Introduction to Operations Management Ch 1. Introduction to Operations Management Hansoo Kim (金翰秀), Ph.D Dept. of Management Information Systems, YUST 1 Announcement Class Homepage http://yustOM.wikispaces.com/ Good Material for studying OM, "The Encyclopedia of Operations Management Terms" You can download it from the Class Homepage About Textbook? Please use “Useful websites” for studying OM You can find some links from the Class Homepage 2 What you should have done! Read Chapter 1 and 2 (Text Book?) Play with MS-Excel.. 3 OM Overview Class Overview (Ch. 0) X Operations, Productivity, and Strategy (Ch. 1, 2) Project Management (Ch. 17) Mgmt of Quality/ Six Sigma Quality (Ch. 9, 10) Queueing/ Simulation (Ch. 18) Supply Chain Management (Ch 11) Demand Mgmt Forecasting (Ch 3) Aggregated Planning (Ch. 13) Inventory Management (Ch. 12) Strategic Capacity Planning (Ch. 5, 5S) Location Planning and Analysis (Ch. 8) MRP & ERP (Ch 14) Process Selection/ Facility Layout; LP (Ch. 6, 6S) JIT & Lean Mfg System (Ch. 15) Term Project Today’s Outline What is OM? Types of OM Problem and Models Why should study OM? Three Major Functions of Organization Value-added process Goods vs. Service Scope of Operations Management History of Operations Management Trends in Business Learning Objectives 1. 2. 3. 4. 5. 6. 7. 8. Define the term operations management. Identify the three major functional areas of organizations and describe how they interrelate. Compare and contrast service and manufacturing operations. Describe the operations function and the nature of the operations manager’s job. Differentiate between design and operation of production systems. Describe the key aspects of operations management decision making. Briefly describe the historical evolution of operations management. Identify current trends in business that impact operations management. Question? Wal-Mart Boeing In the late 1970s, Wal-Mart was a niche marketer, with about 200 stores, mostly in the South. At the time, Sears, JC Penney, and Kmart dominated the retail market. Over the years, Wal-Mart gained market share at the expense of the previous market leaders, and it has now become the largest and most profitable retailer in the world! In the 1990s, the Boeing Company ran into trouble when it could not meet production deadlines. As a result, Boeing lost some orders, which had a negative impact on earnings and its stock price. Why do some companies thrive while others struggle or fail? There are a variety of reasons, to be sure. However, an important key in a company’s success or failure is how well it manages its operations. Dell.com Why?? How?? 9 What is OM(运作管理) Operations Management (OM): the set of activities(活动) that creates value(价值) in the form of goods(商品) and services(服务) by transforming inputs into outputs What activities (어떤 活动이 있는가)? How to evaluate (어떻게 评价할 것인가)? We need evaluation measures – Productivity!! (生产率) What are the better activities? (어떤 활동을 어떻게 하면 생산성이 좋을까?) Production(生产): Creating goods and services 10 Organizational Functions (企业组织的职能) 生产 Essential functions: Marketing (营销) Generates demands (需求) Gets customers(顾客) 企业组织 三个 基本职能 营销 财务/会计 Production/Operations (生产/运作) Creates product or service Procurement (获取) of required material Finance(财务)/Accounting(会计) Obtains funds, pays bills, collects money 11 Operations: Value-added(增值) Process, Transformation Process The operations function involves the conversion of inputs into outputs Input-Transformation-Output Relationships for Typical Systems Primary Transformation Functions Typical Desired Output System Primary Inputs Hospital Patients MDs, nurses, medical supplies, equipment Health care Healthy individuals Restaurant Hungry Customer Food, chef, wait staff, environment Well-prepared, wellserved food; agreeable environment Satisfied customers Automobile factory Sheet steel, engine parts Tools, equipment, workers Fabrication and assembly of cars High-quality cars Collage or university High school graduates Teachers, books, Classrooms Teaching knowledge and skills Educated individuals Department store Shoppers Displays, stocks of goods, sales clerks Attract shoppers, promote products, fill orders Sales to satisfied customers Distribution Center Stock keeping units (SKUs) Storage bins, stock pickers Storage and redistribution Fast delivery, availability of SKUs Resources Operations are not only for manufacturing!!! 