D30 Process Analysis

Operations Management:
Process Analysis and Applications Module
Changing Sources of Competitive Advantage Targeting Improvement: Operational Measures - Time T, Inventory I, Throughput rate R
Link through Littles Law Link to Financial Measures Targeting improvement: CRU Computer Rentals
Capacity and Flow Time Analysis

Pizza Pazza Levers for Improvement
Multi-product Capacity Management and Investment

Joint Marketing & Production Decisions Optimal Capacity Investment National Cranberry Cooperative
S. Chopra/Operations/Process Analysis & Apps
How can operations help a company compete? The changing sources of competitive advantage
Low Cost & Scale Economies (< 1960s) You can have any color you want as long as it is black Focused Factories (mid 1960s) Flexible Factories and Product variety (1970s) A car for every taste and purse.
Quality (1980s) Quality is free. Time (late 1980s-1990s) We love your product but where is it? Dont sell what you produce. produce what sells.
2
What is Improvement? Operational Performance Measures

Flow time Throughput Inventory Process Cost Quality
The business imperative: creating economic value

Improvement levers Revenues Price x Quantity Material + Labor + Energy + Overhead 1. 2. Increase price Increase throughput
Profit
Costs Economic value added (EVA) -
3. 4.
Reduce costs Improve quality
Capital invested Opportunity cost x Weighted average cost of capital
PP&E + Inventory + Other
5. 6.
Reduce capital intensity Reduce inventory
Reduce time
Operational metrics
4
Financial metrics
Relating operational measures (flow time T, throughput R & inventory I) with Littles Law
Inventory I Flow rate/Throughput R
...
... ...
[units]
... ...
[units/hr]
Flow Time T [hrs]
Flow time = Inventory / Throughput T = I/R Turnover = Throughput / Inventory = 1/ T

5
Process Flow Examples

Customer Flow: Taco Bell processes on average 1,500 customers per day (15 hours). On average there are 75 customers in the restaurant (waiting to place the order, waiting for the order to arrive, eating etc.). How long does an average customer spend at Taco Bell and what is the average customer turnover? Job Flow: The Travelers Insurance Company processes 10,000 claims per year. The average processing time is 3 weeks. Assuming 50 weeks in a year, what is the average number of claims in process.
Material Flow: Wendys processes an average of 5,000 lb. of hamburgers per week. The typical inventory of raw meat is 2,500 lb. What is the average hamburgers cycle time and Wendys turnover?
Process Flow Examples

Cash Flow: Motorola sells $300 million worth of cellular equipment per year. The average accounts receivable in the cellular group is $45 million. What is the average billing to collection process cycle time? Question: A general manager at Baxter states that her inventory turns three times a year. She also states that everything that Baxter buys gets processed and leaves the docks within six weeks. Are these statements consistent?
Targeting Improvement MBPF Inc.: Consolidated Statement

Net Sales Costs and expenses Cost of Goods Sold Selling, general and administrative expenses Interest expense Depreciation Other (income) expenses TOTAL COSTS AND EXPENSES INCOME BEFORE INCOME TAXES PROVISION FOR INCOME TAXES NET INCOME RETAINED EARNINGS, BEGINNING OF YEAR LESS CASH DIVIDENDS DECLARED RETAINED EARNINGS AT END OF YEAR NET INCOME PER COMMON SHARE DIVIDEND PER COMMON SHARE
250.0
175.8 47.2 4.0 5.6 2.1 234.7 15.3 7.0 8.3 31.0 2.1 37.2 0.83 0.21
8
Targeting Improvement MBPF Inc.: Balance Sheet

CURRENT ASSETS Cash Short-term investments at cost (approximate mkt.) Receivables, less allowances of $0.7 mil Inventories Other current assets TOTAL CURRENT ASSETS PROPERTY, PLANT AND EQUIPMENT (at cost) Land Buildings Machinery and equipment Construction in progress Subtotal Less accumulated depreciation NET PROPERTY, PLANT AND EQUIPMENT Investments Prepaid expenses and other deferred charges Other assets TOTAL ASSETS 2.1 3.0 27.9 50.6 4.1 87.7
2.1 15.3 50.1 6.7 74.2 25.0 49.2 4.1 1.9 4.0 146.9
Targeting Improvement MBPF Inc.: Inventory and Cost of Goods

INVENTORY Raw materials (roof) Fabrication WIP (roof) Purchased parts (base) Assembly WIP Finished goods TOTAL COST OF GOODS SOLD Raw materials Fabrication (L&OH) Purchased parts Assembly(L&OH) TOTAL 6.5 15.1 8.6 10.6 9.8 50.6
50.1 60.2 40.2 25.3 175.8
10
Targeting Improvement
MBPF Business Process Flows

