Process Analysis II
Operations -- Prof. Juran
Outline
• Types of Processes
• Kristin
• Benihana
• Littlefield
Operations -- Prof. Juran
Low
Volume,
One of a
Kind
I.
Job
Shop
Few
High
Major
Volume,
Multiple
High
Products, Products,
Higher StandardLow
Volume
ization
Volume
Flexibility (High)
Unit Cost (High)
Commercial
Printer
French Restaurant
II.
Batch
III.
Assembly
Line
IV.
Continuous
Flow
Operations -- Prof. Juran
These are
the major
stages of
product and
process life
cycles
Heavy
Equipment
Automobile
Assembly
Burger King
Sugar
Refinery
Flexibility (Low)
Unit Cost (Low)
Process Flow Structures
• Continuous Flow (ex. Petroleum manufacturer)
• Assembly Line (ex. Automobile manufacturer)
• Batch shop (ex. Copy center making 10,000 copies of
an ad piece for a business)
• Job shop (ex. Copy center making a single copy of a
student term paper)
• Extreme Case: Project (ex. Legal Counsel for a
Criminal Trial)
Operations -- Prof. Juran
Bakery Video
• Continuous Flow (loaves of bread)
• Batch Process (pastries)
• Job Shop (custom decorated cakes)
Operations -- Prof. Juran
Kristin’s Cookies
Order
Entry
Wash Bowl, Mix Ingredients
Resource: Self
Capacity: 3
Cycle Time: 6 minutes
Fill Tray
Resource: Roommate
Capacity: 1
Cycle Time: 2 minutes
Start Oven
Resource: Roommate, Oven
Capacity: 1
Cycle Time: 1 minute
Bake
Resource: Oven
Capacity: 1
Cycle Time: 9 minutes
Cool
Resource: none
Capacity: 1
Cycle Time: 5 minutes
Remove
Resource: Roommate
Capacity: 1
Cycle Time: 0 minutes
Pack, Collect Money
Resource: Roommate
Capacity: 1
Cycle Time: 3 minutes
Operations -- Prof. Juran
1. How long will it take for you to fill a rush order?
Assuming this order is for one dozen cookies, we will need to do the following:
Activity
Resource
Cycle Time
Order Entry
E-mail
0 minutes
Wash Bowl, Mix
Self
6 minutes
Fill Tray
Self
2 minutes
Prepare Oven
Roommate
1 minute
Bake
Oven
9 minutes
Remove
Roommate
0 minutes
Cool
None
5 minutes
Pack, Collect Money
Roommate
3 minutes
Therefore, the minimum time to fill an order is 26 minutes.
Operations -- Prof. Juran
Start Time
00:00
00:00
06:00
08:00
09:00
18:00
18:00
23:00
Finish Time
00:00
06:00
08:00
09:00
18:00
18:00
23:00
26:00
Operations -- Prof. Juran
2. How many orders can you fill in a night, assuming you are open four hours
each night?
Here is a Gantt chart for two batches of one dozen cookies each. It doesn't take
twice as long to produce two batches as it does to produce one batch, because
you can start mixing the second batch without having to wait for the whole firstbatch process to be completed (you can start washing out the bowl as soon as
you finish filling the tray). It is possible to produce two batches in 36 minutes.
Operations -- Prof. Juran
In general, a formula for the number of minutes
to produce n one-dozen batches is given by this
expression:
16  10 n
Operations -- Prof. Juran
5. How many food processors and baking trays will you need?
We ought to be able to see that the processor is idle for long periods of time, and
that the real bottleneck is the oven. Buying another food processor won't
improve the productivity of the system at all.
The number of baking trays ought to equal the maximum number of trays you
will be using at any one time. Three is probably enough.
Operations -- Prof. Juran
Benihana Restaurant
Operations -- Prof. Juran
Benihana: Process Analysis
Assume that the dining process takes 60 minutes, and that we want
customers in the bar for 24 minutes.
