)
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