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- Herausgeber: John Wiley & Sons
- Kategorie: Fachliteratur
- Sprache: Englisch
This book is a novel treatment of Operations Management. It takes a fresh insight to this increasingly important topic, exploring fundamental principles equally applicable to service and manufacturing situations. The book adapts a strategic stance by providing a framework for effective decision making and is aimed at practising managers who need to design working processes, manage change and make decisions within a strategic framework. The framework and supporting case vignettes allow the practitioner to grasp essential concepts quickly in a range of different operational contexts.
"Bamford and Forrester have done an excellent job in creating a concise, salient, and appealing approach - they have captured the essential elements of designing processes, products and work organizations; exploring approaches to operations planning and control; managing change through effective project management and technology transfer; and then managing quality and improvement strategies".
—Professor Rob Handfield, Professor of Supply Chain Management, North Carolina State University, USA
"This is an excellent concise text that introduces students to all of the key areas - it's an invaluable aid for students in understanding all of the major aspects of operations and their importance to the success of businesses".
—Professor Steve Brown, Professor of Management, University of Exeter Business School, University of Exeter, UK
"For today's or tomorrow's business leaders this text has well structured invaluable content ready for immediate adoption. Follow the guide, put it into practice, and the rewards will follow".
—Mr Vernon Barker, Managing Director, First TransPennine Express, First Group Plc, UK
"This book combines technical theory 'book smarts' with real life experience 'street smarts' in a flowing read".
—Mr Stephen Oliver, Vice President Marketing & Sales, Vicor Corporation, Boston, USA
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Veröffentlichungsjahr: 2010
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Table of Contents
Cover
Contents
Title Page
Copyright
1: Operations Management in Context
Introduction
Basic principles of operations systems performance
The scope of operations management
The evolution of operations management
Summary
Further reading
Useful internet sites
Useful academic journal articles
2: Designing Business Processes
Introduction
Capacity management
Aggregate planning
Three ways of reconciling capacity and demand
Location choices
Classification and features of operations systems
Job systems
Batch systems
Flow systems
Other types of operations systems
Facilities layout
Basic layout types
The system design process
Contemporary forms of process designs
Group technology and cellular manufacturing
Autonomous group working
Differences between service and manufacturing business process design
Process mapping
Summary
Further reading
Useful internet sites
Useful academic journal articles
3: Designing Products and Services
Introduction
New products
Managing the design process
Quality function deployment
‘Simultaneous’ or ‘Concurrent’ design
Design for operations
Product redesign and value analysis
Familiarization
Speculation
Evaluation
Recommendation
Implementation
Product liability
Summary
Further reading
Useful internet sites
Useful academic journal articles
4: The Transfer of Technology
Introduction
Vertical and horizontal transfer
The components of technology transfer
Technology transfer contexts
Theories of technology transfer
Contemporary theory
Dimensions of technology transfer
Elements in the transfer process
The (many) mechanisms of technology transfer
Summary
Further reading
Useful internet sites
Useful academic journal articles
5: Controlling Enterprise Resources
Introduction
Section 1 – operations planning and control
Control theory
Capacity management
Aggregate planning
Forecasting demand
Scheduling
Optimized production technology (OPT)
Section 2 – inventory and materials management
Purchasing and inventory management
Stock control parameters
Demand (A)
Ordering costs (Co)
Storage costs (iCm)
Service levels
Reorder level policy
Reorder cycle policy
Statistical inventory control in practice
Materials requirements planning (MRP)
The Master Production Schedule (MPS)
The Bill of Material (BOM)
The Inventory Status File
The MRP algorithm
Operation of an MRP system
MRP in practice
Manufacturing Resources Planning (MRPII)
Summary
Further reading
Useful internet sites
Useful academic journal articles
6: Developing Lean Operations
Introduction
What is ‘lean’
‘Push’ versus ‘pull’ logistics
The JIT concept
Internal JIT systems
JIT supply
Continuous improvement and quality
Implementing JIT
Supply Chain Management
Lean and the MIT research project
Running the operations
Lean design
Lean supply management
Dealing with customers in lean operations
Agile manufacturing
Summary
Further reading
Useful internet sites
Useful academic journal articles
7: Managing Projects
Introduction
Project planning
Project scheduling
Program Evaluation and Review Technique (PERT)
Project control
Organizational issues in project management
Responsibilities of the project manager
Summary
Further reading
Useful internet sites
Useful academic journal articles
8: Managing Operations Strategically
Introduction
What is strategy?