Consider two scenarios:
Bar - 16 seats; Dining Area - 80 seats
Bar - 48 seats; Dining Area - 120 seats
Operations -- Prof. Juran
Benihana: Process Analysis
Bar - 16 seats; Dining Area - 80 seats (1:5 ratio)
It takes 60 minutes for one customer to eat dinner, and there are 80 seats in the
dining area. Therefore 80 people eat every 60 minutes (throughput).
On the average a dinner cycle is completed every 60 minutes/80 people = 0.75
minutes per person (cycle time).
We know that dinners are processed in batches of 8, so on the average a table
of 8 finishes every 8 * 0.75 = 3 minutes.
To deliver a flow of 80 diners per hour and keep the dining area full, the
16-seat bar must empty 80/16 = 5 times per hour (every 12 minutes).
We would like for the bar to empty out every 24 minutes. Therefore, it
would appear that the ratio of 1:5 (16 bar seats to 80 dining seats) is too
small.
Operations -- Prof. Juran
Benihana: Process Analysis
Bar - 48 seats; Dining Area - 120 seats (2:5 ratio)
It takes 60 minutes for one customer to eat dinner, and there are 120 seats in
the dining area. The dining room throughput is therefore 120 people per hour.
On the average a dinner cycle is completed every 60 minutes/120 people = 0.5
minutes per person (cycle time). On the average a table of 8 finishes every 4
minutes.
To send 8 people into the dining area every 4 minutes means that the 48-seat
bar must empty every 120 / 48 = 2.5 times per hour, or once every 24 minutes.
Perfect!
Given our assumptions regarding the cycle times of the bar and the dining
area, it would appear that a ratio of bar seats to grill seats of 2:5 (or 0.4 bar seat
per dining seat) is about right.
(In our case 120:48, but the ratio is more important than the specific numbers.)
Operations -- Prof. Juran
Littlefield Technologies
•Setting Up the Game
•Round 1
•Round 2
Operations -- Prof. Juran
Registering Your Team
http://tech.responsive.net/lt/juran/start.html
Today! Create your team
name and password
No apostrophes!
Operations -- Prof. Juran
Playing Round 1
Sunday Juran “initializes” and then pauses the game, generating 50
days of data.
While the game is paused, you can view your factory and analyze the
first 50 days of data, but you can’t make changes yet:
http://tech.responsive.net/lt/juran/entry.html
Juran re-starts the game ~11:00 AM Sunday Jan. 18
The game ends automatically after 4 days, 22 hours, and 35 minutes
(9:35 AM on Friday Jan. 23)
Operations -- Prof. Juran
Playing Round 1
Objective: Finish the game with the most cash
Decision variables: Purchases/sales of machines at three manufacturing
stations
Written deliverable January 17: What is the situation in the factory?
What decisions do you intend to make when the game re-starts? What
analysis led you to make those decisions? 2 pages max.
Written deliverable Jan. 31: How did your strategy work? What did you
learn from this game? 2 pages max.
Operations -- Prof. Juran
Record Holders (Round 1)
juranjuran
$1,428,756
name
$1,423,124
Shaurav Datta
Gus Giacoman
Jordin Greene
Julia Lamm
Paulo Souza
(all MBA’11 NYU)
Eliza Core
Stewart Frey
Rosny Hartono
Philip Schubert
Carlin Swint
(all EMBA’09 Cornell)
Operations -- Prof. Juran
Record Holders (Round 2)
synergy5
$1,604,719
webvan2
$1,536,599
Neil Mayer
Douglas Monaster
Yothin Peanpanich
Jeff Shiue
Diana Tsirlina
(all MBA’10 NYU)
Angela Best
Alex Cass
Steve Kang
Ryan Mazeffa
Richard Zhang
(all EMBA’09 Cornell)
Operations -- Prof. Juran
Record Holders (Total)
synergy5
$2,984,853
topops
$2,790,077
Neil Mayer
Douglas Monaster
Yothin Peanpanich
Jeff Shiue
Diana Tsirlina
(all MBA’10 NYU)
Jason Apuzzio
Piyush Bhatnagar
Jason Farrell
Yeliz Karakaya
Lynne Mazin
(all EMBA’09 Cornell)
Operations -- Prof. Juran
Summary
• Types of Processes
• Kristin
• Benihana
• Littlefield
Operations -- Prof. Juran