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Unit 8 Operational Efficiency and Business Process Performance
Unit 8 Operational Efficiency and Business Process Performance
Performance
NOTES
❖ The production is based on the forecasted amounts, not the demands of the customer
❖ Large quantity of Raw Materials is set aside (idle assets, where capital of firm is tied up)
❖ Raw Materials must be counted (use time) and inspected (reports) Non-Value Adding
❖ Require storage facility which increases costs (rent, security, counting the raw material)
❖ Higher production, setup and maintenance costs
❖ Some purchased parts and components may not be used in the production (idle asset)
❖ Massive Inventory production may result in Mask Production Problems (issues when
production that are recovered in the quality inspection stage, considered as a loss)
❖ Quality Inspection (non-adding value to the customer)
❖ Higher carrying costs (ex- warehouse, security, insurance, taxes, etc.)
❖ Risk of obsolescence (the products become old or deteriorate)
❖ Push system doesn’t meet the customer’s demand
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2. Just In Time (JIT)
This method is favored by the modern inventory planning, it views the inventory as a liability
and limits the output to the demands of the subsequent operations. The process starts when the
customer makes an order. Also called as Push System or Demand-Driven System or Back
Flush Costing System. Under JIT, it is a reaction the trends of global and competition and rapid
technological improvements resulting in a shorter product life cycle and greater product diversity
(variety) for the customer. EDI (Electronic Data Interchange) is utilized that allows the supplier
to access the buyer (firm) online inventory system.
Objectives of JIT
Higher Productivity, lower order costs as well as carrying costs. Faster and cheaper setups,
shorter manufacturing cycle times. Enhanced Quality and more flexible processes. The main goal
is to increase competitiveness and higher profits
Features of JIT
JIT is a pull system; items are pull through production by current demand. Demand-Driven
Production allows inventory levels to be minimized, reducing the non-value adding. Decrease
in suppliers and be dependent on a specific supplier. Buyer supplier relation is facilitated by EDI.
The electronic message reduces the paper-work and there is a coordination in the production
schedules.
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Effects of JIT on the Operations
Lower inventory levels and elimination of internal controls. Frequent receipts of deliveries mean
that there is a less need for sophisticated inventories. The JIT may also eliminate receiving areas
and hardcopy reports and storage areas of Raw Materials. Furthermore, manufacturing lead time
is also reduced because of on-time deliveries. The quality of parts is verified by using a statistical
control rather than inspection of each item.
Implementation of JIT
In order to implement a JIT inventory system, the manufacturing is reorganized around the
manufacturing cells. In the traditional system, each department is specialized into one task,
however, with the new system, a cellular layout is implemented, and each cell is grouped into a
U shape OR semi-circle that produces a given product. Each worker must multi-task, otherwise
workers will be in idle. The organization must operate as effective teams, so employee’s
empowerment (delegation) is vital, to achieve continuous improvements and zero defects.
Advantages of JIT
✓ Production is based on the customer demands
✓ There must be a close relationship with the supplier, the supplier must be reliable and
should be chosen carefully. The number of suppliers must also be limited
✓ Raw Materials arrive exactly at the right time (JIT)
✓ Receiving areas and warehouses for Raw Materials are eliminated as it is directly loaded
in the production line
✓ No counting or inspection of Raw Materials when they arrive
✓ Factory/Production Line must be organized perfectly U shaped
✓ Only what is needed by the next order is produced (no over-production or backup) just
what is required
✓ Lower costs to setup machines and machine break-downs (break for machine)
✓ Each worker is in a cell (area) and must multi-task as in being able to operate all
machines, perform support tasks (ex- setup, maintenance, move WIP and quality
inspection)
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✓ Units are inspected for quality during the production phase, so any defects are fixed
immediately
✓ Zero defects
✓ No storage, inventory, taxes or obsolescence risk as products go straight to the customer
✓ Units are produced and delivered JIT as per the customer’s requests
✓ No WIP at the end of the year
Disadvantages of JIT
❖ JIT is an expensive system as employees must be trained to multi-task and it is based on a
lot of machines
❖ Stock-out cost risk which means that any defect will result in the products arriving late to
the customer, and the firm may lose the customer, losing the sale
❖ This system is not suitable for producing complex products with high mix environment,
so products must be similar. Dis-similar products such as fuel factories is quite difficult
to implement such system
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3. Lean Manufacturing
Also called as Lean Process. It is a part of JIT and its main focus is accomplishing more with less
resources and providing customers with what they want and meeting their expectations. There
are 5 principles of lean manufacturing:
1) Value- identifying the feature of the product or service that the customer values
2) Value Stream- examining every process, identifying the processes that add value and
eliminate the processes that do not have value
3) Flow and Pull- designing a system that is capable of pulling the demand from customers
and maximizing the flow of product
4) Empowerment- provide each worker the knowledge and authority to make timely
decisions to increase value and eliminate waste
5) Perfection- focus on constant improvements
4. Role of Kanban
Kanban means ticket, this ticket controls the flow of
production or parts so that they are produced at a needed
amount at a needed time. This system includes:
a. Stating the quantity to be process
b. Stating the output
c. What, how much, where and when to deliver
When the worker sees the card/ticket, it acts as an
authorization to release the next step. Workers cannot
move from a stage to the other until the Kanban indicates
it being ready for the next stage.
