Chapter four
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Learning objectives
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4.1 Introduction
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4.2 Understanding processes
• Use systems thinking in design phase so that: -
– User requirements are met
– Users understand the process
• Continuous process improvement necessary for
continued process effectiveness & efficiency
Process design characteristics for ease of understanding : -
– Accurate definition of product or service to be produced
– Clear understanding of target market needs
– Identification of all potential suppliers
– Accurate definition of production process to be used
– Error free
– Continuous process performance feedback
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4.4 Process structures for
manufacturing
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Definitions
• Job process is structured around
particular events
• Batch process make use of small or large
batches
• Continuous Flow process is also known as
the product-focused process.
• Line process produces one type of
product in a straight-line process
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Process Design
Check all
Conduct Collect Test
Materials
Test Materials
handed in
Test Papers
Hand out
Students Students
Tests get get
into Boxes Scripts Marks
Line of Visibility
Test Venue
Lecturer
Tests to
Go to
Marks to Students
Print
Send to Get Test Mark
Question
Invigilator Material Tests
Papers
Design Print Test Capture
Test Master Books & Marks Marks
MCQ Sheets in System
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Process performance measurement
• Process performance specifications must be
determined at process design phase
Performance metrics:
• Benchmarking – aligning process performance to the
industry best practice
• Process performance ratios:
– efficiency
– Productivity
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Efficiency
• Efficiency ratio compares the actual output to the desired output
Example:
• A machine has been designed to fill 30 bottles per minute (design
capacity) but the output measurement found that the machine filled
60 bottles per minute.
• Calculate the Efficiency (in percentage) of this machine?
• Formula:
• Efficiency = [Actual rate/Designed production rate] x 100
• Efficiency = [60 bottles / 30 bottles] x 100
= 200%
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Productivity
Productivity – measure of the output against the input (labour time)
used
Example:
In a Factory that manufactures leather shoes, it takes 153 labour
hours to produce 85 pairs of shoes. Calculate the factory’s labour
productivity (i.e. shoes produces per hour)
Formula
• Productivity = Output / Input
• Productivity = 85 pairs / 153 hours
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Productivity (cont’d)
Example:
Thoko has a small business called Bedazzled. She currently
employs 3 women who produce 84 bracelets in a 7 – hour
working day. What is their productivity? (i.e. bracelets produced
per hour)
• Input 3 x 7hrs = 21 hrs
• Productivity = Output / Input
• Productivity = 84 bracelets / 21 hrs
• Productivity = 4 bracelets produced per hour
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4.5 Strategies for manufacturing
processes
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