$60.2/yr $25.3/yr
$50.1/yr
$6.5
Raw Materials (roofs)
$15.1
Fabrication (roofs)
$110.3/yr
$10.6
Assembly
$175.8/yr
$9.8
$175.8/yr
$40.2/yr
$8.6
Purchased Parts (bases)
Finished Goods
$40.2/yr
11
Targeting Improvement MBPF Inc.: Flow Times
Raw Materials Throughput R $/Year $/Week Inventory I ($) Flow Time T = I/R (weeks) 50.1 0.96 6.5 6.75
Fabrication
Purchased Parts 40.2 0.77 8.6 11.12
Assembly
Finished Goods 175.8 3.38 9.8 2.90
110.3 2.12 15.1 7.12
175.8 3.38 10.6 3.14
12
Targeting Improvement
Flow rate R ($/week)
5.0
3.38
Accounts
Assembly
2.12 0.96 0.77

Fabrication
Receivabl e
Finished Goods
Purchased Parts
11.12
Raw Materials
6.75
7.12
3.14
2.90
5.80
Flow Time T (weeks)

S. Chopra/Operations/Process Analysis & Apps 13
Why the Difference in Performance?

Inventory Over Last 8 Quarters (Ending Q3 2001)
6000
5000
4000
Inventory
3000
Nokia Ericsson Motorola
2000
1000
0 0 1 2 3 4 5 6 7 8 9
Quarter
CRU Computer Rentals
15
Learning Objectives Basic Process Analysis

Process Measures: time, inventory, and throughput What is an improvement?
Link financial and operational measures Good operational measures are leading indicators of financial performance
Using Littles law for process flow analysis Targeting areas and performance measures for improvement
16
Operations Management:
Process Analysis and Applications Module
Changing Sources of Competitive Advantage Operational Measures: Time T, Inventory I, Throughput rate R
Link through Littles Law Link to Financial Measures Targeting Improvement: CRU Computer Rentals
Capacity and Flow Time Analysis

Pizza Pazza Levers for Improvement
Multi-product Capacity Management and Investment

Joint Marketing & Production Decisions Optimal Capacity Investment National Cranberry Cooperative
17
Operational Performance Measures

How to measure and decrease flow times? How to measure and increase throughput?
18
Pizza Pazza Flow Chart
19
Process Architecture is defined and represented by a process flow chart:

Process = network of activities performed by resources 1. Process Boundaries:
input output
2. Flow unit: the unit of analysis 3. Network of Activities & Storage/Buffers

activities with activity times routes: precedence relationships (solid lines)
4. Resources & Allocation 5. Information Structure & flow (dashed lines)

Operational Measure: Flow Time Driver: Critical Activity Times

(Theoretical) Flow Time Critical Activity Flow Time efficiency
21
Most time inefficiency comes from waiting:

E.g.: Flow Times in White Collar Processes
Industry Life Insurance Consumer Packaging Commercial Bank Hospital Automobile Manufacture Process New Policy Application New Graphic Design Average Flow Theoretical Flow Flow Time Efficiency Time Time 72 hrs. 18 days 7 min. 2 hrs. 34 min. 3 hrs. 5 hrs 0.16% 0.14% 2.36% 3.75% 5.60%
Consumer Loan 24 hrs. Patient Billing Financial Closing 10 days 11 days
22
Levers for Reducing Flow Time
Decrease the work content of critical activities

work smarter work faster do it right the first time change product mix
Move work content from critical to non-critical activities

to non-critical path or to ``outer loop
Reduce waiting time.

23
Operational Measure: Capacity Drivers: Resource Loads

(Theoretical) Capacity of a Resource Bottleneck Resource (Theoretical) Capacity of the Process Capacity Utilization of a Resource/Process =
throughput [units/hr] capacity [units/hr]
24
A Recipe for Capacity Measurements

Resource Unit Load Resource Capacity (time/job) Unit Capacity # of units Total Process Resource Capacity Utilization*
* assuming system is processing at full capacity
25
Pricing and Capacity Investment: Pans + Rent another oven at 10/hr?

Resource cost = 8/hour Material cost = 1.4/pizza
Minimum
sale price =
Contribution margin if sale price is 5 / pizza =
26
Cost Capacity Profile

Demand Capacity
[units/time]
Process Capacity
Resource x
NCX-10
Furnaces
Marginal Investment Cost

[$/unit/time]
27
Levers for Increasing Process Capacity
Decrease the work content of bottleneck activities

work smarter work faster do it right the first time change product mix
Move work content from bottlenecks to non-bottlenecks

to non-critical resource or to third party
Increase Net Availability

work longer increase scale (invest) increase size of load batches eliminate availability waste: decrease changeover time
28
Increasing Process Capacity in The Goal

is
to increase the capacity of only the bottlenecks

increase availability of bottleneck resources eliminate non-value added work from bottlenecks
ensure the bottlenecks time is not wasted
reduce/eliminate setups and changeovers reduce starvation & blockage
synchronize flows to & from bottleneck
the load of the bottlenecks (give it to non-bottlenecks)

move work from bottlenecks to non-bottlenecks need resource flexibility
unit capacity and/or

invest
#of units.
29
Other factors affecting Process Capacity

Batch (Order) Sizes Product Mix other managerial policies ...
30
Product Mix Decisions: Pizza Pazza offers 2 products