13 Major Service Jobs (federal, state, local). Goods vs.Government Service Wholesale/retail (clothing, food, appliances, stationery, toys, etc.). Financial services (banking, stock brokerages, insurance, etc.). Health care (doctors, dentists, hospitals, etc.). Personal services (laundry, dry cleaning, hair/beauty, gardening, etc.). Business services (data processing, e-business, delivery, employment agencies, etc.). Education (schools, colleges, etc.). READING!! (Text book) Why manufacturing matters The challenges of managing service U.S. manufacturing versus service employment, 1940-2005 Why? Productivity and Outsourcing Decline in Manufacturing (制造业) Jobs Productivity Increasing productivity allows companies to maintain or increase their output using fewer workers Outsourcing Some manufacturing work has been outsourced to more productive companies Why Manufacturing Matters Over 18 million workers in manufacturing jobs Accounts for over 70% of value of U.S. exports Average full-time compensation about 20% higher than average of all workers Manufacturing workers more likely to have benefits Productivity growth in manufacturing in the last 5 years is more than double U.S. economy Why Manufacturing Matters More than half of the total R&D performed is in the manufacturing industries Manufacturing workers in California earn an average of about $25,000 more a year than service workers When a California manufacturing job is lost, an average of 2.5 service jobs are lost Challenges of Managing Services Service jobs are often less structured than manufacturing jobs Customer contact is higher Worker skill levels are lower Services hire many low-skill, entry-level workers Employee turnover is higher Input variability is higher Service performance can be affected by worker’s personal factors Why Should Study OM? 4 Reasons OM is one of three major functions of any organization, and it is integrally related to all the other business functions We want to know how goods(商品) and services(服务) are produced We study OM to understand what operations(运作) managers do. By understanding, we can develop the skills necessary to become such a OM Expert OM is such a costly part of an organization About 40% of all jobs are in OM 20 Scope of Operations Management Class Overview (Ch. 0) Operations, Productivity, and Strategy (Ch. 1, 2) Project Management (Ch. 17) Mgmt of Quality/ Six Sigma Quality (Ch. 9, 10) Queueing/ Simulation (Ch. 18) Supply Chain Management (Ch 11) Demand Mgmt Forecasting (Ch 3) Aggregated Planning (Ch. 13) Inventory Management (Ch. 12) Strategic Capacity Planning (Ch. 5, 5S) Location Planning and Analysis (Ch. 8) MRP & ERP (Ch 14) Process Selection/ Facility Layout; LP (Ch. 6, 6S) JIT & Lean Mfg System (Ch. 15) Term Project 21 Model Based Decision-Making Physical model Schematic model Mathematical model Assumptions Real World Problem Modeling Find Solution Feed-back ? Solution for RW Problem Model Interpretation Exact or Heuristic method Solution for Model Experiences/ Intuition What is Trade-off (절충) ? What is System? What is Pareto-Phenomenon? Example: Product Mix(产品组合) (Product mix decision making) Smart furniture company manufactures two products, Chair and Table. The profit of selling a Chair is $10.00 and that of Table is $20.00. To make a Chair, it requires 5 units of wood, 3 units of steel and 20 units of nails, and to make a Table, it requires 10 units of wood, 10 units of steel, and 10 units of nail. Suppose that the Smart furniture has 1000 units of wood, 300 units of steel, and 1000 units of nail, how many Chairs and Tables should be produced to make maximum profits? Wood: 1000 units Wood: 5 units Steel: 3 units Nail: 20 units $10.00 Wood: 10 units Steel: 10 units Nail: 10 units $20.00 Steel: 300 units Nail: 1000 units 23 Example: Forecasting(预测) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Demand 800 1400 1000 1500 1500 1500 1300 1800 1700 1300 1700 1700 1500 2300 2300 2000 1700 1800 2200 1900 ??? Past Demand for Chairs, Smart Furniture 2500 2000 Demand Week 1500 1000 500 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 W eek Demand > Products --- Lost Sales Demand < Products --- Inventory cost What is demand in 21st week? 24 Example: Waiting Line (Queueing) (排队) Which bank has better performance? Average waiting time should be less than 25 minutes !!! 