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Chapter 6
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Redesigning a Process
Through Capacity Change
Define
scope
2
Identify Document
opportunity process
1 3
Implement Evaluate
changes performance
6 4
Redesign Process
(Capacity change)
5
Figure 6.1
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Utilization
Average output rate
Utilization = x 100%
Maximum capacity
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Bottlenecks
To
Inputs 1 2 3
customers
200/hr 50/hr 200/hr
Figure 6.2
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Bottlenecks
To
Inputs 1 2 3
customers
200/hr 200/hr 200/hr
Figure 6.2
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Theory of Constraints
1. Identify the system
bottleneck(s)
2. Exploit the bottleneck(s)
3. Subordinate all other
decisions to Step 2
4. Elevate the bottleneck(s)
5. Do not let inertia
set in
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Economies and
Diseconomies of Scale
250-bed 750-bed
(dollars per patient)
hospital
Economies Diseconomies
of scale of scale
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Strategies
Planned unused Forecast of
capacity capacity required
Capacity
Capacity
increment
Time between
increments
Time
(a) Expansionist strategy
Figure 6.4
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Strategies
Planned use of Forecast of
short-term options capacity required
Capacity
Capacity
increment
Time between
increments
Time
(b) Wait-and-see strategy
Figure 6.4
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Linking Process Capacity
and Other Decisions
• Competitive Priorities
• Quality
• Process
Design
• Aggregate
Planning
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Estimating Capacity
Requirements
A process serves 50 customers per day, utilization is about 90%,
and demand is expected to double in five years. Management
wants to increase the capacity cushion to 20%.
50
M= = 62.5 customers per day
50[1.0 – .20)]
Example 6.1
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Estimating Capacity
Requirements
Capacity requirement =
Processing hours required for year’s demand
Hours available from a single capacity unit
per year, after deducting desired cushion
Dp
M=
N[1 – (C/100)]
D = demand forecast for the year
p = processing time
N = total number of hours per year during which the process operates
C = desired capacity cushion
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Estimate Capacity Requirements
Example 6.2
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Estimate Capacity Requirements
Example 6.2
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Estimate Capacity Requirements
Example 6.2
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Estimate Capacity Requirements
Example 6.2
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Estimate Capacity Requirements
5305
M= = 3.12 4 machines
1700
Example 6.2
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Evaluate Alternatives
Example 6.3
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Evaluate Alternatives
Example 6.3
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Evaluate Alternatives
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Simulation Figure 6.6(a)
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Simulation Figure 6.6(b)
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Decision Trees
Low demand
Don’t expand
High demand
2
Expand
1
Low demand
High demand
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Decision Trees
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Decision Trees
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Decision Trees
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Decision Trees
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Expected Payoff = Event * Event Probability
Capacity Decisions
Decision Trees
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Expected Payoff = Event * Event Probability
Decision Trees
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Expected Payoff = Event * Event Probability
Decision Trees
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Expected Payoff = Event * Event Probability
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Expected Payoff = Event * Event Probability
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Expected Payoff = Event * Event Probability
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Expected Payoff = Event * Event Probability
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Expected Payoff = Event * Event Probability
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Expected Payoff = Event * Event Probability
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Expected Payoff = Event * Event Probability
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Decision Trees
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Decision Trees
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Decision Trees
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Decision Trees
Figure 6.7
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Solved Problem 1 Figure 6.8(a)
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Solved Problem 1 Figure 6.8(b)
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.
Capacity Decisions
Solved Problem 2
TABLE 6.1
CASH FLOWS FOR TWO-STAGE EXPANSION OF GRANDMOTHER’S CHICKEN RESTAURANT
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved.