CH 9 PRC-5 PDF
CH 9 PRC-5 PDF
CH 9 PRC-5 PDF
Chapter 9
Business operations of a manufacturing organisation
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Making the decisions involved in the effort to attain these goals is the job of the
operations manager. That person’s responsibilities can be grouped as follows:
Making the decisions involved in the effort to attain these goals is the job of the
operations manager. That person’s responsibilities can be grouped as follows:
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Production
Mass-customization Customization
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Production
Mass-customization Customization
Dell computers is a common example. ▪ Building individual houses is a
American Leather, a Dallas-based common example.
furniture manufacturer, which uses mass- ▪ Another example is a print shop
customization to produce couches and which may handle a variety of
chairs to customer specifications within projects, including newsletters,
30 days. The basic frames in the furniture brochures, stationery, and reports.
are the same, but automated cutting ▪ A manufacturing firm that produces
machinery precuts the color and type of goods in response to customer
leather ordered by each customer. Using orders is called a job shop.
mass-production techniques, they are
then added to each frame.
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Production
Timing
Intermittent
Continuous process
process
A continuous process uses long In an intermittent process, short
production runs that may last days, production runs are used to make batches
weeks, or months without of different products. Machines are shut
equipment shutdowns. This is best down to change them to make different
for high-volume, low-variety products at different times.
products with standardized parts, This process is best for low-volume, high-
such as nails, glass, and paper. variety products such as those produced
by mass customization or customization.
Job shops are examples of firms using an
intermittent process.
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5) Layout: The goal is to determine the most efficient and effective design for
the production process. A manufacturer might opt for a U-shaped production
line, for example, rather than a long, straight one, to allow products and
workers to move more quickly from one area to another. Main types of facility
layouts are process, product (or assembly-line), fixed position, and cellular
manufacturing. Workers are positioned according to the selected layout.
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Production Workers
The production worker is at the bottom of the manufacturing organizational
chart. However, the production worker is one of the most important pieces to
the manufacturing strategy set forth by executive management. The production
worker, when trained properly and given the proper tools needed to complete
his job efficiently, can be the reason for the success or failure of the
manufacturing strategy. Production workers report to the production line
supervisor.
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Division of Labour
Division of Labour means that the main process of production is split up into
many simple parts and each part is taken by different workers who are
specialized in the production of that specific part.
Different workers perform different parts of production on the basis of their
specialization. The result is that goods come to the final shape with the co-
operation of many workers. For example – in a large-scale readymade garment
factory, one person cut the fabric, the second person stiches it with machines,
the third buttons, the fourth perform folding and packing, etc.
Adam Smith (1723–1790), an economist, was the first person to introduce the
concept of division of labour in his famous book The Wealth of Nations in 1776.
He illustrated the way goods or services are produced when divided into a
number of tasks that are performed by different workers, instead of all the tasks
being done by the same person.
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Departmentalization
Manufacturing companies typically use traditional structures for organizing
their resources. These almost always involve departmentalization so that
similar tasks can be grouped together. Traditional structures are quite rigid,
grouping employees by one or more of the following criteria:
▪ Function
▪ Products
▪ Processes
▪ Customers
▪ Regions
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Two other types of business structures are contemporary and team structures.
These are more flexible than traditional structures, allowing management to
move employees as needed to respond to dynamic working environments.
Project-based companies, like software companies and service companies, for
example, would often benefit from these more-flexible types of structures.
Functional Departmentalization
Functional departmentalization bases the departments on the primary
functions conducted by the company.
Functions could include
▪ Manufacturing,
▪ Engineering,
▪ Legal,
▪ Finance,
▪ Human resources,
▪ Sales and marketing.
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Product Departmentalization
Product departmentalization divides company resources based on the products
being manufactured.
A good example of product departmentalization is witnessed in an automobile manufacturing
company. In such a company, we generally see departments like a two-wheeler department,
three-wheeler department, four-wheeler department, heavy motors department.
Process Departmentalization
Process departmentalization divides departments based on the work being
done.
Best example of process departmentalization can be seen in a textile mill where we may
have a spinning department, weaving department, dyeing department, printing
department, etc. Here, inside a textile mill, all activities, which are directly or indirectly
related with spinning are grouped together to make a spinning department.
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Customer Departmentalization
Customer departmentalization usually involves different units based on the
type of customers being served.
Customer Departmentalization
In customer departmentalization, departments are separated from each other based on the
types or groups of customers to be handled or dealt with.
For example, customers can be classified under types such as, international or foreign
customers, inland or domestic customers, bulk purchasing or wholesale customers, retail
customers, etc.
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Customer Departmentalization
For example, one manufacturing unit would be catering to products being sold
to industrial consumers and another manufacturing unit would be churning out
products for household consumers.
Another example is for a lubricants manufacturing company where a specific
manufacturing facility would be making lubricants for large scale machinery
and another would be making specialized products for cars and other
automotive.
Marketing could be further divided into different marketing efforts, such as
online marketing and retailer relations. Sales departments are often divided
into units based on internal and external sales forces or different types of
clients or customers.
Geographic Departmentalization
When a manufacturer has more than one location, it's often advantageous
to divide the company by region. How this is done depends on the size of the
company and the work being done in each location. At one end of the
spectrum, a large manufacturer with independent operations in different
countries, like an auto manufacturer, could have separate companies in each
country. A smaller company may have a plant manager at each location,
each reporting to the VP of operations.
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Geographic Departmentalization
When a manufacturer has more than one location, it's often advantageous to
divide the company by region. How this is done depends on the size of the
company and the work being done in each location. At one end of the spectrum,
a large manufacturer with independent operations in different countries, like an
auto manufacturer, could have separate companies in each country. A smaller
company may have a plant manager at each location, each reporting to the VP
of operations.
Ford Motor Company, for example, has three global divisions: Americas, Asia-
Pacific, Europe, Middle East and Africa. An executive VP is in charge of each of
these divisions. These are in addition to the company's functional groups, which
operate at a global level.
Delegation
If all organisational activities, strategic and routine, could be managed by the
top executives, the need for a formal organisational structure with functional
departments, staffed with people of different calibre, carrying out different
activities would not have arisen. Since it is not possible, because of physical
and mental limitations, for one person to perform all activities with respect to
all functional areas, it becomes necessary that he gives part of his workload
to subordinates along with commensurate authority to carry out the assigned
task. This concept is called delegation.
Delegation is a process the manager uses in distributing work to the
subordinates.
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5. Fifth Pillar: Global business services division also uses a geographic model to
support its other business units in areas like accounting, information technology,
payroll and facilities managemen
2.3 Choosing an Organizational Structure
A small manufacturing unit with a limited workforce may be able to work
efficiently as a functional structure. However, when the company grows, when
more products are added to production facilities and when a second or third plant
is needed, the questions surrounding organizational structure become much more
complex.
It is important to align the choices in organizational structure with the company’s
strategies. This involves asking critical questions such as:
• Should manufacturing responsibility be centralized, or should decisions be
made locally to account for regional differences?
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• How can you best ensure technology standards are implemented across all
business units?
• Should units like engineering, asset management and maintenance be
integrated into manufacturing or separated from it?
• How much responsibility will plant managers have?
• How will responsibility be organized below the plant manager?
Overall, a manufacturing business functions best when its facilities, technologies,
and policies are integrated with recognized priorities of corporate strategy.
That’s how a manufacturing business gain efficiency by improving its operations
and productivity.
The manufacturing organizational structure also needs to be consistent with the
corporate priorities. However, simplicity of design is the main element, which in
turn requires to have a balance between two extreme structures such as either a
product- or a process-focused form of organization. The proper selection of an
optimal organization structure can smooth a company’s growth by lending
stability and efficiency to its operations.
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• control of inventory
• deciding the best production methods and factory layout.
• Close collaboration will usually be necessary between Production and
various other functions within the organisation, for example:
• Research and Development, concerning the implications of product design
for production methods and cost
• Marketing, concerning desired product functionality, appearance, quality,
durability and so on
• Finance, concerning the availability of funds for purchase of new equipment
and maintaining the optimal inventory levels.
• Human Resource Management, concerning staff motivation implications of
job design and production methods.
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Purchasing
The Purchasing department is responsible for purchase and sourcing of all raw
material and other resources used in the production. The primary responsibility
of the Purchase department is to find and acquire the most suitable material at
the most optimum price in alignment with the overall objectives of the company
and the production department.
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Increased teamwork
Manufacturing operations management requires different departments to work
together to produce quality products. This helps improve business productivity
and meet the expectations of your customers.
Ensure that you employ innovative technology to help your company achieve its
set goals and objectives. You also need to ensure that your system is working by
carrying out regular statistical control methods.
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