Operations Management

MANAGEMENT AND OPERATIONS

Process Design and Layout Types,

Process Mapping

Agenda for Today

1. Process Types
2. Layout Types
3. Case Studies
4. Process Mapping

Dr. Nguyen Thi Duc Nguyen 1

Operations Management

Process Types: Volume-Variety

Manufacturing Process Types
Complex Project One-off
Processes
Jobbing
Processes
Process Batch Process
Tasks Processes Flow
Mass
Processes
Continuous
Processes
Repeated Continuous
Low Volume High
High Variety Low

• Project Processes:
– Well-defined start and finish, long time between starting different jobs. Process
map = complex. E.g. Shipbuilding, Construction, Movie production
• Jobbing Processes:
– High variety and low volume, share resources, e.g. Specialist tool-makers, furniture
restorers, bespoke tailors, printing tickets for local events.
• Batch Processes:
– Produce more than one, fairly repetitive, e.g. Machine tool manufacturing, frozen
food, components parts for mass-produced assemblies of automobiles
• Mass Processes:
– e.g. automobile plant, TV factory, food processes, DVD production. Thousands
variants of car with different engine size, colour, extra equipment but does not
affect the basic processes of production.
• Continuous Processes:
– e.g. Petrochemical refineries, electricity utilities, steel making, paper making,
continuous water treatment process

Dr. Nguyen Thi Duc Nguyen 2

Operations Management

Process Types: Volume-Variety

Service Process Types
Complex One-off
Professional
Services

Process Service Process

Tasks Shops Flow

Mass
Services
Repeated Continuous
Low Volume High
High Variety Low

Process and Basic Layout Types

Manufacturing Basic Layout Service

Process Types Types Process Types
Project Fixed-Position Professional
Processes Services
e.g. Shipbuilding Layout e.g. Surgery
Manufacturing
- Large Product
- Delicate Product
No Move:
- Materials
- Customers
- Information
Move:
- The equipment
- The workers

Dr. Nguyen Thi Duc Nguyen 3

Operations Management

Process and Basic Layout Types

Manufacturing Basic Layout Service

Process Types Types Process Types
Project Fixed-Position
Processes
Layout
Jobbing
Processes Functional
e.g. Small Job
Production Layout Service
Shops
Similar processes e.g. Supermarket
locate together Products onto
Shelf
The products, people
and information move
from process to process

Functional Layout

Dr. Nguyen Thi Duc Nguyen 4

Operations Management

Process and Basic Layout Type

Manufacturing Basic Layout Service

Process Types Types Process Types
Process or Product
Approach

Products, People
and information move
from sub-operation
to sub-operation. Service
Batch Shops
Mass Processes Cell
Processes Layout
The route is usually
connected
Mass
Services

Cell Layout

Dr. Nguyen Thi Duc Nguyen 5

Operations Management

Process and Basic Layout Types

Manufacturing Basic Layout Service

Process Types Types Process Types
Products, People and
Information move along
a linear route.
The route is usually
linear or connected

Continuous Product Mass

Processes Layout Services

Process and Basic Layout Types

Manufacturing Basic Layout Service

Process Types Types Process Types
Project Fixed-Position Professional
Processes Services
Layout
Jobbing
Processes Functional
Layout Service
Batch Shops
Mass Processes Cell
Processes Layout
Continuous Product Mass
Processes Layout Services

Dr. Nguyen Thi Duc Nguyen 6

Operations Management

Four Different Layout Types

TYPE ADVANTAGES DISADVANTAGES

Flexible High unit cost
Fixed- No movement Space can be a problem
Position Variety for staff Movement of plant/people
Flexible Low utilisation
Functional Easy supervision High work in progress
Resists disruption Complex flow
Balance cost/flexible Costly to rearrange
Cell Rapid throughput More plant/machinery
Group work? Low utilisation
Low cost/high volume Low mix flexibility
Product Specialization Disruption is a problem
Movement balanced Repetitive work

Dr. Nguyen Thi Duc Nguyen 7

Operations Management

Process Map
<Microsoft Visio>

Process Mapping
Definition:
Describing processes in terms of how the activities within
the process relate to each other
also called: Process Blueprinting, Process Analysis

Process Mapping Symbols:

The symbols that are used to classify different types of
activity; they usually derive either from information
systems flow charting or scientific management

Dr. Nguyen Thi Duc Nguyen 8

Operations Management

Process Mapping Symbols derived from

Scientific Management
Operation (an activity that
directly adds value)
Inspection (a check of some sort)

Transport (a movement)

Delay (a wait, e.g. Materials)

Storage (Deliberate storage,

opposed to a delay)

Sandwich Production Process Map

Raw Stored Transport
Materials Assembly Sandwiches to Store

Stored Receive
Sandwiches Sell Payment

Customer Request

Dr. Nguyen Thi Duc Nguyen 9

Operations Management

Process Mapping Symbols derived from

System Analysis
Beginning or End of Process

Activity

Input or Output from the Process

Direction of Flow

Decision (Exercising discretion)

Student Administration Process Map (Available on Moodle)

Dr. Nguyen Thi Duc Nguyen 10

Operations Management

Aluminium
Manufacturing &
Remanufacturing
Process Map

Company RAL :
Aluminium
Manufacturer &
Waste Residue
Remanufacturer

(Available on Moodle)

Metal
Manufacturing &
Remanufacturing
Process Map

Company MM :
Metal Manufacturer
Company Mss:
Stainless Steel
Manufacturer
Company RM1 & RM2:
Metal Remanufacturers

(Available on Moodle)

Dr. Nguyen Thi Duc Nguyen 11

Operations Management

3rd Party Reverse

Logistics (3PRL)
Process Map

Company L3PRL:
3rd Party Reverse
Logistics provider who
collects wastes from
Fortune 500 companies

(Available on Moodle)

Dr. Nguyen Thi Duc Nguyen 12