Process Design =
A group of resources & activities which add value by turning specific inputs into outputs
Process =
Mechanism by which ‘transforming resources’ are used to transform inputs into outputs
Layout =
How transforming resources are arranged in relation to one another
Flow =
How work moves through the layout
What are the 5 types of manufacturing process?
- project process
- Jobbing Process
- Batch process
- Mass (line) process
- Continuous process
Project process =
One-off, complex large-scale products with high work content necessitating many skills e.g. building a bridge
Jobbing process =
One-off, high variety, low repetition, broad skill requirement e.g. bespoke furniture
Batch process =
Standard product, repeating demand, can be specialised, narrow skills e.g. baking
Mass (line) process =
Like batch process but higher volume & low skills e.g. making cars
Continuous process =
Extreme volume & low variety, standard, repeat product. Expensive to start/stop. e.g. petrochemicals
3 Types of service:
- Professional Service
- Service shops
- Mass services
Professional service =
Knowledge-based, high customer contact e.g. lawyer, GP, architect
Mass services =
High volume, low customisation e.g. supermarkets, airports, call centres
Service shops =
Between pro and mass services; medium volume e.g. banks, high-street shops
5 Types of layout
- Fixed position layout
- Functional Layout
- Cell layout
- Product layout
- Retail layout
Fixed Position Layout =
Product/ recipient doesn’t move, everything else moves to it e.g. construction sites, film production
Functional (process) layout =
Groups similar processes & resources together.
Layout is designed around functions, not products. e.g. hosptials (x-ray, surgery, wards), university
Cell Layout =
Arranges different transforming resources together to produce a family of similar products with minimal movement. e.g. kitchen with different work stations all near eachother
Product Layout =
Orders resources in exact sequence of operations according to production process e.g. car assembly line, bottling plant
Retail Layout (service specific) =
Designed to influence consumer behaviour to increase spending e.g. bakery at start of Lidl, IKEA pathing, treats at checkout
As volume increases and variety decreases…
layouts become more fixed and flow-oriented
Why is flow not an issue with low volume and high variety?
The focus is on handling complexity/flexibility, not efficiency.
Lead time =
Amount of time between when an order is placed and when it is delivered
Cycle Time =
Amount of time spent working to complete an order e.g. manufacturing to order, shipping process