25 Example: Inventory(库存) Price Break Consider the following case, where D=10,000 units (annual demand) S= $20 to place each order i = 20% percent of cost (annual carrying cost, storage, interest, obsolescence, etc.) C=Cost per unit (according to the order size; 0 ~ 499, $5.00 per unit 500~999, $4.50 per unit 1000, $3.9 per unit Which quantity should be ordered? 26 Operational Decisions Project Management(项目管理) Process Analysis Product Design and Process Selection Facility Layout(设施布置) Waiting Line Management(等候队列) Quality Management and Control(质量管理和控制) Supply Chain Management(供应链管理) Just-In-Time(准是生产) and Lean Manufacturing(精生产益) System Forecasting(预测) Aggregate Production Planning(综合计划) Inventory Control(库存控制) Material Requirements Planning (MRP) Enterprise Resource Planning (ERP) Operation Scheduling 27 History of Operations Management 28 Eli Whitney Born 1765; died 1825 In 1798, received government contract to make 10,000 muskets Showed that machine tools could make standardized parts (标准化零件) to exact specifications Musket parts could be used in any musket © 1995 Corel Corp. 29 Frederick W. Taylor Born 1856; died 1915 Known as ‘father of scientific management’(科学管理) In 1881, as chief engineer for Midvale Steel, studied how tasks were done Began first motion & time studies Created efficiency principles © 1995 Corel Corp. 30 Taylor: Management Should Take More Responsibility for Matching employees to right job Providing the proper training Providing proper work methods and tools Establishing legitimate incentives for work to be accomplished 31 Maslow’s Hierarchy of Needs 1. 2. 3. 4. 5. 자아실현 욕구 최상의 욕구로서 앞 단계의 모든 욕 구가 충족 될 때에 나타난다. 자신의 재능, 능력, 잠재력 등을 충분히 발 휘하기 위해 노력한다. 자기 존중 욕구 능력, 신뢰감, 개인의 힘, 적합성, 성 취, 독립, 자유, 명성, 인식, 수용, 주 목, 지위, 평판 애정 소속 욕구 사랑하고, 사랑을 받고, 집단에 소속 되어서 집단의 일원으로서 의미를 찾으려 하는 욕구 안전 욕구 개인의 환경 내에서 확실성, 정돈, 조직, 예측성 등을 보장받고자 하는 욕구 생리 욕구 인간의 가장 기본적 욕구로서 음식 물, 물, 산소, 잠, 성, 추위나 더위로 부터 보호 등 32 X이론, Y이론 1960년대, D.맥그레거에 의하면 경영자나 관리자는 종업원을 대하는 관점이 경험을 통하거나 또는 타성적인 속단에서 보통 다음과 같은 인간관을 가진다고 하였다. ① 인간은 선천적으로 일을 싫어하며, 가능한 한 일을 하지 않고 지냈으면 한다. ② 기 업내의 목표달성을 위해서는 통제 ·명령 ·상벌이 필요하다. ③ 종업원은 대체로 평범 하며, 자발적으로 책임을 지기보다는 명령받기를 좋아하고 안전제일주의의 사고 ·행 동을 취한다. 맥그레거는 이 3가지를 X이론이라 하고, 이는 명령통제에 관한 전통적 견해이며 낡은 인간관이라고 비판하였다. 그는 또 이러한 인간관에 입각한 조직원칙 ·관리기법으로는 새로운 당면문제나 목표 달성을 위해 조직의 총력을 결집하는 행동을 바라기 어렵다고 하면서, X이론을 대신 할 새로운 인간관으로서 다음과 같은 Y이론을 제창하였다. ① 오락이나 휴식과 마찬가지로 일에 심신을 바치는 것은 인간의 본성이다. ② 상벌만 이 기업목표 달성의 수단은 아니다. 조건에 따라서 인간은 스스로 목표를 향해 전력을 기울이려고 한다. ③ 책임의 회피, 야심의 결여, 안전제일주의는 인간의 본성이 아니 다. ④ 새로운 당면문제를 잘 처리하는 능력은 특정인에게만 있는 것은 아니다. ⑤ 오 히려 현재 기업 내에서 인간의 지적 능력이 제대로 활용되지 않고 있을 가능성이 많다. 이와 같은 Y이론은 인간의 행동에 관한 여러 사회과학의 성과를 토대로 한 것인데, 이 러한 사고방식을 가진다면, 종업원들은 자발적으로 일할 마음을 가지게 되고, 개개인 의 목표와 기업목표의 결합을 꾀할 수 있으며, 능률을 향상시킬 수 있다고 보았다. Naver 백과사전, http://100.naver.com/100.php?id=111325 33 Frank & Lillian Gilbreth Frank (1868-1924); Lillian (1878-1972) Husband-and-wife engineering team (부부공학팀) Further developed work measurement (작업측정) methods Applied efficiency methods to their home & 12 children! 16-THERBLIG Symbol Fundamental motions of hands of a worker. Motion Study Pioneer of “Ergonomics” What is Ergonomics? 34 THERBLIG(基本元素) Therbligs: The Keys to Simplifying Work Therbligs comprise a system for analyzing the motions involved in performing a task. The identification of individual motions, as well as moments of delay in the process, was designed to find unnecessary or inefficient motions and to utilize or eliminate even split-seconds of wasted time. Frank and Lillian Gilbreth invented and refined this system, roughly between 1908 - 1924. 35 Henry Ford Born 1863; died 1947 In 1903, created Ford Motor Company In 1913, first used moving assembly line to make Model T ‘Make them all alike!’ Unfinished product moved by conveyor past work station Paid workers very well for 1911 ($5/day!) Fordism: “the mass production of standardized goods, using dedicated machines and moving assembly lines, employing unskilled and semi-skilled labor in fragmented jobs, with tight labor discipline, in large factories.” 36 W. Edwards Deming Born 1900; died 1993 Engineer & physicist Credited with teaching Japan quality control methods in postWW2 Used statistics(统计学) to analyze process His methods involve workers in decisions Refer to http://www.lii.net/deming.html 37 Trends in Business The Internet, e-commerce, and e-business Management of technology Globalization Management of supply chains Outsourcing Agility Ethical behavior Management of Technology Technology: The application of scientific discoveries to the development and improvement of goods and services Product and service technology Process technology Information technology Management of Supply Chain Supply Chain: A sequence of activities and organizations involved in producing and delivering a good or service Summary Operations management is responsible for producing goods and providing services. As such, it is the core function of every business organization. Operations management plans and coordinates the use of the organization’s resources to convert inputs into outputs. Operations decisions involve design decisions and operating decisions. Design decisions are strategic; they relate to capacity planning, product design, process design, layout of facilities, and selecting locations for facilities. Operating decisions relate to quality assurance, scheduling, inventory management, and project management. In for-profit organizations, effective operations management can lead to higher productivity, lower costs, higher quality, and other competitive advantages, and increased shareholder wealth. In not-for-profit organizations, effective operations management can lead to lower costs, higher levels of customer service, and more efficient use of resources. The chapter also presents a brief overview of the historical evolution of operations management and it ends with a list of strategic issues that are currently high priority for business organizations. At the top of that list are the Internet and e-business, outsourcing, supply chain management, management of technology, and agility. Key Terms Agility(敏捷): The ability of an organization to respond quickly to demands or opportunities. Craft production(工艺生产): System in which highly skilled workers use simple, flexible tools to produce small quantities of customized goods. Division of labor(劳动力分工): The breaking up of a production process into small tasks, so that each worker performs a small portion of the overall job. E-business(电子商务): Use of the Internet to transact business. E-commerce: Consumer-to-business transactions. Interchangeable parts(通用件): Parts of a product made to such precision that they do not have to be custom fitted. Lead time(周期): The time between ordering a good or service and receiving it. Lean production(精益生产): System that uses minimal amounts of resources to produce a high volume of high-quality goods with some variety. Key Terms Mass production(大量生产): System in which low-skilled workers use specialized machinery to produce high volumes of standardized goods. Model(模型): An abstraction of reality; a simplified representation of something. Operations management: The management of systems or processes that create goods and/or provide services. Outsourcing: Obtaining a product or service from outside the organization. Pareto phenomenon( 柏拉图 现象): A few factors account for a high percentage of the occurrence of some event(s). Six sigma: A process for reducing costs, improving quality, and increasing customer satisfaction. Supply chain: A sequence of activities and organizations involved in producing and delivering a good or service. System: A set of interrelated parts that must work together. Technology: The application of scientific discoveries to the development and improvement of goods and services. Value-added(增值): The difference between the cost of inputs and the value or price of output Introduction to Operations Management Ch. 2. Competitiveness, Strategy, and Productivity Hansoo Kim (金翰秀), Ph.D Dept. of Management Information Systems, YUST 44 Learning Objectives 1. 