PROCESS MANAGEMENT

process: A set or sequence of activities that adds value to an organization by taking inputs and transforming them into outputs.
process mapping: a.k.a. flowcharting, a graphical representation of a process that uses the following basic symbols:

Activity, task, or operation step:

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Decision point:

Storage or queue:

Flow of people, material, information, or money:

Process Measurement
cycle time: The average time between completion of successive products in a process.
flow time: The average time a product, task, or customer takes to move through the entire process (i.e., time-in-system).
Little’s law: WIP = Throughput Rate × Flow Time.
operation time: Setup Time + Run Time.
run time: The time required to actually make a product or do a task.
setup time: The time needed to prepare machines or other resources to make a product or do a task.
throughput rate: The output rate of a process.
work-in-process (WIP): Material or work that is in between the various steps in a process.
Process Types
batch: Moderate-volume, moderate-variety customized products or intermittent work processes, using moderately skilled workers and some flexible equipment (e.g., baking cookies and university education).
continuous flow: Very-high-volume, low-variety, highly standardized, nondiscrete-product, continuous (flow) processes; can be low to high skill; uses nonflexible (specialized) equipment (e.g., generating electricity
and refining petroleum).
job shop: Low-volume, high-variety highly customized products, using intermittent work processes, highly skilled workers, and flexible general-purpose equipment (e.g. auto servicing and hospital emergency room
service).
process selection: Strategic decision of selecting an appropriate process for making a product, depending on the product volume to be produced.
project: Very low volume (usually of one) and very high customization, using nonroutine, nonrepetitive activities (e.g., constructing buildings and building ships).
repetitive flow: High-volume, low-variety standardized discrete products or repetitive processes, with relatively low-skilled workers and less-flexible equipment (e.g., automobile and computer assembly lines).
Facility Layouts
cellular layout: Layout in which workstations are grouped into “cells” of workstations; cells process items or parts that require similar processing steps; has less work-in-process, reduced material handling or
movement through the production process, and faster setup times; referred to as a hybrid layout as it combines product and process layouts.
line balancing: Assigning tasks to workstations so that each workstation takes approximately the same time for work done, and the work is balanced across workstations, reducing workstation (resource) idle time and
cycle time.
process layout: For nonrepetitive processing or a discontinuous flow of products, equipment and tasks are arranged in groups of similar functions or departments where similar tasks are performed; work flows
between groups or departments as required for making the product (e.g., university campus of colleges and departments); a.k.a. functional layout.
product layout: For repetitive processing or a continuous flow of products, equipment and tasks arranged in a fixed sequence of workstations as needed for making the product; work flows progressively through the
sequence of work stations (e.g., production lines, assembly lines).
project layout: The product is in one position, and equipment and other resources are brought to the product; a.k.a. fixed-position layout.
service layout: Designed to maximize revenue, increase customer convenience and flow, or facilitate greater communication and teamwork in office layouts.
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