Process Design

Design:“To design” refers to the process of originating and developing a plan for a product, service or process.

Process:Is any part of an organization which takes a set of input resources which are then used to transform something into outputs of products or services.

Process Design

Processes that Design Products

and Services

Concept Generation

Screening

Preliminary Design

Evaluation and Improvement

Prototyping and final design

Processes that Produce Products

and ServicesSupply Network Design

Layout and Flow

Process Technology

Job Design

Process design

Nature of the design activity:

1) Design is inevitable – products, services and the processes which produce them all have to be designed.

2) Product design influences process design – decisions taken during the design of a product or service will have an impact on the decisions taken during the design of the process which produces those products or services and vice versa.

Product & services design are interrelated to its process design

Decisions taken during the design of the product or service will have an impact on the process that produces them and vice versa

Products and services should be designed in such a way that they

can be created effectively

Processes should be designed so they can

create all products and services which

the operation is likely to introduce

Designing the Product or

Service

Designing the Processes that

Produce the Product or Service

Process Design and Product/Service Design are Interrelated

• To commit to the detailed design of a product or service consideration must be given to how it is to be produced.

• Design of process can constrain the design of products and services.

• The overlap is greater in the service industry:• Service industry - it is impossible to separate service

design and process design – they are the same thing.• Manufacturing industry - it is possible to separate

product design and process design but it is beneficial to consider them together because the design of products has a major effect on the cost of making them.

Process and product/service design must satisfy customer• Products/services designer customers satisfaction criteria

• Aesthetically pleasing• Reliability• Meets expectation• Inexpensive• Quality• Easy to manufacture and deliver• Speedy

• Process designer customers satisfaction achieved through:• Layout• Location• Process technology• Human skills

The design activity is itself a process Finished designs which are:

High quality: Error-free designs which fulfil their purpose in an effective and creative way

Speedily produced: Designs which have moved from concept to detailed specification in a short time

Dependably delivered: Designs which are delivered when promised

Produced flexibly: Designs which include the latest ideas to emerge during the process

Low cost: Designs produced without consuming excessive resources

TRANSFORMED RESOURCES

Technical informationMarket informationTime information

TRANSFORMING RESOURCES

Test and design equipment

Design and technical staff

THE DESIGN ACTIVITY OUTPUTINPUTS

Designing processes• Process mapping• Process mapping symbols• Improving processes• Process performance• Throughput, cycle time & work in process

Process mapping• Used to identify different types of activities.

• Shows the flow of material, people or information.

• Critical analysis of process maps can improve the process.

Process performance• Process performance can be judge against the

five key performance objective: Quality Speed Dependability Flexibility Cost

Throughput, work content, cycle time, and work in process

• Throughput – the time for a unit to move through the process

• Work content – the total amount of work required to produce a unit of output (measured in time)

• Cycle time – The average time between units of output emerging form the process

• Work in process (WIP) –unfinished items in a production process waiting for further processing e. g. when customers join a queue in a process they become WIP

throughput = work in process x cycle time

Process Types

Project Processes

• One-off, complex, large scale, high work content “products”

• Specially made, every one customized• Defined start and finish: time, quality and cost

objectives• Many different skills have to be coordinated • Fixed position layout

Project Process

Jobbing Processes• Very small quantities: “one-offs”, or only a few

required

• Specially made. High variety, low repetition.

• Skill requirements are usually very broad

• Skilled jobber, or team of jobbers complete whole product

• Fixed position or process layout (routing decided by jobbers)

Jobbing Process

Batch Processes

• Higher volumes and lower variety than for jobbing

• Standard products, repeating demand. But can make specials

• Specialized, narrower skills• Set-ups (changeovers) at each stage of

production• Process or cellular layout

Batch Process

Mass (Line) Processes

• Higher volumes than Batch• Standard, repeat products• Low and/or narrow skills• No set-ups, or almost instantaneous ones• Cell or product layout

Mass Process

Continuous Process

• Extremely high volumes and low variety: often single product

• Standard, repeat products• Highly capital-intensive and automated• Few changeovers required• Difficult and expensive to start and stop the

process• Product layout: usually flow along conveyors

or pipes

Continuous Process

VolumeLow High VolumeLow High

Var

iety

Lo

wH

igh

Var

iety

Lo

wH

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Project

Jobbing

Batch

Mass

Contin-uous

Professional service

Service shop

Mass service

Service process types

Manufacturing process types