The role of strategy in operations management
Hayes and Wheelwright
Structured approaches to formulating manufacturing strategy
Hill’s framework for analysing manufacturing strategy
The DTI/Cambridge group methodology
Strategy and the product life cycle
Achieving a strategic edge in operations
Summary
Further reading
Useful internet sites
Useful academic journal articles
9: Managing Quality Systems
Introduction
Definitions of quality
Quality systems
International quality standards
The responsibility and organization for quality
Supplier/customer relationship
Measuring quality
Statistical Process Control (SPC)
Acceptance sampling
Summary
Further reading
Useful internet sites
Useful academic journal articles
10: Improving the Operations
Introduction
Writers on quality management
Summarizing the writers on quality
Programmes for quality improvement
Criticisms of quality improvement programmes
Quality award schemes
Summary
Further reading
Useful internet sites
Useful academic journal articles
11: Making It All Work!
Introduction
Making it all work
Summary
Selected References
Index
List of Illustrations
1: Operations Management in Context
Figure 1.1 Five key performance indicators (KPIs)
Figure 1.2 Volume, variety, variation and visibility (the four Vs)
Figure 1.3 The process life cycle
Figure 1.4 The levels of operations management decision making (Bennett and Forrester, 1993)
Figure 1.5 The evolution of operations management as a subject and practice
2: Designing Business Processes
Figure 2.1 Basic capacity plans
Figure 2.2 Categorization of production systems design
Figure 2.3 Volume and production systems design
Figure 2.4 Features of conventional systems
3: Designing Products and Services
Figure 3.1 A product life cycle
Figure 3.2 The product design process
Figure 3.3 Quality function deployment – the ‘house of quality’
4: The Transfer of Technology
Figure 4.1 Vertical and horizontal transfer of technology
Figure 4.2 International technology transfer channels
Figure 4.3 Formal agreements for technology transfer
Figure 4.4 The technology transfer process
Figure 4.5 Technology choice
5: Controlling Enterprise Resources
Figure 5.1 An ‘open’ system – no control
Figure 5.2 A ‘closed-loop’ system – in control
Figure 5.3 Economic order quantity (EOQ)
Figure 5.4 Stock control using a reorder level policy
Figure 5.5 Stock control using a reorder cycle policy
Figure 5.6 Comparison of ROL versus ROC
Figure 5.7 Relationship between MRP modules
Figure 5.8 The MRP calculation process
6: Developing Lean Operations
Figure 6.1 The JIT pond analogy (adapted from Singo, 1996)
7: Managing Projects
Figure 7.1 Simplistic Gantt chart
Figure 7.2 Activity on arrow information
Figure 7.3 Activity on arrow critical path
Figure 7.4 Beta distribution for PERT
Figure 7.5 The performance triangle – performance objectives and ‘trade-offs’
8: Managing Operations Strategically
Figure 8.1 Framework for analysing production/operations strategy (adapted from Hill, 2005)
Figure 8.2 DTI/Cambridge group methodology for the development of manufacturing strategy
Figure 8.3 The product life cycle
Figure 8.4 Performance objectives polar diagram
9: Managing Quality Systems
Figure 9.1 Overview of a basic quality system
Figure 9.2 Normal distribution
Figure 9.3 Different shape bell curves
Figure 9.4 X-Bar chart
Figure 9.5 R chart
10: Improving the Operations
Figure 10.1 Quality costing behaviour
Figure 10.2 Optimal quality costs
Figure 10.3 Six sigma (6σ) process capability
Figure 10.4 EFQM excellence model
11: Making It All Work!
Figure 11.1 Continual contribution of operations
List of Tables
2: Designing Business Processes
Table 2.1 Some capacity measures
9: Managing Quality Systems
Table 9.1 Why are range charts useful?
Guide
Cover
Contents
Start Reading
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‘This book combines technical theory ‘book smarts’ with real life experience ‘street smarts’ in a flowing read. The kind of book you can easily read cover-to-cover or dip into occasionally as a quick reference. It is applicable for all levels and functions within a company. At a high level, it enables an appreciation of the tasks and responsibilities of peers. At a detailed level, it provides practical examples to copy or to adapt into local work flows and processes to bring immediate benefits in understanding, process efficiency and subsequent increased margins.’
