Session 1 Introduction to Operations Management_Dr. Vinay
Session 1 Introduction to Operations Management_Dr. Vinay
By:
Dr. Vinay Surendra Yadav
Assistant Professor
Operations and Quantitative Techniques
Indian Institute of Management Shillong, India
1
Contents
• Me in a Nutshell
• Myths and Warnings
• What is Operations Management?
• History of Operations Management
• Goods and Services
• ITO Model
• Basics and Overlapping Functions in an Organizations
• Metrics and Trade-off
• Hierarchical Planning
• Quality
• Productivity
2
Me in a Nutshell Scopus Author ID: 57196010557
Orcid ID: 0000-0002-0744-2384
Last update:
Education : Ph.D. (Supply Chain) 29/09/2024
M.Tech (Industrial Engg. & Mgmt.)
B.E. (Mech Engg.)
Past Affiliations: Post Doc (IIT Delhi)
Research Productivity:
• 25 Journals Articles (11 A, 1 B and 3 C Category: ABDC, 22 SCI/SSCI)
• 3 Book Chapters (SCOPUS)
• 6 Conferences (4 SCOPUS)
Service to Research Community:
➢ Reviewer of more than 30 International Journals and some internationally
Areas of Interest:
renowned conferences. • Supply Chain
Professional Bodies: • Blockchain
➢ Life Member of IIIE, ORSI, IEI and GIFT. • Multiple-Criteria Decision Making
• Mathematical Programming
Selected Recognitions: • Industry 4.0 Technologies
• Gold Medallist (M.Tech) Tools:
• Top Reviewer for Sustainable Production and Consumption (2022-23) • R, MATLAB, MS-Excel (Advanced),
• Best Track Paper at 8th Asian Conference on IEOM, Indonesia SPSS, AMOS, BibExcel, VOSViewer,
3 Citespace and Tableau etc.
Myths and Warning
❑ Myths:
Operations Management and Operations Research are same
Operations Management is all about complex math
Operations Management is difficult to understand
❑ Warnings:
✓ Don’t come to the class unprepared!
✓ Don’t be late for the class
✓ Don’t take Operations Management lightly
4
What is Operations Management?
What is operations?
The part of a business organization that is responsible for producing goods or services
https://www.youtube.com/watch?v=IdxE5giy0a0&list=PPSV - Hindi
https://www.youtube.com/watch?v=aPb-slJH9Vs - English
5
The Transformation Process
Value-Added
❑ Services are activities that provide some combination of time, location, form or
psychological value.
❖ Air travel
❖ Education
❖ Haircut
❖ Legal counsel
7
Differences Between Goods and Services
CHARACTERISTICS OF SERVICES CHARACTERISTICS OF GOODS
Intangible: Ride in an airline seat Tangible: The seat itself
Produced and consumed simultaneously: Beauty salon Product can usually be kept in inventory (beauty care
produces a haircut that is consumed as it is produced products)
Unique: Your investments and medical care are unique Similar products produced (iPods)
High customer interaction: Often what the customer is Limited customer involvement in production
paying for (consulting, education)
Inconsistent product definition: Auto Insurance changes Product standardized (iPhone)
with age and type of car
Often knowledge based: Legal, education, and medical Standard tangible product tends to make automation
services are hard to automate feasible
Services dispersed: Service may occur at retail store, local Product typically produced at a fixed facility
office, house call, or via internet.
Quality may be hard to evaluate: Consulting, education, Many aspects of quality for tangible products are easy to
and medical services evaluate (strength of a bolt)
Reselling is unusual: Musical concert or medical care Product often has some residual value
8
History of Operations Management
Technology Focus
Now
9
The Heritage of Operations Management
Division of labor (Adam Smith 1776; Charles Babbage CPM/PERT (DuPont 1957, Navy 1958)
1852) Material requirements planning (Orlicky 1960)
Standardized parts (Whitney 1800) Computer aided design (CAD 1970)
Scientific Management (Taylor 1881) Flexible manufacturing system (FMS 1975)
Coordinated assembly line (Ford/ Sorenson 1913) Baldrige Quality Awards (1980)
Gantt charts (Gantt 1916) Computer integrated manufacturing (1990)
Motion study (Frank and Lillian Gilbreth 1922) Globalization (1992)
Quality control (Shewhart 1924; Deming 1950) Internet (1995)
Computer (Atanasoff 1938)
10
Basic and Overlapping Functions of Business
Organizations
Organization
12
Why Study Operations Management?
Every aspect of business affects or is affected by operations
Many service jobs are closely related to operations
Financial services
Marketing services
Accounting services
Information services
Through learning about operations and supply chains you will have a better
understanding of:
The world you live in
The global dependencies of companies and nations
Reasons that companies succeed or fail
The importance of working with others
13
Scope of OM
14
Operations and Supply Chain: Career Opportunities
Operations manager
Production analyst
Schedule coordinator
Production manager
Industrial engineer
Purchasing manager
Inventory manager
Quality manager
15
OM-Related Professional Societies
APICS - The Association for Operations Management
16
Process Management
Variations can be disruptive to operations and supply chain processes. They may
result in additional costs, delays and shortages, poor quality, and inefficient work
systems.
