Title: Syllabus
1Syllabus
- Class 1 (Mar 10) chap 1 chap 2, case study
- March 17 No Class
- Class 2 (Mar 24) chap 5 chap 6 ( thru 243)
- Class 3 (Mar 31) chap 7 chap 9 (Take home exam)
- Class 4 (Apr 7) Webster Spring Break
- Class 5 (Apr 14) chap 10, chap 11
- Class 6 (Apr 21) chap 6 (243-250) chap 12, case
study - Class 7 (Apr 28) Reverse Logistics need The
Forklifts Have Nothing To Do! Available in the
Lewis and Clark Bookstore chap 14 chap 16
Supply Chain Security - Class 8 (May 5) Chap 13 Chap 3, Take home exam
- Class 9 (May 12) No Class
- Other requirements
- ?visit Harley-Davidson Plant in Kansas City to
see operations management in practice and write a
3-5 page paper comparing the class slides and
readings to the Harley operations -
2Grades
- Class Participation 10
- Mid Term 40
- Final Exam 40
- Harley Paper 10
3 4The Payoff Table
- A method of organizing illustrating the payoffs
from different decisions given various states of
nature - A payoff is the outcome of the decision a Craps
table pay off chart is an example of a payoff
chart
5Payoff Table
- States Of Nature
- (Alternatives)
- Decision a b
- 1 Payoff 1/a Payoff 1/b
- 2 Payoff 2/a Payoff 2/b
6Decision Making Criteria Under Uncertainty
- Maximax criterion (optimistic)
- Choose decision with the maximum of the maximum
payoffs - Minimin criterion (pessimistic) ? Choose
decision with the minimum of the minimum
payoffs - Maximin criterion
- Choose decision with the maximum of the minimum
payoffs
7Maximums 1,300,000 500,000 Minimums 500,000
320,000 -150,000
8(No Transcript)
9Chapter 5
10Product Design
- Specifies materials
- Determines dimensions tolerances
- Defines appearance
- Sets performance standards
11Service Design
- Specifies what the customer is to experience
- Physical items
- Sensual benefits
- Psychological benefits
12An Effective Design Process
- Matches product/service characteristics with
customer needs - Meets customer requirements in simplest, most
cost-effective manner - Reduces time to market - haste vs. speed to
market - Minimizes revisions - quality designed into the
product
13Stages in the Design Process
- Idea Generation Product Concept - can you
create your own market? What role does the voice
of the customer play in idea generation? - Feasibility Study Performance Specifications
- Preliminary Design Prototype - testing and
redesign - Final Design Final Design Specifications
- Process Planning Manufacturing Specifications
- make to order/stock assembly line?
14The Design Process
15Idea Generation
- Suppliers, distributors, salespersons
- Trade journals and other published material
- Warranty claims, customer complaints, failures
- Customer surveys, focus groups, interviews
- Field testing, trial users
- Research and development
16More Idea Generators
- Perceptual Maps
- Visual comparison of customer perceptions
- Benchmarking
- Comparing product/service against best-in-class
- Reverse engineering
- Dismantling competitors product to improve your
own product
17Perceptual Map of Breakfast Cereals
18Perceptual Map of Breakfast Cereals
19Feasibility Study
- Market Analysis - Market Segmentation
- Economic Analysis
- Technical / Strategic Analysis
- Performance Specifications
Not unlike mission analysis or Intelligence
Preparation of the Battlefield
20Risk Analysis
- 1. Identify the Hazards
- 2. Assess hazards to determine risks.
- 3. Develop controls and make risk decisions.
- 4. Implement controls.
- 5. Supervise and evaluate.
From FM 100-14
21Preliminary Design
How will it look?
- Create form functional design
- Build prototype
- Test prototype
- Revise prototype
- Retest
22Functional Design(How the Product Performs)
- Reliability
- Probability product performs intended function
for specified length of time - Maintainability
- Ease and/or cost or maintaining/repairing product
23Computing Reliability
Components in series
0.90 x 0.90 0.81
24Computing Reliability
Components in series
0.90 x 0.90 0.81
Components in parallel
0.95 0.90(1-0.95) 0.995
25System Availability
26System Availability
27System Availability
SAA 60 / (60 4) .9375 or 93.75 SAB 36 /
(36 2) .9473 or 94.73 SAC 24 / (24 1)
.96 or 96
28Production Design
- Part of the preliminary design phase
- Simplification
- Standardization
- Modularity
29Final Design Process Plans
- Produce detailed drawings specifications
- Create workable instructions for manufacture
- Select tooling equipment
- Prepare job descriptions
- Determine operation assembly order
- Program automated machines
30Improving the Design Process
- Design teams
- Concurrent design
- Design for manufacture assembly
- Design to prevent failures and ensure value
- Design for environment
- Measure design quality
- Utilize quality function deployment
- Design for robustness
- Engage in collaborative design
31 Breaking Down Barriers to Effective Design
32Design Teams
Preferred solution cross functional teams
- Marketing, manufacturing, engineering
- Suppliers, dealers, customers
- Lawyers, accountants, insurance companies
33Concurrent Design
- Improves quality of early design decisions
- Decentralized - suppliers complete detailed
design - Incorporates production process
- Scheduling and management can be complex as tasks
are done in parallel - include the customer in the process!!