Mr Stephen Oliver, Vice President Marketing & SalesVicor Corporation, Boston, USA
‘Bamford and Forrester have done an excellent job in creating a concise, salient, and appealing approach to explain the basics of Operations Management to students who desire a primer on the subject. They have captured the essential elements of designing processes, products and work organizations; exploring approaches to operations planning and control; managing change through effective project management and technology transfer; and then managing quality and improvement strategies.’
Professor Rob Handfield, PhD, Bank of America University Distinguished Professor of Supply Chain Management, Consulting Editor, Journal of Operations ManagementDepartment of Business Management, College of Management, North Carolina State University, USA
‘This is an excellent concise text that introduces students to all of the key areas of operations management. It should be an invaluable aid for students in understanding all of the major aspects of operations and their importance to the success of businesses.’
Professor Steve Brown, Professor of Management, Head of the Department of ManagementUniversity of Exeter Business School, University of Exeter, UK
‘For today’s or tomorrow’s business leaders the Essential Guide to operations management is just that; arriving with well structured invaluable content ready for immediate adoption. Follow the guide, put it into practice and the rewards will follow.’
Mr Vernon Barker, Managing DirectorFirst TransPennine Express, First Group Plc, UK
‘A practical and easy to read introductory guide to operations management in which the reader benefits from the treatment of both service and manufacturing related scenarios.’
Dr Mike Niblett, Programmes and Accreditation ManagerThe Manufacturing Institute, UK
ESSENTIAL GUIDE TO OPERATIONS MANAGEMENT
Concepts and Case Notes
David R. Bamford
Paul L. Forrester
© 2010 John Wiley & Sons, Ltd
Registered office
John Wiley & Sons Ltd, The Atrium, Southern Gate, Chichester, West Sussex, PO19 8SQ, United Kingdom
For details of our global editorial offices, for customer services and for information about how to apply for permission to reuse the copyright material in this book please see our website at www.wiley.com.
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Library of Congress Cataloging-in-Publication Data
Bamford, David R.
Essential guide to operations management : concepts and case notes / by David R Bamford & Paul L Forrester.
p. cm.
Includes bibliographical references.
ISBN 978-0-470-74949-4
1. Production management. I. Forrester, Paul L., 1961- II. Title.
TS155.B2476 2009
658.5-dc22
2009037049
978-0-470-74949-4
A catalogue record for this book is available from the British Library.
1OPERATIONS MANAGEMENT IN CONTEXT
Introduction
The aim of any service, public sector or retail or industrial operation is to deliver goods and services of the quality, quantity, cost and availability that will satisfy the customers’ needs while at the same time making most effective use of resources. This can only be achieved by giving attention to the design of products, processes and work for employees, and through competent planning and control. This is what Operations Management is about. This book presents the fundamental principles of operations management in a novel and structured way that is appropriate to the needs of contemporary Operations Managers, and students in this field.
Operations management covers decision making in the organization, from top level management issues such as developing an operations strategy congruent with the company’s business and marketing strategies, to the immediate control of operations. It is, therefore, more than operational management. Each chapter develops an understanding of the theory and practice of key operational concepts to enable delivery of the strategy.
The book is structured in a unique manner, to better reflect the concerns of the contemporary Operations Manager in the twenty-first century. The book is based around the conceptual model of operations management.
The model centres upon the idea that operations management comprises three essential components:
Design of operations
processes, products and services, and the work of individuals;
Planning and control
of operations once designs are in place and operational; and
Ensuring
quality
of products and services produced and delivered, and (wherever possible) improving on these.
However these cannot be addressed in isolation. The essential element in effective operations management is the integration of these components. The book therefore contains three integrating chapters:
We need to understand
operations management in context.
What is its purpose in a business sense? And how and where does it relate to the other business functions.
How might we
manage operations strategically
? Design, planning and control activities must not be conducted totally independently of one another, so we need the means to coordinate our activities within a formulated operations strategy. We believe that operations strategy is best covered not at the start or end of the text (as you find in most other operations management books), but in the middle, after the principles of design and operations planning and control are well understood.
We need to consider the implementation of the principles contained in this book, so we need to look at
making it all work
in the final chapter. Implementation is identified by practitioners as the most critical activity, but is often overlooked or skimmed over in texts, so we address this head-on in this book.
The conceptual model offers a comprehensive and up-to-date view of the operations management function and it can be seen that we have integrated contemporary topics such as technology transfer, project management and lean operations (often discussed and also critical in business, but often overlooked in any depth within existing texts). But, before embarking on these topics, it is important that we fully grasp and comprehend what the practice of operations management comprises, and also where it has evolved from in an historical and theoretical context.
