McGraw-Hill/Irwin Copyright © 2009 by The McGraw-Hill Companies, Inc. All Rights Reserved. Chapter 1 Introduction to Operations Management Our aim in taking Operations Management is to give you a comprehensive understanding of the issues and techniques of operations management

McGraw-Hill/Irwin Copyright © 2009 by The McGraw-Hill Companies, Inc. All Rights Reserved. Operations Management is important, exciting, challenging, and everywhere your look! Important, because it’s concerned with creating all of the products and services upon which we depend. Exciting, because it’s at the centre of so many of the changes affecting the world of business. Challenging, because the solutions that we find need to work globally and responsibly within society and the environment. And everywhere, because every service and product that you use – the cereal you eat at breakfast, the chair you sit on, and the radio station you listen to while you eat – is the result of an operation or process.

1-3 Production and Operations Management What is production and operations? –The part of a business organization that is responsible for producing goods or services How can we define production and operations management? –The management of systems or processes that create goods and/or provide services

1-4 Why study operations management? 4 1.Operations management activities are at the core of all business organizations. 2.50% or more of all jobs are in operation management related areas such as customer service, quality assurance, production planning and control, job design, inventory management and more. 3.Other areas of business organizations such as finance, marketing, HR, logistics and accounting are interrelated with operation management activities.

1-5 Supply & Demand SupplyDemand > SupplyDemand < SupplyDemand = Wasteful Costly Opportunity Loss Customer Dissatisfaction Ideal Operations & Supply Chains Sales & Marketing

1-6 Basic Functions of the Business Organization Organization Finance Operation Marketing

1-7 The Transformation Process Inputs Land Labor Capital Information Outputs Goods Services Transformation/ Conversion Process Control Feedback Value-Added Feedback = measurements taken at various points in the transformation process Control = The comparison of feedback against previously established standards to determine if corrective action is needed.

1-8 Automobile Assembly, Steelmaking Products are typically neither purely service- or purely goods- based. GoodsServices Computer Repair, Restaurant Meal Surgery, Teaching Goods-service Continuum

1-9 Tangible Act-Oriented Goods Services Manufacturing and Service Organizations differ chiefly because manufacturing is goods-oriented and service is act-oriented. Manufacturing vs. Service?

1-10 Managing Services is Challenging 1.Jobs in services are often less structured than in manufacturing 2.Customer contact is generally much higher in services compared to manufacturing 3.In many services, worker skill levels are low compared to those of manufacturing employees 4.Services are adding many new workers in low-skill, entry-level positions 5.Employee turnover is high in services, especially in low-skill jobs 6.Input variability tends to be higher in many service environments than in manufacturing 7.Service performance can be adversely affected by many factors outside of the manager’s control (e.g., employee and customer attitudes)

1-11 Production of goods versus service operation 11 Characteristic goods services Output tangible intangible Uniformity of output high low Uniformity of input high low Measurement of prod -uctivity easy difficult Customer contact low high Opp to correct quality Problems. High low Evaluation easier more difficult lecturer: Ahmed El Rawas

1-12 The operations function includes many interrelated activities such as: –Forecasting –Capacity planning –Scheduling –Managing inventories –Assuring quality –Motivating employees –Deciding where to locate facilities –And more... Scope of Operations Management The scope of operations management ranges across the organization.

1-13 The Operations Function consists of all activities directly related to producing goods or providing services. A primary function of the operations manager is to guide the system by decision making. –System Design Decisions –System Operation Decisions Role of the Operations Manager

1-14 System Design Decisions System Design –Capacity –Facility location –Product and service planning –Acquisition and placement of equipment These are typically strategic decisions that require long-term commitment of resources

1-15 System Operation Decisions System Operation –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

1-16 Type of operations 16 Craft production: ( customized process)involves producing high variety of customized goods, low volume output with skilled workers. Main advantage is the flexibility to produce a wide variety of output, the main disadvantage is its inability to produce at low cost e.g: tailoring, landscaping. lecturer: Ahmed El Rawas

1-17 Type of operations 17 Mass production( Batch process) involves producing a few standardized goods at high volume of output with low skilled workers. Main advantage is low cost, efficient production, the main disadvantage is that it does not allow easy changes in volume of output or product design e.g: automobiles, computers. lecturer: Ahmed El Rawas

1-18 Type of operations 18 Lean production (continuous) it provides producing more variety of goods than most production at moderate to high volume of output. It requires high skilled workers, quality, employee involvement, teamwork and flatter organizational structure with fewer level of management. It combine both advantages high volume, low cost and variety, flexibility. lecturer: Ahmed El Rawas

1-19 Decision Making Most operations decisions involve many alternatives that can have quite different impacts on costs or profits Typical operations decisions include: –What: What resources are needed, and in what amounts? –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 product or service be designed? How will the work be done? How will resources be allocated? –Who: Who will do the work?

1-20 General Approach to Decision Making Modeling is a key tool used by all decision makers –Model - an abstraction of reality; a simplification of something. –Common features of models: They are simplifications of real-life phenomena They omit unimportant details of the real-life systems they can be focused on the most important aspects of the real-life system

1-21 Models Types of Models: –Physical Models Look like their real-life counterparts –Mathematical Models Do not look at all like their real-life counterparts

1-22 Understanding Models Keys to successfully using a model in decision making –What is its purpose? –How is it used to generate results? –How are the results interpreted and used? –What are the model’s assumptions and limitations?

