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and
Leadership
Operations Management
Cost
If an organization is competing on price
then it is essential that it keeps its cost
base lower than the competition
Business
Strategy
Functional
Functional Area
Area
Strategies
2-
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Strategies for Competitive Advantage
Differentiation
Cost leadership
Quick response
2-
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Competing on Differentiation
Uniqueness can go beyond both the
physical characteristics and service
attributes to encompass everything that
impacts customer’s perception of value
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Competing on Response
Flexibility
Reliability
Timeliness
Requires institutionalization within the firm
of the ability to respond
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OM’s Contribution to Strategy
Operations Specific Competitive
Decisions Examples Strategy Used Advantage
Quality FLEXIBILITY
Sony’s constant innovation of new products Design
Product HP’s ability to follow the printer market Volume
Location DELIVERY
Pizza Hut’s five-minute guarantee at lunchtime Speed
Layout Federal Express’s “absolutely, positively on time”
Dependability Differentiation
(Better)
Human Resource
QUALITY
Motorola’s automotive products ignition systems
Conformance Response
Supply Chain Cost (Faster)
Motorola’s pagers Performance leadership
(Cheaper)
Inventory
IBM’s after-sale service on mainframe computers
AFTER-SALE SERVICE
Scheduling
Fidelity Security’s broad line of mutual funds
BROAD PRODUCT LINE
Maintenance
Performance Durability
Features Serviceability
Reliability Aesthetics
Conformance Perceived quality
Value
Internal Failure
Prevention
Appraisal
Quality Improvement
Table 6.1
12/10/2018 Compiled by: Matiwos Ensermu, PhD 59
Deming’s Fourteen Points
8. Drive out fear
9. Break down barriers between departments
10. Stop haranguing (to criticize or question
somebody )workers
11. Support, help, improve
12. Remove barriers to pride in work
13. Institute a vigorous program of education and
self-improvement
14. Put everybody in the company to work on the
transformation
Table 6.1
12/10/2018 Compiled by: Matiwos Ensermu, PhD 60
Seven Concepts of TQM
Continuous improvement
Six Sigma
Employee empowerment
Benchmarking
Just-in-time (JIT)
Taguchi concepts
Knowledge of TQM tools
1.Plan
4. Act Identify the
Implement the improvement and make
plan a plan
3. Check 2. Do
Is the plan Test the
working? plan
Figure 6.3
Statistical
2,700 defects/million
definition of a process that is
99.9997% capable, 3.4 defects per
3.4 defects/million
million opportunities (DPMO)
A program designed to reduce defects,
lower costs, and improve customer
satisfaction Mean
±3
±6
Figure 6.4
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Compiled by: Matiwos Ensermu, PhD 66
Six Sigma
1. Define critical outputs
and identify gaps for DMAIC Approach
improvement
2. Measure the work and
collect process data
3. Analyze the data
4. Improve the process
5. Control the new process to
make sure new performance is
maintained
12/10/2018 Compiled by: Matiwos Ensermu, PhD 67
Six Sigma Implementation
Emphasize defects per million opportunities
as a standard metric
Provide extensive training
Focus on corporate sponsor support
(Champions)
Create qualified process improvement
experts (Black Belts, Green Belts, etc.)