Rule
JIT JIC
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8.2 Enterprise Resource Planning and Outsourcing
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3. Manufacturing Resource Planning (MRP II)
This is more advanced system than the MRP. It is a closed loop (automatically controlled system
than gives feedback) that integrates business process including production, sales, inventories,
schedules, and cash flows. The same system is used for financial reporting and managing
operations. MRP is a component of MRP II.
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ERP system connects all functional financial and non-financial sub-systems and also connects
the organization with the supplier and the customer. The organization may also utilize the
business process reengineering, which is recreating the business process to improve quality and
reduce costs.
The main drawback of the traditional ERP system is that it is very complex, so customizing the
software to fit the business process may be difficult.
6. Outsourcing
Outsourcing- the management of day to day execution of an entire business by a third-party
provider. Outsourced services can be on or off premises, in the same country or separate country.
Outsourcing enables the company to focus on the core business rather than being concerned with
the marginal activities.
Benefits of Outsourcing include- Reliable services at a reduced cost, as well as, avoiding the risk
of obsolescence and access to technology.
Limitations of Outsourcing include- Dependence on outside party and loss of control over a
necessary function.
Insourcing- the transfer of an outsourced function to an internal department of a company to be
managed by employees only. (Transfers the employee from a department to the other with the
transfer of knowledge as well)
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8.3 Theory of Constraints
The idea of theory of constraint (TOC) is improving any process by focusing on the slowest part
of the process not max efficiency of all other process. The slowest part of the system is called
constraint or bottleneck. Constraint causes Backup of WIP and vacancy for the next process,
as the other processes need to wait for the constraint part. Increasing efficiency of processes that
are not constraint creates backup of WIP in the system.
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2. Determine the most profitable product mix in light of the
constraint
This is a short run phase (temporary solution), that requires maximizing the contribution margin
within the constraint, known as throughput margin.
Sales Revenue
- (Direct Materials)
Throughput Margin
NOTE
For external reporting, absorption costing is used. Therefore, an adjusting entry is required to
restate the inventory. Different costing method can result in different cost per unit, which can
affect the ending inventory.
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3. Maximize the flow within the constraint
This is a short run stage, the aim is to keep up with the current situation. The production flow is
managed using the drum-buffer-rope (DBR) system. The previous department before the
constraint must be studied as the issue maybe from the previous department as it produces a lot.
Drum- it’s the bottleneck operations
Buffer- the minimum amount of WIP to keep the drum maintained
Rope- the sequence of activities before and including the bottleneck operation that must be
coordinated to avoid inventory backing up.
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4. Increase capacity at the constraint
In the short run, TOC encourages managers to make the best use of the bottleneck operation. The
medium-term step for improvement is increase the bottleneck operation (ex- increase machines,
hire or train more staff, convert to automated machines)
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8.4 Capacity Management
1. Capacity Levels
Theoretical (ideal) Capacity- is the optimal level of output that can be completed with zero
downtime (no maintenance) and zero waste. This capacity is not recommended as it is not
reasonable
Practical Capacity- is the highest level of output that can be reasonably attained assuming
planned and unplanned downtime (ex- setup costs, maintenance, and breakdowns) and expected
waste. This is the closest to the market needs.
Normal Capacity- is the average level of output that can be completed over a period of time, it
is also the closest to the market.
2. Capacity Planning
Capacity Planning is an element of strategic planning and is closely related to capital budgeting
(fixed assets). In order to maximize the capacity, an understanding of the nature and resources of
the firm is required. Effective capacity cost requires:
1) Investment Analysis
a. In the short run, the current investments must be used in order to upgrade to the
higher capacity (question- is the current capacity fully utilized?).
b. Minimize the requirement for future investment (question do we really need to but
this new machinery?)
c. Useful costing information must be provided on the current capacity compared to
the future ones.