17
Supply & Demand
Operations &
Supply Chains Sales & Marketing
Wasteful
Supply
> Demand Costly
Opportunity Loss
Supply
< Demand Customer
Dissatisfaction
Supply
= Demand Ideal
18
Role of Operations Manager
The Operations Function consists of all activities directly related to producing
goods or providing services.
19
System Design Decisions
• System Design
– Capacity
– Facility location
– Facility layout
– Product and service planning
– Acquisition and placement of equipment
20
System Operation Decisions
• System Operation
• These are generally tactical and operational decisions
– Management of personnel
– Inventory management and control
– Scheduling
– Project management
– Quality assurance
• Operations managers spend more time on system operation decision than any other decision
area
• They still have a vital stake in system design
21
OM Decision Making
Most operations decisions involve many alternatives that can have quite
different impacts on costs or profits
When: When will each resource be needed? When should the work be scheduled? When
should materials and other supplies be ordered?
Where: Where will the work be done?
How: How will he product or service be designed? How will the work be done? How will
resources be allocated?
Who: Who will do the work?
22
Metrics and Trade-Offs
23
Key Issues for Operations Managers Today
➢ Economic conditions
➢ Innovating
➢ Quality problems
➢ Risk management
24
Environmental Concerns
Sustainability
Using resources in ways that do not harm ecological systems that support
human existence
Sustainability measures often go beyond traditional environmental and economic
measures to include measures that incorporate social criteria in decision making
25
Competitiveness
Competitiveness
How effectively an organization meets the wants and needs of customers relative to others
that offer similar goods or services
Organizations compete through some combination of their marketing and operations
functions
• What do customers want?
• How can these customer needs best be satisfied?
Marketing’s Influence
Identifying consumer wants and/or needs
Pricing and quality
Advertising and promotion
26
Businesses Compete Using Operations
27
Why Some Organizations Fail
1. Neglecting operations strategy
2. Failing to take advantage of strengths and opportunities and/or failing to recognize
competitive threats
3. Too much emphasis on short-term financial performance at the expense of R&D
4. Too much emphasis in product and service design and not enough on process
design and improvement
5. Neglecting investments in capital and human resources
6. Failing to establish good internal communications and cooperation
7. Failing to consider customer wants and needs
28
Hierarchical Planning
Mission
Goals
Organizational Strategies
Functional Strategies
Tactics
29
Mission and Goals
Mission
The reason for an organization’s existence
Goals
Provide detail and the scope of the mission
30
Strategies
Strategy
A plan for achieving organizational goals
Serves as a roadmap for reaching the organizational destinations
The organizational strategy guides the organization by providing direction for, and alignment of,
the goals and strategies of the functional units
The organizational strategy is a major success/failure factor
❖ Organizational strategies
Overall strategies that relate to the entire organization
Support the achievement of organizational goals and mission
31
Tactics and Operations
Tactics
The methods and actions taken to accomplish strategies
The “how to” part of the process
Operations
The actual “doing” part of the process
32
Core Competencies
33
Sample Operations Strategies
Differentiation:
Innovation 3M, Apple
Newness
Differentiation: Flexibility Burger King (Have it your way”)
Variety Volume McDonald’s (“Buses Welcome”)
Differentiation: Disneyland
Superior customer service
Service IBM
Differentiation:
Convenience Supermarkets; Mall Stores
Location
34
Strategy Formulation
Effective strategy formulation requires taking into account:
Core competencies
Environmental scanning - SWOT
36
Operations Strategy
The approach, consistent with organization strategy, that is used to guide the operations
function.
