introduction to operations and production management

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Islamic University, Gaza - Palestine

Department of Industrial Engineering

Introduction to Operations and Production Management

Presented by

Assistant Prof. Abed Schokry


As Engineering

designed it.

© 1984-1994 T/Maker Co.

As Operations made it.

© 1984-1994 T/Maker Co.

As Marketing interpreted it.

© 1984-1994 T/Maker Co.

As the customer wanted it.

© 1984-1994 T/Maker Co.

Humor in Product Design

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Quality Function Deployment

• Product design process using cross-functional teams

– Marketing, engineering, manufacturing

• Translates customer preferences into specific product characteristics

• Involves creating 4 tabular ‘Matrices’ or ‘Houses’

– Breakdown product design into increasing levels of detail


Quality Function Deployment (Cont.)

• Identify customer wants

• Identify how the good/service will satisfy customer wants

• Relate customer wants to product hows

• Identify relationships between the firm’s hows

• Develop importance ratings

• Evaluate competing products


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QFD - House of Quality


House of Quality Sequence Indicates How to Deploy Resources to Achieve Customer Requirements


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Idea Generation Stage

• Provides basis for entry into market

• Sources of ideas

– Market need (60-80%); engineering & operations (20%); technology; competitors; inventions; employees

• Follows from marketing strategy

– Identifies, defines, & selects best market opportunities


Customer Requirements Stage

• Identifies & positions key product benefits– Stated in core benefits proposition (CBP)

– Example: Long lasting with more power (Sears’ Die Hard Battery)

• Identifies detailed list of product attributes desired by customer – Focus groups or

1-on-1 interviews

House of Quality

Customer Requirements

Product Characteristics


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Functional Specification Stage

• Defines product in terms of how the product

would meet desired attributes

• Identifies product’s engineering characteristics

– Example: printer noise (dB)

• Prioritizes engineering characteristics

• May rate product compared

to competitors’

House of QualityHouse of Quality

Customer Requirements

Product Characteristics


• Determines how product will be made

• Gives product’s physical specifications

– Example: Dimensions, material etc.

• Defined by engineering drawing

• Done often on computer

– Computer-Aided

Design (CAD)

Product Specification Stage

House of QualityHouse of Quality

ProductCharacteristics

Component Specifications


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You’ve been assigned temporarily to a QFD team. The goal of the team is to develop a new camera design. Build a House of Quality.

House of Quality Example


Mass Customization

• Using technology and imagination to rapidly mass-produce products that cater to sundry unique customer desires.

• Under mass customization the three process models become so flexible that distinctions between them blur, making variety and volume issues less significant.


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Robust Design and Modular Design

Robust Design:

• Product is designed so that small variations in production or assembly do not adversely affect the product

Modular Design:

• Products designed in easily segmented components.

• Adds flexibility to both production and marketing


• Designing products at a computer terminal or work station

– Design engineer develops rough sketch of product

– Uses computer to draw product

• Often used with CAM

© 1995 Corel Corp.

Computer Aided Design (CAD)


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• Shorter design time

• Database availability

• New capabilities

– Example: Focus more on product ideas

• Improved product quality

• Reduced production costs

Extension of CAD

• Design for Manufacturing and Assembly (DFMA)

• 3-D Object Modeling

• CAD/CAM – CAD info is translated into machine control instructions (CAM)

Benefits of CAD/CAM


Computer Integrated Manufacturing (CIM)

• Extension of flexible manufacturing systems

– Backwards to engineering and inventory control

– Forward into warehousing and shipping

– Can also include financial and customer service areas

• Reducing the distinction between low-volume/high-variety, and high-volume/low-variety production

• Heavy reliance on information technology


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Virtual Reality and Value Analysis

Virtual Reality:

• Computer technology used to develop an interactive, 3-D model of a product.

• Especially helpful in design of layouts (factory, store, home, office)

Value Analysis:

• Focuses on design improvement during production

• Seeks improvements leading either to a better product or a product which can be more economically produced.


Reliability

• Reliability

– The ability of a product, part, or system to perform its intended function under a prescribed set of conditions

– Reliability is expressed as a probability:

• The probability that the product or system will function when activated

• The probability that the product or system will function for a given length of time

Reliability– Over Time• In this case, reliabilities are determined relative to specified

length of time.

• This is a common approach to viewing reliability when establishing warranty periods


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End of Chapter 4


introduction to operations and production management

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