Basic principles of operations systems performance
The task of the operations manager can be summarized at a basic level as converting a range of resource inputs, through the operations process, into a range of outputs in the form of products. However, the various elements that together make up this management function are diverse and complex in nature. The operations manager must have competencies in human resource management, strategic awareness, product knowledge, systems and organizational design and, at the operating level, of planning and control. Moreover, the task of the operations manager is often misunderstood and is often relegated to a reactive rather than a positive and proactive role within the organization. To indicate the importance of the operations function to the business it is useful to identify five key performance indicators for any operations system. These are quality, speed, dependability, flexibility and cost, where:
Quality
reflects the extent to which operations are performed in line with specifications and/or satisfy the customer (i.e.
getting things right);
Speed
reflects how quickly and responsively we supply and deliver our products and services (i.e.
doing things quickly);
Dependability
indicates our reliability to the customer or recipient of the product or service (i.e.
doing things consistently and on time);
Flexibility
reflects our ability to adapt and respond to differing needs (i.e.
being able to change what we do);
and
Cost
reflects the expense we have incurred in a financial sense to deliver the product and/or service to the recipient (i.e.
doing things cheaply).
Figure 1.1 Five key performance indicators (KPIs)
In a simplistic sense, and in the ‘ideal world’, we might argue that an operation should seek to optimize all five of these performance objectives. If an operation delivers the best quality, in the fastest time, more reliably, in the most flexible way and at cheapest cost, it is inevitable that this operation would perform better and therefore more effectively than its competitors. However this is a panacea. As Hill (1993) originally, and others have since argued, operations management comprises a set of ‘trade-off’ decisions, whereby a decision to improve performance for one indicator often (though not always necessarily) results in a negative effect on another. Most obvious in this respect is cost. Often decisions to reduce cost can impact upon quality, speed, reliability and flexibility if improperly thought through. This book will, later, indicate where costs and other indicators might be simultaneously improved, but we need to recognize there are often constraints on what we might be able to achieve. And this indicates the second important factor of operations management: it is about managing constrained resources (human, physical and financial) which places limitations upon what we can achieve.
In the same way as the performance objectives above in Figure 1.1 can be used to compare and contrast different operations systems, so can the ‘four Vs’. Let’s investigate each of these individually, starting with volume. Figure 1.2 shows low volume on the left-side of the continuum and high volume on the right. Operations systems producing low volumes of products and services invariably result in: low repetition of tasks; operations performing a large proportion of the job (and perhaps the complete set of activities); less systemization; high unit costs. The opposite applies to high volume operations: greater repetition, a greater division of work, greater systemization and lower unit costs through economies of scale. The other three Vs run counter to volume, with ‘high’ on the left-side and ‘low’ on the right. This reflects the tendency for low volume operations systems to have high variety, high variation and frequently higher visibility. So high variety operations, those that produce a wide range of products and services, offer flexibility, are able to cope with and match customer needs and tend towards higher unit costs. Low variety operations, producing more standard products and services, have the opposite features. Variation reflects ability of the operations systems to flex and change, usually in response to the nature of demand (frequent and rapid changes on the left-side, very stable, unchanging demand on the right. High variation operations systems feature the ability to change capacity of output, anticipation, flexibility response and generally high unit costs. Finally visibility reflects the extent to which operations facilities and workers are physically seen or capable of being monitored by customers and clients, or whether they are out of sight and contact (back office type operations). High visibility operations feature short waiting tolerance, the need for customer contact skills, variety and responsiveness in service, and high unit cost.
Figure 1.2 Volume, variety, variation and visibility (the four Vs)
It has already been noted that the four Vs are arranged in Figure 1.2 so that volume has low on the left and a high on the right, whilst the others run opposite. This is for a reason. The features of operations systems occupying positions near the left-side of the continuum feature flexibility as a major concern: the ability to be flexible, to provide a flexible service. Whilst the right-side concurs with repeatability: the ability to economically produce products and services in high volume and at a relatively low unit cost. An example at this point serves to illustrate this.