34Design for Manufacture and Assembly
- Design a product for easy economical production
- Incorporate production design early in the
design phase - Improves quality and reduces costs
- Shortens time to design and manufacture
- also known as Design for Six Sigma
35Design for Six Sigma
- Define the goals of the design activity
- Measure customer input to determine what is
critical to quality from the customers
perspective what are customer delighters? What
aspects are critical to quality? - Analyze innovative concepts for products and
services to create value for the customer - Design new processes, products, and services to
deliver customer value - Verify new systems perform as expected
36DFM Guidelines
- Minimize the number of parts, tools, fasteners,
and assemblies - Use standard parts and repeatable processes
- Modular design
- Design for ease of assembly, minimal handling
- Allow for efficient testing and parts replacement
37Design for Assembly (DFA)
- Procedure for reducing number of parts
- Evaluate methods for assembly
- Determine assembly sequence
38Design Review
- Failure Mode and Effects Analysis (FMEA)
- A systematic approach for analyzing causes
effects of failures - Prioritizes failures
- Attempts to eliminate causes
39Value Analysis (Value Engineering)
Is there value added?
- Ratio of value / cost
- Assessment of value
- 1. Can we do without it?
- 2. Does it do more than is required?
- 3. Does it cost more than it is worth?
- 4. Can something else do a better job
- 5. Can it be made by less costly method, tools,
material? - 6. Can it be made cheaper, better or faster by
someone else? Should we contract it out?
40Design for Environment
- Design from recycled material
- Use materials which can be recycled
- Design for ease of repair
- Minimize packaging
- Minimize material energy used during
manufacture, consumption disposal - green laws in Europe -
41Examples
- Recycling of oil
- carpets in land fills - 4 billion pounds in land
fills annually - Xerox and Hewlett-Packard - pay for return of
printer cartridges on larger printers
42Metrics for Design Quality
- Percent of revenue from new products or services
- Percent of products capturing 50 or more of the
market - Percent of process initiatives yielding a 50 or
more improvement in effectiveness - Percent of suppliers engaged in collaborative
design
43Metrics for Design Quality
- Percent of parts that can be recycled
- Percent of parts used in multiple products
- Average number of components per product
- Percent of parts with no engineering change
orders (ULLS/SAMS/SARSS) - Things gone wrong - should be identified by the
returns process
44Quality Function Deployment (QFD)
- Translates the voice of the customer into
technical design requirements - Displays requirements in matrix diagrams
- First matrix called house of quality
- Series of connected houses
45Design for Robustness
- Product can fail due to poor design quality
- Products subjected to many conditions
- Robust design studies
- Controllable factors - under designers control
- Uncontrollable factors - from user or environment
- Designs products for consistent performance
46Consistency is Important
- Consistent errors are easier to correct than
random errors - Parts within tolerances may yield assemblies
which arent - Consumers prefer product characteristics near
their ideal values
47Characteristics of Services
- Services are intangible
- Service output is variable
- Service have higher customer contact
- Services are perishable
- Service inseparable from delivery
- Tend to be decentralized and dispersed
- Consumed more often than products
- Services can be easily emulated
- Call girl principle value diminishes after
service is rendered
48A Well-Designed Service System is
- Consistent with firms strategic focus
- Customer friendly
- Easy to sustain
- Effectively linked between front back office
- Cost effective
- Visible to customer
49Design for High-Contact Services
DESIGN DECISION HIGH-CONTACT SERVICE LOW-CONTACT
SERVICE
50Design for High-Contact Services
DESIGN DECISION HIGH-CONTACT SERVICE LOW-CONTACT
SERVICE
51Chapter 6
- Processes and Technologies
52Process Strategy
- Overall approach to producing goods and services
- Defines
- Capital intensity
- Process flexibility
- Vertical integration
- Customer involvement
53Types of Processes
- Projects
- Batch production
- Mass production
- Continuous production
54Process Selection with Break-Even Analysis
Total cost fixed cost total variable
cost TC cf vcv Total revenue volume x
price TR vp Profit total revenue - total
cost Z TR - TC vp - (cf vcv)
55Process Selection with Break-Even Analysis
Total cost fixed cost total variable
cost TC cf vcv Total revenue volume x
price TR vp Profit total revenue - total
cost Z TR - TC vp - (cf vcv)
cf fixed cost v volume (i.e., number of units
produced and sold) cv variable cost per
unit p price per unit
56Solving for Break-Even Volume
57Break-Even Analysis
Fixed cost cf 2,000 Variable cost cv
5 per raft Price p 10 per raft
58Break-Even Analysis
Fixed cost cf 2,000 Variable cost cv
5 per boogie board Price p 10 per board
The break-even point is
59Process Planning
- Make-or-buy decisions
- Process selection
- Specific equipment selection
- Process plans
- Process analysis
60Make-or-Buy Decisions
- 1. Cost
- 2. Capacity
- 3. Quality
- 4. Speed
- 5. Reliability
- 6. Expertise
What about Proprietary Information? Barrier to
Make-or-Buy?
