Process Design

1. Process Design

2. Chapter Coverage • What are design and process? • Product and services design and process design are interrelated. • Design activity is a process itself • Designing processes • Process types

3. Design: “To design” refers to the process of originating and developing a plan for a product, service or process. Process: Is any part of an organization which takes a set of input resources which are then used to transform something into outputs of products or services.

4. Preliminary Design Concept Generation Screening Process design Evaluation and Improvement Prototyping and final design Process Design Processes that Design Products and Services Processes that Produce Products and Services Supply Network Design Layout and Flow Process Technology Job Design

5. Nature of the design activity: • Design is inevitable – products, services and the processes which produce them all have to be designed. • Product design influences process design – decisions taken during the design of a product or service will have an impact on the decisions taken during the design of the process which produces those products or services and vice versa.

6. Designing the Processes that Produce the Product or Service Designing the Product or Service Processes should be designed so they can create all products and services which the operation is likely to introduce Products and services should be designed in such a way that they can be created effectively Decisions taken during the design of the product or service will have an impact on the process that produces them and vice versa Product & services design are interrelated to its process design

7. Process Design and Product/Service Design are Interrelated • To commit to the detailed design of a product or service consideration must be given to how it is to be produced. • Design of process can constrain the design of products and services. • The overlap is greater in the service industry: • Service industry - it is impossible to separate service design and process design – they are the same thing. • Manufacturing industry - it is possible to separate product design and process design but it is beneficial to consider them together because the design of products has a major effect on the cost of making them.

8. Process and product/service design must satisfy customer • Products/services designer customers satisfaction criteria • Aesthetically pleasing • Reliability • Meets expectation • Inexpensive • Quality • Easy to manufacture and deliver • Speedy • Process designer customers satisfaction achieved through: • Layout • Location • Process technology • Human skills

9. Finished designs which are: TRANSFORMED RESOURCES High quality: Error-free designs which fulfil their purpose in an effective and creative way Speedily produced: Designs which have moved from concept to detailed specification in a short time Dependably delivered: Designs which are delivered when promised Produced flexibly: Designs which include the latest ideas to emerge during the process Low cost: Designs produced without consuming excessive resources Technical information Market information Time information THE DESIGN ACTIVITY OUTPUT INPUTS Test and design equipment Design and technical staff TRANSFORMING RESOURCES The design activity is itself a process

10. 100% Percentage of final product cost committed by the design Percentage of design costs incurred 0% Finish of the design activity Start of the design activity Relatively early in the design activity the decisions taken will commit the operation to costs which will be incurred later

11. Designing processes • Process mapping • Process mapping symbols • Improving processes • Process performance • Throughput, cycle time & work in process

12. Process mapping • Used to identify different types of activities. • Shows the flow of material, people or information. • Critical analysis of process maps can improve the process.

13. Process mapping symbols Beginning or end of process Operation (an activity that directly adds value) Activity Inspection (a check of some sort) Transport (a movement of some thing) Input or Output from the process Delay (a wait, e.g. for materials) Direction of flow Storage (deliberate storage, as opposed to a delay) Decision (exercising discretion) Process mapping symbols derived from Systems Analysis Process mapping symbols derived from “Scientific Management”

14. Raw Materials Stored Sandwiches Move to Outlets Stored Sandwiches Take Payment Assembly Sell Standard sandwich process Customer Request Take Payment Raw Materials Assembly Customer Request Customized sandwich old process

15. The operation of making and selling customized sandwiches Assemble as required Take payment Prepare Sandwich materials and customers Customers “assembled” to sandwiches Bread and Base filling The outline process of making and selling customized sandwiches Assemble whole sandwich Use standard “base”? No Yes Fillings The detailed process of assembling customized sandwiches Customer Request Assemble from standard “base” Stored “Bases”

16. Assemble whole sandwich Assembly of “sandwich bases” Take Payment Use standard “base”? No Fillings Yes Bread and Base filling Customer Request Assemble from standard “base” Stored “Bases” Customized sandwich improved new process

17. Right hand Left hand Wait Pick up base plate Insert into fixture Hold base plate Pick up two supports Locate back plate Pick up screws Locate screws Pick up air driver Fasten screws Wait Replace air driver Pick up centre assembly Inspect centre assembly Hold centre assembly Locate and fix Switch on timer Wait to end test Inspect Inspect Transfer grasp Transfer grasp Wait Put aside ‘Two handed’ process chart

18. Process performance • Process performance can be judge against the five key performance objective: • Quality • Speed • Dependability • Flexibility • Cost

19. Throughput, work content, cycle time, and work in process • Throughput – the time for a unit to move through the process • Work content – the total amount of work required to produce a unit of output (measured in time) • Cycle time – The average time between units of output emerging form the process • Work in process (WIP) –unfinished items in a production process waiting for further processing e. g. when customers join a queue in a process they become WIP • throughput = work in process x cycle time

20. One-off, complex, large scale, high work content “products” Speciallymade, every one customized Defined start and finish: time, quality and cost objectives Many different skills have to be coordinated Fixed position layout Project Processes

21. Project Process

22. Very small quantities: “one-offs”, or only a few required Speciallymade. High variety, low repetition. Skill requirements are usually very broad Skilled jobber, or team of jobbers complete whole product Fixed position or process layout (routing decided by jobbers) Jobbing Processes

23. Jobbing Process

24. Higher volumes and lower variety than for jobbing Standard products, repeating demand. But can make specials Specialized, narrower skills Set-ups (changeovers) at each stage of production Process or cellular layout Batch Processes

25. Batch Process

26. Higher volumes than Batch Standard, repeat products Low and/or narrow skills No set-ups, or almost instantaneous ones Cell or product layout Mass (Line)Processes

27. Mass Process

28. Extremely high volumes and low variety: often single product Standard, repeat products Highly capital-intensive and automated Few changeovers required Difficult and expensive to start and stop the process Product layout: usually flow along conveyors or pipes Continuous Process

29. Continuous Process

30. Manufacturing process types Service process types High High Project Professional service Jobbing Service shop Batch Variety Variety Mass Mass service Contin- uous Low Low High Low Volume High Low Volume