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Unit 5 - Operations Management
Unit 5 - Operations Management
Batch production:
Batch production involves producing items in identical groups. Small changes are made in each
batch so that a range of customers’ needs can be fulfilled.
● If a company is going to adopt a batch production system effectively, it must have a
range of similar products to meet different consumers' needs.
Advantages Disadvantages Possible examples
Flow/mass production:
● These two methods of production have some similarities. Both are capital intensive and
will produce on a large scale. Both should also enjoy significant economies of scale.
Mass production:
● Mass production is the highly automated assembly of a product.
● Likely to be capital intensive as it uses more machinery relative to workers. It involves
production lines where workers remain at a single station, performing the same task over
and over again, perhaps thousands of times a day.
Flow production:
● Flow production (also called process production) involves the continuous production of a
single product
● Flow production is likely to be even more capital intensive than mass production.
Workers may not be involved directly in the production process at all.
Advantages DIsadvantages Possible examples
Cellular production:
→ (Or cell production) is a form of lean production technique that involves teams of people
working on a certain section of the production process
● Each team (or cell) works on a significant part or complete unit of output within the
overall production process
● Cell production is an extension of flow production, but splits production into
self-contained units or items
● Team members are skilled at a number of different roles, hence avoiding the
monotonous nature of flow/mass production
5.3 Lean production and quality management
Lean production
: Producing goods and services with the minimum of wasted resources while mainitning high
quality
→ Minimum of wasted resources: Minimum quantity for factors of production available
● Lean production is a philosophy based on the idea that levels of waste can always be
reduced
● The overall objective of this production method is to produce quality output with fear
resources thas is waste reduction, greater efficiency and elimination of non-value added
activities
● Lean means cutting out anything in the production process that adds complexity, cost,
and time and does not add value to the customer
Less waste
● The seven main sources of waste in industry have been identified as: TIMWOOD
○ Transportation – moving components between work stations or from suppliers.
○ Inventory – building up excessive stocks, resulting in storage costs.
○ Motion – staff risking injury while making the product.
○ Waiting – delays in the production process.
○ Over-processing – adding features to a product that are not required by the
customer and therefore do not add value.
○ Over-production – producing an inventory of finished goods before they are
needed. This can lead to wastage in fast-moving markets.
○ Defects – finished goods that do not meet quality control standards.
Example:
Principal methods
→ continuous improvement
● It involves businesses holding regular, scheduled meetings where staff are invited to give
their opinions and suggest improvements.
● Not all ideas are taken forward, but at least some will be of value to the business
Advantages Disadvantages
A range of ideas are suggested, so the It may lead to lost production time as a result
company is more likely to make the ‘best’ of meetings and evaluation of ideas, possibly
decision. reducing productivity.
Employees may have a greater knowledge of Involving staff in improvements may result in
the problem than managers/directors who them demanding higher wages for increased
may traditionally make decisions. responsibility.
Just in Time
→ Just-in-time (JIT) production aims to minimise costs by reducing or even eliminating the stock
being held by a firm.
● JIT works on the principle of placing smaller, regular orders that are delivered just in time
for them to be used.
● Sophisticated IT systems allow new products to be ordered from suppliers the instant
they are scanned at the sales checkout.
● Firms liked to hold large quantities of stock 'just in case'
○ this system of inventory control proved expensive: It led to high storage costs and
potential waste if the good went out of date or was damaged in storage.
Advantages Disadvantages
It improves cash flow by reducing stock It carries high risks. Production may halt if a
holding small part of the supply chain breaks down.
Any delay in delivery becomes critical for
production.
It has positive benefits for stock-holding It restricts a firm’s ability to react to massive,
costs. With less warehouse space needed unexpected orders.
and less chance of waste and damage, costs
are reduced.
With less stock holding, there may be more It may not be suitable for businesses with
room available for production, which could seasonal demand (such as fireworks
increase capacity. manufacturers), where large inventories are
typically built up ready for short periods of
high demand.