61Source Aberdeen Research, Low-Cost Country
Sourcing Success Strategies Maximizing and
Sustaining the Next Big Supply Savings
Opportunity, Jun 2005
62Specific Equipment Selection
- Purchase cost
- Operating cost
- Annual savings
- Revenue enhancement
- Replacement analysis
- Risk and uncertainty
- Piecemeal analysis one piece at
- a time
63Process Plans
- Blueprints
- Bill of material Flat or multiple layers - part
or assembly - Assembly chart /product structure diagram
- Operations process chart - list of operations
involved in assembly - Routing sheet - sequence of events
64Operations Process Chart
65Process Analysis
- The systematic examination of all aspects of a
process to improve its operation - Faster
- More efficient
- Less costly
- More responsive
- Basic tools
- Process flowchart
- Process diagrams
- Process maps
66Process Flowchart Symbols
67Process Flowchart
68Process Diagram
69Process Map
70Continuous Improvement and Breakthroughs
71Process Reengineering
72Principles for Redesigning Processes
- Remove waste, simplify, consolidate
- Link processes to create value
- Let the swiftest and most capable execute
- Capture information digitally and propagate
73Principles for Redesigning Processes
- Provide visibility through information about
process status - Fit the process with sensors and feedback loops
- Add analytic capabilities
- Connect, collect and create knowledge around the
process - Personalize the process
74Other ways to redesign the process
- Define
- Measure
- Analyze
- Improve
- Control
Velocity Management Methodology
General Electrics Six Sigma Methodology
75Techniques for Generating Innovative Ideas
- Vary entry point to a problem
- Draw analogies
- Change your perspective
- Use attribute brainstorming
76Information Technology
- Management Information Systems (MIS)
- Move large amounts of data
- Decision Support Systems (DSS)
- Add decision making support
- Expert System
- Recommend decision based on expert knowledge
77Decision Support System
78Decision Support System
79Decision Support System
Figure 4.12
80Artificial Intelligence
- Neural networks
- Emulate interconnections in brain
- Genetic algorithms
- Based on adaptive capabilities in nature
- Fuzzy logic
- Simulate human ability to deal with ambiguity
81Enterprise Software
- Collect, analyze, and make decisions based on
data - ERP - Enterprise Resource Planning
- Managing wide range of processes
- Human resources, materials management, supply
chains, accounting, finance, manufacturing, sales
force automation, customer service, customer
order entry - Finding hidden patterns through data mining
82ERP
- SAP 42 of market forecast to 43 in 2006
- Oracle 20 forecast to 23 2006
- Sage Group 6
- Microsoft 4
- Horror Stories Hersheys, Dell
83Advanced Communications
- Electronic data interchange (EDI)
- Internet, extranets
- Wireless communications
- Teleconferencing telecommuting
- Bar coding, Radio Frequency Identification
- Virtual reality
Distance Learning?
84RFID
- Active Tags
- Always on
- Battery powered
- Can be read from up to 300 ft
- US Army
- Savi Tags
- Passive Tags
- Small
- Must be activated
- May be turned off
- England
- California
- Rolex
85Automated Material Handling
- Conveyors
- Automated guided vehicle (AGV)
- Automated storage retrieval system (ASRS)
Grainger/Defense Distribution Center, San Joaquin
86Flexible Manufacturing Systems (FMS)
- Programmable machine tools
- Controlled by common computer network
- Combines flexibility with efficiency
- Reduces setup queue times
- cellular layout - more on design next week
87Robotics
- Programmable manipulators
- Follow specified path
- Better than humans with respect to
- Hostile environments
- Long hours
- Consistency
- Adoption has been slowed by ineffective
integration and adaptation of systems - Welding at Harley Davidson Plant
88Next Week
- Chapter 7, 9
- Handout Mid Term