Set stretch objectives
This cannot be accomplished without a major commitment from
top level management
Techniques
Build communication networks
that include employees
Develop open, supportive supervisors
Move responsibility to employees
Build a high-morale organization
Create formal team structures
Table 6.3
12/10/2018 Compiled by: Matiwos Ensermu, PhD 72
Best Practices for Resolving
Customer Complaints
Make it easy for clients to complain
Respond quickly to complaints
Resolve complaints on first contact
Use computers to manage complaints
Recruit the best for customer service
jobs
Work in process
inventory level
(hides problems)
Unreliable Capacity
Vendors Scrap Imbalances
Unreliable Capacity
Vendors Scrap Imbalances
Hour
Defect 1 2 3 4 5 6 7 8
A /// / / / / /// /
B // / / / // ///
C / // // ////
Figure 6.6
12/10/2018 Compiled by: Matiwos Ensermu, PhD 83
Check Sheets
A straightforward quality control tool often used to collect
data for fact-finding and solving quality problems, e.g.to
count the number of defects against known causes
Month: May 20xx Steel Stationery Cabinet: Customer Returns
Region Defect Category TOTAL
Scratches Dents Paint Finish Colour Other
A IIII III II 10
E IIII II II I 10
TOTAL 36 21 4 11 3 75
The data is often used to construct histograms (bar charts) & Pareto
diagrams 12/10/2018 Compiled by: Matiwos Ensermu, PhD 84
Seven Tools of TQM
(b) Scatter Diagram: A graph of the value of one variable
vs. another variable
Productivity
Absenteeism
Figure 6.6
12/10/2018 Compiled by: Matiwos Ensermu, PhD 85
Scatter Diagrams
Used to establish if there is a correlation between two
variables, i.e. the direction & degree of relationship
between these two variables
A correlation may assist in pinpointing the source of a
quality problem
V V V
A A A
R R R
I I I
A A A
B B B
L L L
E E E
Y Y Y
VARIABLE X VARIABLE X VARIABLE X
Positive Correlation Negative Correlation No Correlation
Cause
Materials Methods
Effect
Manpower Machinery
Figure 6.6
12/10/2018 Compiled by: Matiwos Ensermu, PhD 87
Cause-and-Effect (Fishbone) Diagrams
Developed by Ishikawa – as a structured way in improvement
programmes of finding the source causes of problems
Materials Methods
CAUSE CAUSE
12/10/2018 Compiled by: Matiwos Ensermu, PhD 88
Cause-and-Effect Diagrams
Material Method
(ball) (shooting process)
Grain/Feel Aiming point
(grip)
Size of ball
Air pressure Bend knees
Hand position
Balance
Lopsidedness
Follow-through
Missed
Training
free-throws
Rim size
Machine
Manpower
(hoop & Figure 6.7
(shooter)
backboard)
12/10/2018 Compiled by: Matiwos Ensermu, PhD 89
Seven Tools of TQM
(d) Pareto Chart: A graph to identify and plot problems or defects
in descending order of frequency
Frequency
Percent
A B C D E
Figure 6.6
12/10/2018 Compiled by: Matiwos Ensermu, PhD 90
Pareto Charts
Data for October
– 100
70 – – 93
– 88
60 –
54
Frequency (number)
– 72
50 –
Cumulative percent
40 –
Number of
30 –
occurrences
20 –
12
10 –
4 3 2
0 –
Room svc Check-in Pool hours Minibar Misc.
72% 16% 5% 4% 3%
Causes and percent of the total
Figure 6.6
12/10/2018 Compiled by: Matiwos Ensermu, PhD 93
Flow Charts
MRI Flowchart
1. Physician schedules MRI 7. If unsatisfactory, repeat
2. Patient taken to MRI 8. Patient taken back to room
3. Patient signs in 9. MRI read by radiologist
4. Patient is prepped 10. MRI report transferred to
5. Technician carries out MRI physician
6. Technician inspects film 11. Patient and physician discuss
8
80%
1 2 3 4 5 6 7 11
9 10
20%
Feasible Conforms
Evaluate Produce Evaluate Submit to
Start End
request sample sample Customer
Distribution
Frequency
40
35
30
Number 25
20
of
15
defects 10
5
0
Scratches Dents Paint Colour Other
Finish Variation
12/10/2018 Compiled by: Matiwos Ensermu, PhD 97
Seven Tools of TQM
(g) Statistical Process Control Chart: A chart with time on the
horizontal axis to plot values of a statistic
Target value
Time
Figure 6.6
12/10/2018 Compiled by: Matiwos Ensermu, PhD 98
Run Charts…
Simple line charts where performance data (vertical axis) is
plotted over time (horizontal axis). e.g. the number of patients
visiting a clinic every day for a particular month
0% | | | | | | | | |
Lower control limit
1 2 3 4 5 6 7 8 9
Game number
Figure 6.8
Customer Complaints
Complaints from external & internal customers are a very
valuable way to pinpoint improvements
Control Charts
Process Capability
Sampling
X X
X X range of
Mean X
normal
X variation
X
mean
12/10/2018 Compiled by: Matiwos Ensermu, PhD 105
Variation
Sampling
Used because a 100% inspection system is generally impractical or
impossible due to cost, time delays or destructive testing. Two options:
1. Sampling for quality control (qc) during production of the good
or service
2. Acceptance Sampling: a technique to determine whether to
accept or reject an entire batch after inspecting / testing a
sample
Table 6.5
Table 6.5
Table 6.5
Table 6.5
Table 6.5
Reliability Credibility
Responsiveness Security
Competence Understanding/
Access knowing the
customer
Courtesy
Tangibles
Communication
Supply Chain
Management
Manufacturer
4 INTEGRATED LOGISTICS
5
Mother Earth SUPPLY CHAIN / SUPPLY NETWORK MANAGEMENT End User
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Supply Chain Management…
…is the management of the acquisition, transformation and delivery
processes that enable and direct the flows of products & services – as
well as the supporting reciprocal flows of information & funds – along a
chain leading from the sources of the original inputs up to the end
customers, all aimed at achieving the best possible customer service at
the lowest possible cost.