2. 3. 4. 5. 6. 7. 8. List and briefly discuss the primary ways that business organizations compete. List five reasons for the poor competitiveness of some companies. Define the term strategy and explain why strategy is important for competitiveness. Contrast strategy and tactics. Discuss and compare organization strategy and operations strategy, and explain why it is important to link the two. Describe and give examples of time-based strategies. Define the term productivity and explain why it is important to organizations and to countries. List some of the reasons for poor productivity and some ways of improving it. Competitiveness (경쟁력,竞争力) How effectively an organization meets the wants and needs of customers relative to others that offer similar goods or services 한 기업이 유사 제품과 서비스를 제공하는 다른 기업에 비해 효과적으로 고객의 필요와 요구를 충족시켜 주는 능력 An important factor in determining whether a company prospers, barely gets by, or fails. 한 기업이 성공할 것인가? 현상을 유지할 것인가? 혹은 실패할 것인가를 결정짓는 중요한 요인 Mission/Strategy/Tactics 使命 / 战略 / 策略 Mission(使命): The purpose or rationale for an organization’s existence (조직의 존재 목적 혹은 근거) Mission Statement Strategy(战略): How an organization expects to achieve its missions and goals Tactics (策略) The methods and actions used to accomplish strategies Strategy Example Example 1 Rita is a high school student. She would like to have a career in business, have a good job, and earn enough income to live comfortably Mission: Goal: Strategy: Tactics: Operations: Live a good life Successful career, good income Obtain a college education Select a college and a major Register, buy books, take courses, study, graduate, get job Achieving Competitive Advantage through Operations Competitive Advantage (竞争优势): The creation of a unique advantage over competitors Competing on Differentiation (差别化竞争) To distinguish the offerings of the organization in any way that the customer perceives as adding value Differentiation is concerned with providing uniqueness Competing on Cost (价格竞争) Competing on Response (时间竞争) Better, Cheaper, Faster!!! 49 Businesses Compete Using Marketing Identifying consumer wants and needs Pricing Advertising and promotion OM’s Contribution to Strategy Operations Decisions Specific Strategy Used Examples Quality Product FLEXIBILITY Sony’s constant innovation of new products HP’s ability to follow the printer market Process Design Volume Southwest Airlines No-frills service LOW COST Location DELIVERY Pizza Hut’s five-minute guarantee at lunchtime Federal Express’s “absolutely, positively on time” Layout Human Resource Supply Chain Speed Dependability Maintenance Differentiation (Better) QUALITY Motorola’s automotive products ignition systems Motorola’s pagers Conformance Performance Inventory Scheduling Competitive Advantage IBM’s after-sale service on mainframe computers Fidelity Security’s broad line of mutual funds Cost leadership (Cheaper) Response (Faster) AFTER-SALE SERVICE BROAD PRODUCT LINE 51 Strategy(战略) and Tactics(策略) Distinctive Competencies The special attributes or abilities that give an organization a competitive edge. Strategy Factors Price Quality Time Flexibility Service Location Examples of Operations Strategies Evaluating Operational Decision Making Performance Measurement Efficiency(效率) vs. Effectiveness(效力) Efficiency: Doing something at the lowest possible cost Effectiveness: Doing the right things to create the most value for the company Productivity (生产率) A measurement of how well resources are used Productivity Units produced = Input used Example: if units produced = 1000 units and labor-hours used is 250, then 1000/250 = 4 units per labor hour The key factor in Operational Decisions is to improve productivity!!! 54 Problems for Measuring Productivity Quality(质量): How to measure the improvement of quality? 