Kanban
→ Kanban regulates the supply of components in a factory through the use of a card system.
● Kanban is a stock control system that uses signals or cards to ensure supplies arrive at
the production line just when they are needed.
● Similar aim to JIT, which is to reduce stocks.
● Kanban is based on the idea of internal customers: anyone in the organisation who
relies on the quality of your work.
Advantages Disadvantages
Lower levels of stock put pressure on staff to Mistakes are more likely to stop the entire
avoid waste. Mistakes are less likely and production line as replacement stock
quality will rise. components may not be available.
Less space is needed on the production line; Delays in deliveries or incorrect orders can
this space can be used for other more lead to production staff running out of
profitable uses. materials to work with.
Andon
→ A notification system that alerts workers to potential problems in the manufacturing process.
● Sensors are fitted to various parts of a production line, designed to measure things such
as broken components or malfunctioning machinery.
● If Andon detects a problem, the system either communicates it by displaying a warning
light or may even stop production altogether.
Advantages Disadvantages
Engineers can be directed straight to the Workers will need to be trained in using the
location of the problem so that it can be fixed system and fixing problems.
quickly.
Quality management
● A quality product meets or exceeds the needs of its target market.
● Quality is defined by the target market of a product
○ Decisions about quality need to reflect a firm’s customers.
→ Quality control:
● Quality control occurs at the end of the production process.
● Finished goods are inspected to assess whether they meet a set of agreed criteria.
● There are two approaches to carrying out quality control:
○ Inspectors check the quality of every finished good.
○ Inspectors check the quality of a sample of finished goods.
● The approach that is used will depend on the nature of the product: If the product is
extremely expensive or made to order, it makes sense to inspect every finished good
● This approach will not be possible for companies involved in mass production, producing
thousands of items every single day.
○ In such situations, inspectors are required to check just a sample of the finished
goods.
Advantages Disadvantages
Use of professional inspectors should Products are only checked at the end of
lead to fewer mistakes in the inspection the manufacturing process. This can allow
process. significant stocks of faulty products to
build up.
→ Quality assurance:
● Quality assurance systems attempt to overcome these problems by involving all staff in
the quality process.
● Emphasis is placed on staff checking their work, rather than on final inspection.
● When using a quality assurance system, a business considers quality in every
operation’s decision it makes.
○ Product design: if quality meets consumers needs
○ Production process: products not damaged during manufacturing
○ Component delivery: only reliable suppliers
○ Regular inspections: to ensure staff is trained
→ Quality improvement:
● If a firm adopts a quality improvement policy, it will see quality improvement as a
continuous process in which it is always possible to improve product quality.
● Three key areas:
- Total quality management
● Every employee is jointly responsible for maintaining the overall quality of the
final product.
● One of the aims of TQM is to operate with zero defects: it aims to prevent errors
from happening in the first place.
● staff are always encouraged to consider the needs of their internal customers.
This should encourage teamwork and greater levels of communication.
● TQM is a method of lean production.
- Quality circles
● A quality circle is a group of employees who meet regularly to discuss potential
improvements to product quality.
● Employees usually come from diverse areas of the company to allow a range of
different viewpoints to be considered.
- Benchmarking
● Benchmarking is the process of comparing yourself with the best and seeing
what you can learn from their techniques
● Two steps
1. Identify which companies have the best processes.
2. Work out how they do things and try to learn from those processes.
5.4 Location
● Deciding on the optimal location for a new business, or relocation for an existing one
● Most important decision
● Selecting the best sites will have a significant effect on many departments of the
business and the profitability of and chances of success of the firm
Quantitative factors
→ Measurable in financial terms and will have direct impact on either the costs of a site or the
revenues from it and its profitability
Labour costs
● The relative importance of this as a locational factor depends on whether the business is
capital or labour-intensive
● If production is labour intensive, it may make sense to move operations to a country that
has a low minimum wage
Transport cost
● Businesses that use heavy or bulky raw material such as steel making will have a high
transport if suppliers are at the great distance firn the steel plant
● Access to efficient transport networks allows customers to visit stores and suppliers to
deliver raw materials.