Fundamentals:
A supply chain is a dynamic concept that involves the constant flow
of resources (products, information, funds) amongst all the
participants along the chain
It is essentially a system of interconnecting chains i.e. a supply
network or a supply web
PURCHASING
OPERATIONS
LOGISTICS
(& INVENTORY)
(Warehousing &
CONTROL
Transportation)
DEMAND
PLANNING
2. Information Flows:
The bi-directional flows of information throughout the chain –
particularly on customer demand which “pulls” the supply chain, but
also on supply conditions & eventual disruptions
3. Funds Flows:
The flows of funds, mainly upstream (payments for goods
& services received) but also in some cases downstream
Funds Flow
Information Flow
E&T Flow
Orange Fruit
farm packing
Food Retail
Mother Earth processor
Distributor outlet
…embraces
& builds upon
TQM and JIT
1. Globalization:
Globalization has increased competition and
changed the way organizations do business,
making supply chains longer & more complex
2. Outsourcing:
Outsourcing is obtaining a product previously produced
internally from an external supplier – it is occurring more
frequently, especially global outsourcing
3. Location:
The choice of location becomes even more complex when taken
from the perspective of the supply chain
5. Time-based Competition:
Organizations and supply chains compete in reducing delivery
lead-times and increasing the speed to produce new products
6. E-business:
A relatively new concept that has developed due to the risks of supply
globalization, single sourcing, outsourcing, lean systems, distribution,
etc.; it is intended to help identify the risks, protect from the
consequences of these risks and minimize any loss
2. Cross-docking:
SCM
Supplier Supplier Supplier
Brilliant & simple
concept developed by
Wal-Mart
Substantially reduces
inventory costs & lead-
times, improving
customer service
Requires sophisticated
systems to be well-
managed
SCM
3. The Bullwhip Effect:
SCM
5. Procter & Gamble’s Perfect Order System:
On-time Delivery
Shipped complete
Invoiced correctly
With no damage in transit
Purchases = $ 12,000,000
Salaries & Wages = $ 6,000,000
Overheads etc. = $ 1,000,000
Several options:
Increase selling prices by 5% - difficult in a competitive
market and probably requiring additional marketing costs
Double Sales - extremely difficult due to capacity and
other resource constraints
Decrease salaries by 16.7% or eliminate overheads-
probably impossible.
Decrease purchasing costs by 8.3% - in most cases the
obvious solution, particularly if extended to reductions in
other SC costs such as transportation, packaging &
materials handling
12/10/2018 Compiled by: Matiwos Ensermu, PhD 145
Greening the Supply Chain:
The Reprocessing Flow
2 Continuous improvement
JIT is a system of enforced problem-solving to eliminate waste
using continuous improvement (kaizen) to achieve its objectives
U F D
N P U D A E
N R E N U I
E N P
E O X N F L L
C C C E D U
O E E E
W E E E C C R T
V S S S R E
E A E T I
I S S S S U
R I T O
T A S V T N
P R W I I O
R I A E
N Y A N R L
O I O
D G S V Y P U F
T T E Z S
U R E
T R E N M O E N
C A T D
T I O D A
M N O T U S T.