Example 1
You have decided to take a vacation at an Island Resort. You wish to treat your nearest and dearest to a nice break in paradise; you want to be accommodated in a small house on stilts over the ocean. It’s an oasis where people come out to you in little motor boats and cook meals for your family, then slip away to leave you in peace. You don’t see anybody else. For this Island Resort volume would be relatively low, given our definitions above. The variety would be high. You expect them to provide a range of facilities. If you want to Jet Ski, they would be able to provide a JetSki. If you want to go Scuba Dive on the coral reef, they would be able to arrange this, plus transportation and any necessary instruction. The cost to you might be high, but the Resort can supply this. Variation is potentially high for the Island Resort because of the unpredictability and needs for varied control systems for the services. Finally, visibility is high. You want to see a chef wearing the necessary outfit and hat preparing and cooking for them on a ‘desert’ island. You are likely to have a short waiting tolerance: if you are paying considerable amounts of money you want and expect efficient service now. The Island Resort, therefore, needs to design and plan their operations with the needs of its customers in mind. The Resort needs excellently designed and constructed accommodation and administrative buildings; staff with good customer contact skills; there is a need to recruit flexible employees who seem genuinely pleased to meet and greet customers and efficiently respond to their every need. All this comes at a high cost, but the customer is willing to pay for this.
Now contrast the Island Resort with a chain of Express Hotels, serving the needs of people who are on business or touring, and need to stay just one night, usually for about 8 hours. The Express Hotel needs to have a bed, a television, tea and coffee making facilities, and sometimes a telephone, not often though because we all have mobile phones. As a customer you need to be able to check-in and check-out quickly, and know that the room meets a standard quality. You don’t care whether you see a member of staff or not. You just want to get into your room for the night, pay your bill and leave. You probably do not even want breakfast because you will take ‘breakfast to go’ with a coffee when on your way to your next destination. So, in contrast to the Island Resort, volume is high, because theHotel and customer alike require fast throughput and high repeatability. They are geared to a high volume of customers with very similar needs, and only willing to pay budget prices. Variety is low. Most of the Express Hotel chain’s rooms look and feel identical. Variation is low because you, as the customer, are not expecting any differences. There is a stable routine, predictable operations and high utilization. Most of these hotels are located adjacent to major highway intersections so they are convenient and easy to get to. Visibility is low. Ideally you do not want to see anybody. After a long day’s work or journey you are in no mood to talk to anybody and just want to soak in the bath or take a shower, then get a good night’s sleep and depart.
To summarize, the four Vs are used within organizations to assess their operations. Organizations can profile customer needs across the four continuums, compare this to their existing facilities (where the operations are currently placed in terms of product or service delivery) and can also develop profiles for direct competitors. Such profiling enables gap analyses where, for example, one can identify any problematic differences between customer needs and actual delivery from our operations system, as well as benchmarking against competitors.
The scope of operations management
Operations management relates to that function of an organization concerned with the design, planning and control of resources for the production of goods or provision of services. As a discipline it is not merely confined to a collection of techniques and quantitative methods. It makes appropriate use of the tools of operational research and statistics where relevant, but is primarily concerned with the broader issues involved in the design, planning and control of products, services and processes.
There are a number of ways of conceptualizing the scope of operations management, some of which are suggested below:
By considering the components of an operations system: Utterbeck and Abernathy’s (1975) model of innovation suggests that any productive unit should be considered as comprising three main elements: product, process and work organization. It is useful to consider the operations manager as having responsibilities in all three of these areas.
By considering the life cycle for products: The operations management function is concerned with, and should have an input to, all stages in a product’s life cycle. The product life cycle of introduction, growth, maturity and decline can be equated to a process life cycle, as illustrated in Figure 1.3. The responsibilities of the operations manager, therefore, should not be merely confined to the production stage, but to all stages of the product and process life cycle.
By considering the organizational scope of operations management: ‘Operations management’ should not be confused with the term ‘operational management’. The management of operations permeates all levels of organizational decision making and is not merely confined to less important, low level and short term decisions. The operations manager should, in turn, enter more widespread strategic debates in addition to maintaining contact with day-to-day operations. Thus the scope for operations management in decision making covers operational management right through to strategic management (see Figure 1.4).
Figure 1.3 The process life cycle
The conceptual model employed in this book identifies and distinguishes ‘design’ activities from operations ‘planning and control’ and ‘quality’. Design, covered in Chapters 2, 3 and 4, involves:
Business process design:
The organization and arrangement of physical facilities, information and material flows, and labour resources to enable the conversion of inputs (materials, orders, labour, etc.) into outputs (goods and services).
Figure 1.4