Market potential
● The level of sales made by a business can depend directly on location.
● In addition certain locations can add a status and image to a business and this may
allows value to be added to the production on the eyes of the consumers
Government grants
● Government grants across the world are very keen to attract new business to located in
their country
● Grants may be offered to add to act as an incentive
● Existing business operating in a country can also be provided with financial assistance to
retain existing jobs or attract new employment to deprived areas of high unemployment
Land costs
● Prime locations cost money
● A shop on a busy high street will pay considerably more in rent than one a few streets
back. If a firm does not need the benefits of an expensive location, it makes little sense
paying for one.
Investment appraisal
Break-even analysis
Qualitative factors
Are non-measurable factors that may influence business decisions. Cannot be measured in
financial terms
Outsourcing → To contact another business to undertake some or all of the additional work.
This is common to occur if a business receives orders that it cannot easily fulfil because of lack
of capacity.
Outsourcing evaluation
● Outsourcing will continue to increase as businesses continue to aim at operational
effectiveness and more opportunities. BUt there are always risks
● Before doing a business-process outsourcing
○ Cost benefit analysis: it would be time-consuming and expensive to reopen and
reestablish if the outsourcing failed
○ Identify the core activities that must be kept under the direct control of the
business
Offshoring → The relocation of a business process done in one country to the same or another
company in another country
Reasons for offshoring:
→ The driving and restraining forces of offshoring are similar to the ones of outsourcing.
Additionally we have the following:
● Low-cost countries offer substantial benefits → major reason
● Even though higher subcontractors in foregin countries implies a high cost, and
offshoring has high transport and communication costs. These ones are outweighed by
the potential profits → finance department
● Multinational consider offshoring to low-wage economies to maintain their
competitiveness - India, China, East Europe
● Subcontracting businesses are likely to easily higher unskilled or semi skilled workers in
developing countries
5.5 Production planning
Managing the supply chain, and stock (inventory levels) → Operations management
responsibilities
Advantages Disadvantages
Stocks of raw materials can be used to allow the There are high opportunity costs of working capital tied
firm to meet increases in demand by increasing up in stock
the rate of production quickly
Raw-material supply hold-ups will not lead to There are high storage costs
production stopping
Economies of scale from bulk discounts will There is a risk of goods being damaged or becoming
reduce average costs outdated
Stocks of finished goods can be displayed to ‘Getting it right first time’ → a key component of lean
customers and increase the chances of sales production → matters less than with JIT (just-in-case
stock management approach) as other supplies are kept
in stock to replace defective times
Stocks of finished goods can be used to meet Space used to store stock cannot be used for productive
sudden, unpredicted increases in demand → purposes
customers can be satisfied without delay
Stock Holdings
● Opportunity costs
● Storage control
● Risk of obsolescence
Formulas
Unit costs
● The average cost of making one unit of output
Productivity rate
● A measurement of the efficiency of resources used in the production process.
Productivity rate: Total output / Total input × 100 = _____ units of production
● Most common type is labour productivity
Labour productivity
● The average output per worker for a given time period (given in number of units of
output)
Labour productivity: Total output / Total number of workers = ____ units of production
● Therefore, the cost of staff wages will be split over a greater number of units of output,
thus reducing average cost.
Capacity utilisation
● The percentage of a firm’s total capacity that is currently being used
Capacity utilisation rate: Actual output / Productivity capacity × 100 = _____ %
● High capacity utilisation means that a firm is using its resources efficiently.
○ This should reduce average costs and hopefully increase profits.
Cost to buy
● The total cost of subcontracting production to a supplier
● This calculation will allow the company to calculate the total cost of outsourcing
production
Cost to make
● The total cost of production if manufacturing is kept in-house
Cost to make: Fixed costs + (Variable costs × Quantity) = $______
● In this context, fixed costs can be thought of as the overheads of running and
maintaining a factory.
