PRODUCTION PROCESS
Modelling
Processes Modelling
Dr. Mujabi Shafic
Outline
Process Model Planning
Process Model Analysis
Process Model Innovation
Dr. Mujabi Shafic
Process Model Planning
Process
◼ a group of related tasks with specific inputs and
outputs
Process design
◼ tasks need to be done and coordinated among
functions, people, and organizations
Process planning
◼ converts designs into workable instructions for
manufacture or delivery
Process strategy
◼ an organization’s overall approach for physically
producing goods and services
Dr. Mujabi Shafic
Process Model Strategy
Capital intensity Model
◼ mix of capital (i.e., equipment, automation) and labor
resources used in production process
Process Model flexibility
◼ ease with which resources can be adjusted in response to
changes in demand, technology, products or services, and
resource availability
Vertical integration Model strategy
◼ extent to which firm will produce inputs and control outputs
of each stage of production process
Customer involvement Model
◼ role of customer in production process
Dr. Mujabi Shafic
Process Plan models
Set of documents that detail manufacturing
and service delivery specifications
◼ assembly charts
◼ operations sheets
◼ quality-control check-sheets
Dr. Mujabi Shafic
What is a Model?
A structure which has been built purposefully
to exhibit features and characteristics of
some other object, System, process or
iteration .
‘Do not use “thing” or “something” in a definition’
For
◼ Improved understanding and communication
◼ Experimentation
◼ Standardization for analysis
Abstraction vs. computability
Dr. Mujabi Shafic
Process Modelling
Process flowcharts
◼ Symbolic representation of processes
◼ Incorporate
⚫ nonproductive activities (inspection,
transportation, delay, storage)
⚫ productive activities (operations)
Dr. Mujabi Shafic
Model Simulation Steps
a.- Problem Definition
b.- Statement of Objectives
c.- Model Formulation and Planning
d.- Model Development and Data Collection
e.- Verification
f.- Validation
g.-Experimentation
h.- Analysis of Results
i.- Reporting and Implementation
j.- Remodel whenever needed
The Basic Principles of Modeling
• To conceptualize a model use
– System knowledge
– Engineering judgement
– Model-building tools
• Remodel as needed
• Regard modeling as an evolutionary
process
Modeling !
Use models
◼ Physical models (prototypes)
◼ Schematic models (Graphs, charts, pictures)
◼ Mathematical models,
⚫ Statistical models
⚫ Inventory models
⚫ Linear programming
⚫ Queuing techniques
⚫ Project management models
Dr. Mujabi Shafic
Some Key Modeling Issues
• Alternatives for Modeling Downtimes
and Failures
– Ignore them
– Do not model directly but adjust processing
time accordingly
– Use constant values for failure and repair
times
– Use statistical distributions
Dr. Mujabi Shafic
Key Modeling Issues -contd
• Time to failure
– By wall clock time
– By busy time
– By number of cycles
• Time to repair
– As a pure time delay
– As wait time for a resource
Dr. Mujabi Shafic
Key Modeling Issues -contd
• What to do with an item in the machine
when machine downtime occurs?
– Scrap
– Rework
– Resume processing after downtime
– Complete processing before downtime
Dr. Mujabi Shafic
Goals of Manufacturing
Modeling
• Manufacturing Systems
– Identify problem areas
– Quantify system performance
• Supporting Systems
– Effects of changes in order profiles
– Truck/trailer queueing
– Effectiveness of materials handling
– Recovery from surges
Dr. Mujabi Shafic
What type of models
Simulation models : to test a proposed
idea
– Monte Carlo Simulation
Optimization models : to create an
optimal idea
– Linear programming
Pattern recognition models : to recognize
a pattern
– Statistics, Forecasting, data mining
Dr. Mujabi Shafic
Decision Making
Models
Quantitative approaches
Analysis of trade-offs
Systems approach
Dr. Mujabi Shafic
Models Are Beneficial
Easy to use, less expensive
Require users to organize
◼ Increase understanding of the problem
◼ Consistent tool
◼ Standardized format
◼ Specific objectives
Systematic approach to problem solving
◼ Analysis of tradeoffs
◼ Enable “what if” questions
Power of mathematics
Dr. Mujabi Shafic
Process Model Symbols
Operations
Inspection
Transportation
Delay
Storage
Dr. Mujabi Shafic
Date: 9-30-02 Location: Graves Mountain
Analyst: TLR Process: Apple Sauce
Distance
Operation
Transport
Description
Storage
Inspect
(feet)
(min)
Time
Delay
Step
of
process
1 Unload apples from truck 20
A Process 2
3
Move to inspection station
Weigh, inspect, sort 30
100 ft
4 Move to storage
Model 5 Wait until needed 360
50 ft
6 Move to peeler 20 ft
of Apple 7
8
Apples peeled and cored
Soak in water until needed
15
20
Processing 9
10
Place in conveyor
Move to mixing area
5
20 ft
11 Weigh, inspect, sort 30
Page 1 0f 3 Total 480 190 ft
Dr. Mujabi Shafic
Principles for Improving a production
Modeling
Remove waste, simplify, and consolidate
similar activities
Link processes to create value
Let the swiftest and most capable enterprise
execute the process
Flex process for any time, any place, any way
Capture information digitally at the source and
propagate it through process
Dr. Mujabi Shafic
Principles for improving a
Process Models (cont.)
Provide visibility through fresher and richer
information about process status
Fit process with sensors and feedback loops
that can prompt action
Add analytic capabilities to process
Connect, collect, and create knowledge around
process through all who touch it
Personalize process with preferences and
habits of participants
Dr. Mujabi Shafic
Performance Measures
in Production Modeling
• Throughput under average and peak loads
• Utilization of resources, labor and
machines
• Bottlenecks
• Queueing
• WIP storage needs
• Staffing requirements
• Effectiveness of scheduling and control
Dr. Mujabi Shafic
Important questions when
modeling
• Some relevant questions
– How a new/modified system will work?
– Will throughput be met?
– What is the response time?
– How resilient is the system?
– How is congestion resolved?
– What staffing is required?
– What is the system capacity?
Assessment questions
1. Using the knowledge acquired from this
presentation. Illustrate a process model of
either;–
a) Your local supermarket
b) Your Hospital or clinic
c) Bank
Use process model symbols for that
illustration. (20 marks)
Dr. Mujabi Shafic
2. Having illustrated the current model,
describe its problems and recommend how
to improve it. ( 20 marks)
Dr. Mujabi Shafic