Sale Price of thin crust pizza: Cost of Materials: Sale Price of deep dish pizza: Cost of Materials: 5.00/pizza 1.40/pizza 7.50/pizza 1.90/pizza
31
Product Mix Decisions

Processing Times Thin Crust Prepare sauce 2 mins. Prepare dough 3 mins Prepare pizza 1 min Load Oven & Set 1 Bake Pack Receive Total
15
25
Deep Dish
29
42
Resource
Jean
Jean
Jean
Jacq+ Oven
Oven
Jacq
Jacq
32
Product Mix Decisions

Margin per thin crust pizza = 3.60 Margin per deep dish pizza = 5.60 Margin per oven minute from thin crust = 3.602 / 16 = 0.450 Margin per oven minute from deep dish = 5.602 / 30 = 0.373
33
National Cranberry Cooperative
34
Learning Objectives: Multi-Product Process Analysis & Apps
Process measures:
Flow time manage critical activities Capacity manage bottleneck resources
Levers for improving

Flow time manage critical activities
Decrease time in critical activities Perform activities in parallel Decrease waiting time
Capacity & Throughput manage bottleneck resources

Decrease unit load of bottleneck resource Move work from bottleneck to non-bottleneck resource Increase availability of bottleneck resource
Shifting bottleneck
Bottleneck affected by product mix, batch size and other factors Product profitability based on $ per unit time on bottleneck

D30 Process Analysis

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Operations Management:

Process Analysis and Applications Module

Capacity and Flow Time Analysis

Multi-product Capacity Management and Investment

S. Chopra/Operations/Process Analysis & Apps

S. Chopra/Operations/Process Analysis & Apps

What is Improvement? Operational Performance Measures

S. Chopra/Operations/Process Analysis & Apps

The business imperative: creating economic value

Costs Economic value added (EVA) -

Reduce costs Improve quality

Capital invested Opportunity cost x Weighted average cost of capital

PP&E + Inventory + Other

Reduce capital intensity Reduce inventory

Flow Time T [hrs]

Flow time = Inventory / Throughput T = I/R Turnover = Throughput / Inventory = 1/ T

S. Chopra/Operations/Process Analysis & Apps

Process Flow Examples

S. Chopra/Operations/Process Analysis & Apps

Process Flow Examples

S. Chopra/Operations/Process Analysis & Apps

Targeting Improvement MBPF Inc.: Consolidated Statement

Targeting Improvement MBPF Inc.: Balance Sheet

S. Chopra/Operations/Process Analysis & Apps

Targeting Improvement MBPF Inc.: Inventory and Cost of Goods

50.1 60.2 40.2 25.3 175.8

S. Chopra/Operations/Process Analysis & Apps

MBPF Business Process Flows

S. Chopra/Operations/Process Analysis & Apps

Targeting Improvement MBPF Inc.: Flow Times

Purchased Parts 40.2 0.77 8.6 11.12

Finished Goods 175.8 3.38 9.8 2.90

110.3 2.12 15.1 7.12

175.8 3.38 10.6 3.14

S. Chopra/Operations/Process Analysis & Apps

2.12 0.96 0.77

Flow Time T (weeks)

Why the Difference in Performance?

Nokia Ericsson Motorola

CRU Computer Rentals

S. Chopra/Operations/Process Analysis & Apps

Learning Objectives Basic Process Analysis

S. Chopra/Operations/Process Analysis & Apps

Process Analysis and Applications Module

Capacity and Flow Time Analysis

Multi-product Capacity Management and Investment

S. Chopra/Operations/Process Analysis & Apps

Operational Performance Measures

S. Chopra/Operations/Process Analysis & Apps

Pizza Pazza Flow Chart

S. Chopra/Operations/Process Analysis & Apps

Process Architecture is defined and represented by a process flow chart:

2. Flow unit: the unit of analysis 3. Network of Activities & Storage/Buffers

4. Resources & Allocation 5. Information Structure & flow (dashed lines)

Operational Measure: Flow Time Driver: Critical Activity Times

(Theoretical) Flow Time Critical Activity Flow Time efficiency

S. Chopra/Operations/Process Analysis & Apps

Most time inefficiency comes from waiting:

Consumer Loan 24 hrs. Patient Billing Financial Closing 10 days 11 days

S. Chopra/Operations/Process Analysis & Apps

Levers for Reducing Flow Time

Decrease the work content of critical activities

Move work content from critical to non-critical activities