1-23 Benefits of Models Models are generally easier to use and less expensive than dealing with the real system Require users to organize and sometimes quantify information Increase understanding of the problem Enable managers to analyze “What if?” questions Serve as a consistent tool for evaluation and provide a standardized format for analyzing a problem Enable users to bring the power of mathematics to bear on a problem.

1-24 Quantitative Methods A decision making approach that frequently seeks to obtain a mathematically optimal solution –Linear programming –Queuing techniques –Inventory models –Project models –Forecasting techniques –Statistical models

1-25 Model Limitations Quantitative information may be emphasized at the expense of qualitative information Models may be incorrectly applied and the results misinterpreted –This is a real risk with the widespread availability of sophisticated, computerized models are placed in the hands of uninformed users. The use of models does not guarantee good decisions.

1-26 Metrics and Trade-Offs Performance Metrics –All managers use metrics to manage and control operations Profits Costs Productivity Forecast accuracy Analysis of Trade-Offs –A trade-off is giving up one thing in return for something else Carrying more inventory (an expense) in order to achieve a greater level of customer service

1-27 Degree of Customization Relative to other standardized products and services customized products: –Tend to be more labor intensive –Tend to be more time consuming –Tend to require more highly-skilled people –Tend to require more flexible equipment –Have much lower volume of output –Have higher price tags Degree of customization has a significant influence on the entire organization –Process selection –Job design –Affects marketing, sales, accounting, finance, and information systems

1-28 Establishing Priorities In nearly all cases, certain issues or items are more important than others Recognizing this allows managers to focus their attention to those efforts that will do the most good –Pareto Phenomenon - a few factors account for a high percentage of occurrence of some event(s) The critical few factors should receive the highest priority This is a concept that is appropriately applied to all areas and levels of management

1-29 Systems Approach System - a set of interrelated parts that must work together –The business organization is a system composed of subsystems marketing subsystem operations subsystem finance subsystem The systems approach –Emphasizes interrelationships among subsystems –Main theme is that the whole is greater than the sum of its parts –The output and objectives of the organization take precedence over those of any one subsystem

1-30 Ethical Issues in Operations Ethical issues arise in many aspects of operations management: Financial statements Worker safety Product safety Quality The environment The community Hiring and firing workers Closing facilities Workers rights

1-31 Supply Chain Suppliers’ suppliers Direct suppliers ProducerDistributor Final Customers Supply Chain – a sequence of activities and organizations involved in producing and delivering a good or service

1-32 The Need for Managing the Supply Chain In the past, organizations did little to manage the supply chain beyond their own operations and immediate suppliers which led to numerous problems: –Inventory stockouts –Late deliveries –Quality problems

1-33 Elements of Supply Chain Management Customers – what products/services do customers want Forecasting – predicting timing and volume of customer demand Design – incorporating customer wants, manufacturability, and time to market Capacity planning – matching supply and demand Processing – controlling quality, scheduling work

1-34 Elements of Supply Chain Management Inventory – meeting demand requirements while managing costs Purchasing – evaluating potential suppliers, supporting the needs of operations on purchased goods and services Suppliers – monitoring supplier quality, on-time delivery, and flexibility; maintaining supplier relations Location – determining the location of facilities Logistics – deciding how to best move information and materials

1-35 Historical Evolution of OM Industrial Revolution Scientific Management Human Relations Movement Decision Models and Management Science Influence of Japanese Manufacturers

1-36 Industrial Revolution Pre-Industrial Revolution –Craft production - System in which highly skilled workers use simple, flexible tools to produce small quantities of customized goods Some key elements of the industrial revolution –Began in England in the 1770s –Division of labor - Adam Smith, 1776 –Application of the “rotative” steam engine, 1780s –Cotton Gin and Interchangeable parts - Eli Whitney, 1792 Management theory and practice did not advance appreciably during this period

1-37 Scientific Management Movement was led by efficiency engineer, Frederick Winslow Taylor –Believed in a “science of management” based on observation, measurement, analysis and improvement of work methods, and economic incentives –Management is responsible for planning, carefully selecting and training workers, finding the best way to perform each job, achieving cooperate between management and workers, and separating management activities from work activities –Emphasis was on maximizing output

1-38 Scientific Management - contributors Frank Gilbreth - father of motion studies Henry Gantt - developed the Gantt chart scheduling system and recognized the value of non-monetary rewards for motivating employees Harrington Emerson - applied Taylor’s ideas to organization structure Henry Ford - employed scientific management techniques to his factories Moving assembly line Mass production

1-39 Human Relations Movement The human relations movement emphasized the importance of the human element in job design –Elton Mayo – Hawthorne studies on worker motivation, 1930 –Abraham Maslow – motivation theory, 1940s; hierarchy of needs, 1954 –Frederick Hertzberg – Two Factor Theory, 1959 –Douglas McGregor – Theory X and Theory Y, 1960s –William Ouchi – Theory Z, 1981

1-40 Decision Models & Management Science F.W. Harris – mathematical model for inventory management, 1915 Dodge, Romig, and Shewart – statistical procedures for sampling and quality control, 1930s Tippett – statistical sampling theory, 1935 Operations Research (OR) Groups – OR applications in warfare George Dantzig – linear programming, 1947

1-41 Influence of Japanese Manufacturers Refined and developed management practices that increased productivity –Credited with fueling the “quality revolution –Just-in-Time production The growth of technology: the wide spread use of personal computer and user friendly software in the workplace may cause a resurgence in the popularity of mgt science technology. The influence of Japanese manufacturer: JIT, TQM,ISO

1-42 Key Trends and Issues in Business E-Business & E-Commerce Management of Technology Globalization Management of Supply Chains Outsourcing Agility Ethical Behavior