2) Capacity Assessment
a. The firm must close any gaps between the market demands and the firm’s
capabilities (the firm may have excess capacities or shortages, these include
physical, human, technological or financial).
b. The firm must also identify the current cost capacity and the impact on the
business cycle and overall company’s performance
c. Identifying capacity to meet strategic and operational objectives
d. Details about the opportunity costs of unused capacity and suggesting ways to
account for these costs
e. Creating common language and understanding for capacity costs management
f. The capacity costs must be identified from several perspectives, including
subsequent disposal of resources
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3) Manufacturing Process Assessment
Capacity Planning is part of the capital budgeting process as an estimation must be done for
future periods regarding acquisition of more capacity or disposal of capacity that is not expected
to be utilized.
Capacity Level affects product costing, pricing decision and financial statements. Excess
capacity has costs, having excess capacity means the firm can charge higher price or report
lower operating income.
Full capacity can also have opportunity cost as the company could generate additional sales if it
had more capacity (ex- if government purchased all units at lower price and then customers
required goods but with higher price).
3. Capacity Expansion
Also referred to as market penetration, as it involves increasing the amounts of existing
product in an existing market. Determining whether the capacity is required to expand is crucial
because once it done, it can’t be reversed. The problem is forecasting long-term demands, market
share and behavior of competitors.
The firm must avoid overcapacity (having capacity that is not utilized). Under capacity in the
short run is not a major issue in a profitable industry.
Over-capacity is also an issue as firms compete on intensity rather than reverse expansion. The
budgeting process also predicts future cash flows related to the expansion eliminating interest
rates and calculating using PV (present values).
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Porter’s Model of Capacity Expansion (Steps)
1) The firm must identify the options related to its size, type, response of competitor and
degree of vertical integration (become its own supplier or retailer).
2) Forecast demands based on input costs and technological developments. The firm
must also be aware of the technology becoming obsolete or future re-designs.
Furthermore, the expansion news may pressure the firm into higher input costs (as
competitor may increase price because of the news)
3) The firm should analyze the competitor to determine the timing to expand. It’s difficult
to predict the competitor’s behavior and potential. Moreover, industry leaders are the
most influence able.
4) At this stage, the firm predicts the total capacity and market share, these estimates go
along the cash flow and expected demands.
5) Testing inconsistencies
In case the demand uncertainty is low, the firm must adopt a strategy for expansion plans.
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8.5 Value-Chain Analysis
To remain in the market, the firm’s product must provide value to the
customer and a profit to the seller as well. The customer assigns the
value to the product and the producer can affect the customer’s
perception of the value by differentiating the product or lowering the
price.
A value-added activity increases the value of a product or service to the customer (ex- setting up
the product to the customer after shipment). The value chain financial statement treats value
added activities as product costs (inventoriable costs). A non-value-added activity does not
increase the value delivered to the customer (ex- testing the shipment after production).
The value chain model is the way in which each function of the company adds value to product.
The value chain approach for assessing competitive advantage is an integral part of the strategic
management process. The value chain also shows how the costs and customer value accumulates
along to lead to an end product.
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1. Value Chain Analysis
A value chain analysis is a strategic analysis tool that allows the firm to focus on those activities
consistent with the overall strategy. This system allows the firm to decide which parts of the
value chain it wants to occupy and then gain its competitive advantage by adding value to
consumers. This system also improves the firm’s knowledge of its relation to customers,
suppliers and retailers.
Steps to perform Value Chain analysis:
1) Identify the firm’s value creating activity
a. Primary Activities- R&D, Product Design, Manufacturing, Marketing, etc.
b. Secondary Activities- HR, Procurement, IT, etc.
Value chain analysis offers an excellent opportunity to integrate strategic planning and guide the
firm to survival and growth.
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The decision to purchase is often made by the decision of the Production Control to insourcing
vs. outsourcing (make vs. buy). The choice of vendors depends on the quality, price, delivery,
shipment and credit terms. It is often viewed that the purchaser and vendor are committed to a
partnership involving joint efforts.
Supply Chain analysis and coordination must extend to all parties of the chain, from materials to
retailers. This cooperation is called bullwhip or backlash effect, which occur when there is a
demand variability at each level of the supply chain.