동일 입력 동일 출력, 그러나 다른 품질.. External elements may influence on the productivity(生产率) 외부적 요소에 쉽게 영향을 받는 경우 예) 석유값이 급등했을 경우... Precise units of measure may be lacking 100만원 짜리 자동차 한대, 10만원 짜리 자동차 1대 55 Productivity To Gain Competitive Advantage… Productivity = Output Input Partial Productivity: 1) Labor Productivity = Output/Labor 2) Capital Productivity = Output/Capital 3) Energy Productivity = Output/Energy Multifactor productivity = Profits Costs How? * Competitive Advantage (경쟁우위) : 56 경쟁자와 비교하여 우월한 성과를 갖도록 기업이 개발한 독특한 위치 Measures of Productivity Partial measures Multifactor measures Total measure Output Labor Output Output Machine Capital Output Labor + Machine Output Energy Output Labor + Capital + Energy Goods or Services Produced All inputs used to produce them Table 2.4 Quiz: ABS Co. has 10 staffs, each working 8 hrs/day (Payroll cost: $100) and overhead cost $50 per day. This company makes 10 audio sets each day. This company trying to buy new machine that allow the processing of 15 audio sets per day. For using this machine, all things are same except for overhead expenses ($ 100/day) Analyze the ABS co. in terms of productivity! 58 Quiz: Calculate Productivity # of staffs 10, each working 8hrs (for a payroll cost of $100/day) and overhead expenses of $50 per day. Output 10 units per day Overhead cost ->$100 per day Labor productivity w/ old system = 10 units per day/80 labor-hour per day = 0.125 units per labor-hour Labor productivity w/ new system = 15/80 = 0.1875 units per laborhour Multifactor productivity w/ old system = 10 units per day/($100+50) = 0.067 units per dollar Multifactor productivity w/ new system = 15/($100 + 100) = 0.075 units per dollar Improvement: (0.1875-0.125)/0.125 = 0.5=> 50 % increased in labor-productivity 0.075/0.0667 = 1.119=> 11.9% increased in multifactor productivity New system: 15 units per day Analysis in terms of Productivity: Caution: unit 59 Productivity Variables Three critical factors to improved productivity Labor(劳动), historically 10% improvement Capital(资金), about 38% improvement Management(经营), about 52% improvement Knowledge has value to improve productivity => Money Technology Knowledge Management (지식경영) 60 Summary Competition is the driving force in many organizations. It may involve price, quality, special features or services, time, or other factors. To develop effective strategies for business, it is essential for organizations to determine what combinations of factors are important to customers, which factors are order qualifiers, and which are order winners. It is essential that goals and strategies be aligned with the organization’s mission. Strategies are plans for achieving organizational goals. They provide focus for decision making. Strategies must take into account present and future customer wants, as well as the organization’s strengths and weaknesses, threats and opportunities. These can run the gamut from what competitors are doing, or are likely to do, to technology, supply chain management, and e-business. Organizations generally have overall strategies that pertain to the entire organization and strategies that pertain to each of the functional areas. Functional strategies are narrower in scope and should be linked to overall strategies. Time-based strategies and qualitybased strategies are among the most widely used strategies business organizations employ to serve their customers and to become more productive. Productivity is a measure of the use of resources. There is considerable interest in productivity both from an organizational standpoint and from a national standpoint. Business organizations want higher productivity because it yields lower costs and helps them to become more competitive. Nations want higher productivity because it makes their goods and services more attractive, offsets inflationary pressures associated with higher wages, and results in a higher standard of living for their people. To be OM Expert !!! Developing Proper Model Understanding Problem Existing Models: LP Model, Queueing Model, Simulation Model, PERT/CPM Model Communicable with other OM People Domain Expert (Studying general Problems and Working Experience) Develop New Models OM EXPERT!! Operations Research (경영과학) Mathematical Programming, and Computational Methodology Finding Solution Technique 62 What you should do by the next time! HW #1 (Due Date: 2008/3/18 Try all examples and Solved Problem Solve the Problem on Chapter Review Ch. 1 and 2 again Important Concepts Important People Keywords Read Ch. 17 63 Good Bye! 64