Decision Area What the Decisions Affect
Product and service design Costs, quality, liability, and environmental issues
Capacity Cost, structure, flexibility
Process selection and layout Costs, flexibility, skill level needed, capacity
Work design Quality of work life, employee safety, productivity
Location Costs, visibility
Quality Ability to meet or exceed customer expectations
Inventory Costs, shortages
Maintenance Costs, equipment reliability, productivity
Scheduling Flexibility, efficiency
Supply chains Costs, quality, agility, shortages, vendor relations
Projects Costs, new products, services, or operating systems
37
Operations Strategy
Quality-based strategy
Strategy that focuses on quality in all phases of an organization
Trying to overcome a poor quality reputation
Desire to maintain a quality image
A part of a cost reduction strategy
Time-based strategies
Strategies that focus on the reduction of time needed to accomplish tasks
It is believed that by reducing time, costs are lower, quality is higher, productivity is higher, time-to-market is
faster, and customer service is improved
Areas where organizations have achieved time reductions:
Planning time Product/service design time
Processing time Changeover time
Delivery time Response time for complaints
38
Quality
❑ "Fitness for intended use" (Dr. Joseph Juran)
39
Total Quality Management
❖ Encompasses entire organization from supplier to customer
40
Seven Concepts of TQM
1. Continuous improvement 5. Just-in-time (JIT)
4. Benchmarking
41
1. Continuous Improvement
► Never-ending process of continual improvement
42
Shewhart’s PDCA Model
4. Act 1. Plan
Implement Identify the
the plan, pattern and
document make a plan
3. Check 2. Do
Is the plan Test the
working? plan
43
1. Continuous Improvement
❑ Kaizen describes the ongoing process of unending
improvement
44
2. Six Sigma
► Two meanings
► Statistical definition of a process that is 99.9997% capable,
3.4 defects per million opportunities (DPMO)
► A program designed to reduce defects, lower costs, save
time, and improve customer satisfaction
45
2. Six Sigma
Lower limits Upper limits
► Two meanings
2,700 defects/million
► Statistical definition of a process that is
3.499.9997%
defects/million capable, 3.4 defects per
million opportunities (DPMO)
► A program designed to reduce defects,
lower costs, save time, and improve
customer satisfaction Mean
► A comprehensive system±3for achieving
and sustaining business ±6success
46
3. Six Sigma
► Originally developed by Motorola, adopted and enhanced
by Honeywell and GE
DMAIC Approach
4. Improves by modifying or redesigning existing processes and procedures
5. Controls the new process to make sure performance levels are maintained
48
Implementing Six Sigma
❑ 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
49
3. Employee Empowerment
► Getting employees involved in product and process
improvements
► 85% of quality problems are due
to process and material
► Techniques
1) Build communication networks
that include employees
2) Develop open, supportive supervisors
3) Move responsibility to employees
4) Build a high-morale organization
5) Create formal team structures
50
Quality Circles
► Group of employees who meet regularly to solve problems
► The method is invented by Dr. Kaoru Ishikawa who is also known for
fishbone (cause-effect) diagram.
51
4. Benchmarking
Selecting best practices to use as a standard for performance
52
Best Practices for Resolving Customer Complaints
Table
BEST PRACTICE JUSTIFICATION
Make it easy for clients to complain It is free market research
Respond quickly to complaints It adds customers and loyalty
Resolve complaints on first contact It reduces cost
Use computers to manage complaints Discover trends, share them, and align
your services
Recruit the best for customer service It should be part of formal training and
jobs career advancement
53
Internal Benchmarking
When the organization is large enough
54
5. Just-in-Time (JIT)
Relationship to quality:
55
5. Just-in-Time (JIT)
► ‘Pull’ system of production scheduling including supply
management
► Production only when signaled
► Taguchi Concepts
► Quality robustness
► Quality loss function
► Target-oriented quality
57
Quality Robustness
► Ability to produce products uniformly in adverse
manufacturing and environmental conditions
58
Quality Loss Function
► Shows that costs increase as the product moves away
from what the customer wants
61
Seven Tools of TQM
(a) Check Sheet: An organized
method of recording data
Hour
Defect 1 2 3 4 5 6 7 8
A /// / / / / /// /
B // / / / // ///
C / // // ////
62
Seven Tools of TQM
(b) Scatter Diagram: A graph of the
value of one variable vs. another
variable
Productivity
Absenteeism
63
Seven Tools of TQM
(c) Cause-and-Effect Diagram: A tool
that identifies process elements
(causes) that might effect an outcome
Cause
Materials Methods
Effect
Manpower Machinery
64
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
We also discussed 80-20 rule.
65
Seven Tools of TQM
66
Seven Tools of TQM
(f) Histogram: A distribution showing the
frequency of occurrences of a variable
Distribution
Frequency
67
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
68
Seven Tools of TQM
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 &
(shooter) backboard)
69
Pareto Charts
Data for October
– 100
70 –
– 93
– 88
60 –
54
Frequency (number)
Cumulative percent
50 – – 72
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
70
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%
71
Statistical Process Control (SPC)
0% | | | | | | | | |
Lower control limit
1 2 3 4 5 6 7 8 9
Game number
73
Attributes Versus Variables
► Attributes
► Items are either good or bad, acceptable or unacceptable
► Does not address degree of failure
► Variables
► Measures dimensions such as weight, speed, height, or strength
► Falls within an acceptable range
74
Productivity
Productivity
A measure of the effective use of resources, usually expressed as the ratio of output
to input
75
Why Productivity Matters?
High productivity is linked to higher standards of living
As an economy replaces manufacturing jobs with lower productivity service jobs, it is more
difficult to maintain high standards of living
76
Productivity Measures
Output
Productivity =
Input
77
Example
What is the
multifactor
productivity?
78
Solution
Output
Multifactor Productivity =
Labor +Material +Overhead
$150,000
=
$42,500
= 3.5294
79
Productivity Growth
Example: Labor productivity on the ABC assembly line was 25 units per hour in 2014. In 2015, labor
productivity was 23 units per hour. What was the productivity growth from 2014 to 2015?
23 - 25
Productivity Growth = 100% = −8%
25
80
Service Sector Productivity
❖ Service sector productivity is difficult to measure and manage because
◦ It involves intellectual activities
◦ It has a high degree of variability
81
Factors Affecting Productivity
Methods
Capital Quality
Technology Management
82
Improving Productivity
83
84