Foundations of “Scientific”

Operations Management:
The Study of Work Systems

Process & Methods Analysis conclusion

Refer Chapter 7
 The Student Syndrome

Degree
of Effort

Uniform
effort line

Deadline

Time on Project
Not to
scale
Process Mapping &
Improvement
 Process Value Analysis
• Examining a process to identify improvement
avenues by eliminating/ reducing Non-Value
Adding and wasteful steps

• “All we are doing is looking at the time line from the

moment the customer gives us an order to the
point when we collect the cash. And we are
reducing that time line by removing the non-value-
added wastes.”
– Taiichi Ohno, pioneer of the Toyota Production System
 Business Oriented Operations Metrics

Input Output
Conversion
(Raw (Finished
(Work In Process)
Material) Goods)

• Order-to-Cash Time

• Inventory Turnover= Sales Value per year ÷ Inventory

Value

• Cash-to-Cash Time
Process Maps - Sequence & Timing
Process Map Across Departments
Process Time Analysis
 Value
Analysis
Framework
 THE USA PRINCIPLE
UNDERSTAND SIMPLIFY AUTOMATE

Existing Processes by Simplified

processes eliminating waste processes

through by using

Process Eliminating, Operations

Mapping, Combining, Technologies,
Diagramming, Rearranging RFID, QR etc.
Brainstorming

“Simplify before Automating, otherwise you Simply Automate Waste.”

- Shigeo Shingo, Japanese Manufacturing Guru
OTHER METHOD STUDY TOOLS
(Motion Study)
 5.Time & Motion Study
“Time and motion studies are the essence of
Indem*. As engineers you should be able to
reduce human actions to measurable tasks
and stop talking there in the third row”, Cherian
said as he threw a piece of chalk at two students
who had found a private joke too good to resist
sharing in class.
* Indem: Industrial Engineering & Management, a
compulsory Operations course in BT(ME) at IITK/D
 About Operational Details

“God is in the details”

– Mies Van Der Rohe, Architect

Alternatively, “The devil is in the details” – Anon

’
Figure 7-4

n
ent
tion

io
FLOW PROCESS CHART ANALYST PAGE

ge
ect
vem
Job Requisition of petty cash D. Kolb 1 of 2

ay
era

a
p

Stor
De l
Ins
Mo
Op
Details of Method
Requisition made by department head
Put in “pick-up” basket
To accounting department
Account and signature verified
Amount approved by treasurer
Amount counted by cashier
Amount recorded by bookkeeper
Petty cash sealed in envelope
Petty cash carried to department
Petty cash checked against requisition
Receipt signed
Petty cash stored in safety box
 Flow Diagram (initial)

Welding

From
Storage bins
press
mach. Paint
shop
Mach. 3 Mach. 4
Machine 1

Mach. 2
Flow Diagram (alternative)

Machine 4 Welding
Machine 3
Paint
Machine 2 shop
Machine 1
From
press Storage
mach. bins
 Operation Chart
(Left Hand/ Right Hand)

Also see
Fig 7-6
APPLICATIONS OF MOTION STUDY
 Snapshot from Dell

A redesigned build table trimmed 20 seconds off the assembly

process: (reduced long reaches by 50%, and lessened “turns”
by 80% - saves cost and reduces risk of injury)
Improving Workplace Productivity
More Examples