○ This will include costs such as electricity or the wages of production staff.
● Variable costs are the direct costs of producing one product.
Make or buy?
Potential reasons to make Potential reasons to buy
Control over the production process and Specialist suppliers are likely to have
quality management is maintained. economies of scale, leading to lower average
costs.
Working conditions can be monitored and The company does not need to invest in
controlled production facilities,
Factors that stop companies turning high R&D budgets into successful products
1. Legal constraints
2. Human resources
● New products are invented by people (not machines/bank accounts)
● If companies don’t have the right mix of people working in their R&D departments → no
amount of budget will lead to success
3. Past experience and culture
● Culture is an effort that describes internal workings of a company
○ Some cultures may breed innovation more than others
● Companies that can instil a culture of teamwork and creativity are more likely to produce
innovative products
4. The level of competition
● Competitor’s R&D may result in them creating more new products
5. Market demand
Innovative creativity
● The process of creating something completely new
● Products developed are unique and usually create new markets for themselves
● Innovative creativity is risky
○ New markets it develops are untested so there is no way to know if it will be
popular
■ This unknown element is enough for companies to stop investing scarce
R&D funds into this area
Adaptive creativity
● Is changing or improving something that already exists
○ Everytime an updated laptop is released → example of adaptive creativity
● Is less costly and carries less risk than innovative creativity as companies are building on
what has gone before
● Adaptive creativity can be extremely profitable: new products are launched into mature
or growing markets with large customer bases
Innovation:
● Creativity is the conception of a new idea, while innovation is the commercial use of that
idea.
● Can be grouped into four different areas:
1. Product innovation:
● Process of developing and improving existing products.
● Examples: Apple Watch or hybrid cars such as the Toyota Prius.
2. Positioning innovation:
● when a product is marketed to a new target audience
3. Process innovation:
● Can be defined as developing new methods of production or product delivery.
● If successful, it will allow the company to deliver customers' orders within an
hour of them being placed, an extremely valuable unique selling point.
● Example: Amazon investing millions of dollars in developing the new drone
distribution service.
4. Paradigm innovation:
Contingency plan
● Outlines the immediate actions a company should take in the event of a crisis.
● It's all about askin what if?
● A firm is likely to have many contingency plans to know what to do, where to go, and
where to seek help if needed.
○ Ex:
■ theatre companies → understudies in case lead actors fall ills.
■ Schools practise drills so that students know what to do in the event of an
emergency such as a fire.
■ Governments even prepare national contingency plans that may be
needed in the case of a national crisis.
Advantages Disadvantages
Crisis management
● Concerns the steps a company can take to limit the damage caused by an unpredicted
event or change
● Aim → to return to normal operations businesses as quickly as possible → use a
contingency plan that was prepared in case the crisis arose
● Crisis management depends on:
1. Communication
● Effective communication with external and internal stakeholders is essential with
crisis
● Internal one-way communication with employees ensures understanding the
problem, the plan and their responsabilites
● Two-way communication can also be necessary → listentning to worker’s
perspectives help managers fully understand problems, find potential solutions
and increase motivation levels
● External communication: keeping an ongoing dialogue with suppliers +
customers + public = goodwill at the time it is needed the most
● Deciding not to communicate is risky because it may damage trust beyond repair
if it is subsequently discovered that there was a cover up
2. Transparency
● May be the best option at time crisis
● In disasters, people tend to be sympathetic and give the benefit of the doubt;
however if hidden information is discovered → sympathy will be gone
3. Speed
● The goal of crisis managemtn is to return to normal operation as rapid as
possible
● Rapid decision making and effective implementation of those decisions will help
achieving the goal
4. Control of situation
● A crisis is one of the few circumstances where an autocratic leader might be the most
effective
○ They make quick decisions and ensure that actions are carried out → lead to
effective response
● People may be motivated by a strong decisive leadership