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8b Updated Process & Methods Analysis XLDel 2023

This document discusses process mapping and analysis techniques used in operations management. It defines process mapping as visually documenting the steps and flow of a process across an organization. Common symbols used in process mapping are explained, such as tasks, decisions, storage areas, and material/people flows. An example multi-stage process map with a buffer is provided. Further process terminology like bottlenecks, buffers, starving, and blocking are defined. Finally, some thoughts on using these techniques to analyze the TechFab case study are outlined.

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Dipayan Maji B23319
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54 views12 pages

8b Updated Process & Methods Analysis XLDel 2023

This document discusses process mapping and analysis techniques used in operations management. It defines process mapping as visually documenting the steps and flow of a process across an organization. Common symbols used in process mapping are explained, such as tasks, decisions, storage areas, and material/people flows. An example multi-stage process map with a buffer is provided. Further process terminology like bottlenecks, buffers, starving, and blocking are defined. Finally, some thoughts on using these techniques to analyze the TechFab case study are outlined.

Uploaded by

Dipayan Maji B23319
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Foundations of “Scientific”

Operations Management:
The Study of Work Systems

PROCESS & METHODS ANALYSIS


Refer Chapter 7
Process Mapping
• Documenting the flow of the process across the
organization as a sequence of steps (usually done
visually/ diagrammatically)
– Walk the process from Start to Finish and observe:
• Activity “Trigger” points
• Decision Points
• Flow regularity, variability situations, and hold-ups/ interruptions
• Fragmentation/ Duplication of effort
• Flow of information

– Alternatively, walk the process from Finish to Start


Process Mapping Symbols ..

Examples: Giving an
Tasks or operations admission ticket to a
customer, installing a
spare part in a car etc.

Examples: How much


Decision Points refund should be given
to a customer, which
type of test should be
performed etc.
.. Process Mapping Symbols

Storage areas or Examples: Sheds,


queues lines of people waiting
for a service etc.

Flows of Examples: Customers


materials or moving to a seat, a
people mechanic fetching a
tool etc.
Sample Process Map:
Multi-stage Process with Buffer

Accept/
Release Stage 1 Buffer Stage 2
Order?

Evaluate process map for different aggregate performance


metrics.
These may vary depending on where the process is on the
continuum of process types or fulfillment types.
Further Process Terminology ..
• Bottleneck
– Occurs when the capacity of (part of) a process limits
the throughput of the system (production/ sales?)
– If a resource (machine/ employee/..) works too slow in
a multi-stage process, pending work will begin to pile
up in the buffer in front of that resource

• Buffer
– Refers to the provision for inventory accumulation in
between process stages
– Arises due to different rates at different process
stages; also helps to decouple stages
TechFab Mini-Case
Broad Discussion Plan
• Based on the case description, what problem(s) would
be possible and better to diagnose/ address using the
numbers given?

• Just Do It (the numbers)!

• Based on the quantitative analysis, what is/ are the


probable root causes for specific issues; and how
should such a system be designed and operated
incorporating other (possibly qualitative) aspects in
addition?
Summary Thoughts
Sample Process Map:
Multi-stage Process with Buffer

Accept/
Release Stage 1 Buffer Stage 2
Order?

Evaluate process map for different aggregate performance


metrics.
These may vary depending on where the process is on the
continuum of process types or fulfillment types.
.. Further Process Terminology
• Starving
– Occurs when the activities in a stage must stop
because there is no work coming to the resource for
processing
– The resource will remain idle until the next unit of work
arrives from the preceding stage
• Blocking
– Occurs when the activities in a stage must stop
because there is no room to deposit the item just
completed
– The resource has to hold on to the completed item until
it is able to discharge it, and is thus unable to start
work on the next item
Manufacturing According to Henry Ford

“How Come When I Want A Pair Of Hands,


I Get A Human Being As Well?”

“Any Color - So Long As It's Black.”

“Quality Means Doing It Right When No One Is


Looking.”

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