Value chain and Supply chain must meet the demands of the customers for better performance
regarding success factors, including:
a. Cost reduction
b. Efficiency
c. Continuous Quality Improvement
d. Eliminating Defects
e. Constant Innovation
f. Faster Production & Customer Response
3. Value Engineering
It means reaching the targeted cost levels. It’s a systematic approach to assess all aspects of
value chain costs buildup for product. The aim is to reduce costs without sacrificing customer
satisfaction. Value Engineering requires differentiating between cost incurrence and locked-in
costs
a. Cost Incurrence- is the actual use of resources
b. Locked-in (designed in) Costs- they are costs that will result in the use of resources in
the future because of a past decisions. The part of value engineering is controlling the
design costs before they get locked in.
c. Life-cycle costing- is sometimes used as basis for cost planning and product pricing. It
estimates the revenues and expenses over a period of time and sets the suitable price to
cover all costs.
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8.6 Other Process Improvement Tools
1. Process Analysis
Process Analysis is the means of linking a firm’s internal processes to its overall strategy.
Types of Process include:
a. Continuous- the production runs nonstop (ex- candy bars)
b. Batch- production is runs and stopped at intervals (ex- beer production)
c. Hybrid- it’s a mix of both continuous and batch
d. Make to Stock- (ex- automobiles assembly)
e. Make to Order- (ex- subway sandwiches)
b. Loose Process- a breakdown in one stage will not affect the subsequent stages, often
found in batch production and other extensive WIP inventories (ex- counting and storing
Finished Goods)
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2. Process Value Analysis
It is an understanding of how the organization generates output. It involves determining which
activities use resources that are value-adding, and which are non-value adding, so that we can
eliminate them. The main goal is to add value to the customer.
The linkage of product costing and continuous improvement of processes is activity-based
management (ABM). ABM also improves the use of resources to increase value for customers
and become efficient.
ABM includes the following:
a. Strategic Analysis- explores the way in which a company can create and sustain
(withstand) a competitive advantage
b. Benchmarking- a method that identifies an activity as the standard by which a similar
activity is judged upon
c. Operational Analysis- seeks to identify, measure and improve performance of key
processes
d. Profitability/Pricing Analysis- assists the company in identifying cost benefit analysis
of a product and launching analysis
e. Process Improvement- focuses on identifying the cause of variation, waste and
inefficiency.
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Activity Analysis- determines what is done, by whom, what costs and resources needed by each
activity.
a. Value Added Activities- are necessary to remain in the
business
b. Non-Value-Added Activities- unnecessary and should
be eliminated
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4. Benchmarking
Involves continuously evaluating he practices of the best-in
class organizations and adapting company process to adopt
these practices. It focus on financial performance and all
aspects of the business. Firms can compare themselves with
firms in different sectors, not only competitor.
It analyzes and measures the key outputs of a business
process against the best and identifying the key actions and root causes that result in these
performance differences. It is an ongoing process that compares quantitative and qualitative
between the company’s performance and best in the world.
• The firm must select and prioritize benchmarking projects. (Department and
Process)
• Understand the organization’s critical success factor (Good Practices)
• Identify the key business process of benchmarking (Process A and Process B)
• Select the criteria and parameter for benchmarking (Time)
• Organize the teams by knowledge, communication skills, teamwork skill,
problem solving and project management
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2) Record and Document the internal process
• The benchmarking team must investigate and document the internal process that
are subject for benchmarking
• Setting up databases
• Choosing information gathering methods (internal and external sources)
• Formatting questionnaires
• Selecting benchmarking partners
5. Cost of Quality
There are 4 categories of costs of quality, they are prevention, appraisal, internal failure and
external failure. The organization must minimize total costs of quality.
Quality Conformance Costs include both Prevention and Appraisal (are both in financial
measures of internal performance).
1) Prevention Costs- attempts to avoid defective output, costs include maintenance,
employee training, equipment redesign and evaluation of supplier
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Non-Conformance Costs include internal failure (measure of internal performance) and external
failure (measure of customer satisfaction)
1) Internal Failure- costs of defective units before shipment (ex- scrap, rework, downtime,
tool changing, re-inspection, lost learning opportunities, researching and correcting
problems)
2) External Failure (lost opportunity)- lost profits from declining market share, as
dissatisfied of customers make no purchases, return products or cancel orders (ex-
rejection, return, repair, recall and complaints). The best solution for external failures is
to provide all employees with training about the importance of quality to customers.
Environmental costs are also external failure (ex- fines, loss of customer goodwill)