I S R S U
O E I C
P Y O K P
N T I R
O N S P E
R L L
L S
T Y O
A S
U
T C R
I H C
O A E
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N
2 Continuous Improvement
…is a fundamental principle of JIT as well as one of the 3 key
elements of TQM, and is crucial to the elimination of waste
Maintenance planning:
Failure Mode and Effect Analysis (FMEA): considers for
each failure type, the mechanism, the risk, and its
effects
The outcome of failure analysis is maintenance
planning
Failure analysis often incorporates the well-known
Bathtub Curve
TIME
12/10/2018 Compiled by: Matiwos Ensermu, PhD 161
Maintenance (cont’d)
Categories:
Categories:
3. Preventive Maintenance
Carried out to ensure that production is not interrupted by
equipment failing or malfunctioning; it is performed before
the equipment or systems break down
4. Predictive Maintenance
Used to predict when equipment is likely to fail by
constantly monitoring it to ascertain when maintenance
should be undertaken
Categories:
Proximity to Customers
Proximity to suppliers
Proximity to labor
Work Systems
Design
Flex-time
Allows employees, within limits, to determine their own
schedules
Part-time
Fewer, possibly irregular, hours
Enlarged job
Task #3 Present job Task #2
(Lock printed circuit (Manually insert and (Adhere labels
board into fixture for solder six resistors) to printed circuit
next operation) board)
Control
(Test circuits after
assembly)
Figure 10.2
12/10/2018 Compiled by: Matiwos Ensermu, PhD 189
Psychological Components of Job
Design
Human resource strategy requires
consideration of the psychological
components
of job design
Skill variety
Job identity
Job significance
Autonomy
Feedback
12/10/2018 Compiled by: Matiwos Ensermu, PhD 192
Job Design Continuum
Self-directed
teams
Increasing
Empowerment reliance on
employee’s
Enrichment contribution
and increasing
Enlargement
responsibility
accepted by
Specialization employee
Job expansion
Figure 10.3
Feedback to operators
The work environment
Illumination
Noise
Temperature
Humidity
Table 10.2
12/10/2018 Compiled by: Matiwos Ensermu, PhD 201
Decibel Levels(unit of loud level)
Environment Common Noise
Noises Sources Decibels
Jet takeoff (200 ft) 120
|
Electric furnace area Pneumatic hammer 100 Very annoying
|
Printing press plant Subway train (20 ft) 90
|
Pneumatic drill (50 ft) 80 Ear protection
Inside sports car (50 mph) | required if
Vacuum cleaner (10 ft) 70 exposed for 8
Near freeway (auto traffic) Speech (1 ft) | or more hours
60 Intrusive
Private business office |
Light traffic (100 ft) Large transformer (200 ft) 50 Quiet
|
Minimum levels, Chicago 40
residential areas at night Soft whisper (5 ft) |
Studio (speech) 30 Very quiet
Table 10.3
12/10/2018 Compiled by: Matiwos Ensermu, PhD 202
The Visual Workplace
Use low-cost visual devices to share
information quickly and accurately
Displays and graphs replace
printouts and paperwork
Able to provide timely information in
a dynamic environment
System should focus on
improvement
Reliability
1. Improving individual components
2. Providing redundancy
Maintenance
1. Implementing or improving preventive maintenance
Rs = R1 x R2 x R3 x … x Rn
R1 R2 R3
Number of failures
FR(N) = Number of unit-hours of operating time
1
MTBF = FR(N)
Maintenance Equipment
parts list
and work order
schedule
Equipment
Repair history reports
history file
Cost analysis
Data entry (Actual vs. standard)
– Work requests
– Purchase
Inventory of requests
spare parts – Time reporting
– Contract work
Work orders
– Preventive
maintenance
– Scheduled
Personnel data downtime
with skills, – Emergency
wages, etc. maintenance
Schedule unreliability
Preventive
maintenance
Costs
costs
Breakdown
maintenance
costs
Maintenance commitment
Optimal point (lowest
cost maintenance policy)
1. Well-trained personnel
2. Adequate resources
3. Ability to establish repair plan and
priorities
4. Ability and authority to do material
planning
5. Ability to identify the cause of
breakdowns
6. Ability to design ways to extend MTBF
12/10/2018 Compiled by: Matiwos Ensermu, PhD 233
Total Productive Maintenance (TPM)