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MindMap Gallery Production Operations Management (Business Management Chapter 11)
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Production Operations Management (Business Management Chapter 11)
Mind map of production operation management (Chapter 11 of Business Management). Production operation management is the management of the design, operation and maintenance process of the production and operation system. It plans, organizes and manages all production and operation activities of the enterprise. control
Edited at 2023-10-20 14:03:13
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Production Operations Management (Business Management Chapter 11)
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- Outline
Production operations management
The concept and development of production operations management
Production operation management is the management of the design, operation and maintenance process of the production and operation system. It plans, organizes and controls all production and operation activities of the enterprise.
The production and operation activities of an enterprise are an "input-transformation-output" process, that is, certain resources are invested, undergo a series of transformations in various forms to increase their value, and finally output and supply in some form to meet the needs social needs process. It can also be said that it is a process in which a social organization provides useful products to society by acquiring and utilizing various resources.
Components of production operations management
products and services
product
Finished or semi-finished products with certain use value
Serve
Mainly refers to intangible products
The needs of users and the market should be met, that is, the right varieties, good quality, cheap prices, and timely delivery.
factors of production
Including people (labor force), finance (funds), objects (land, buildings, machinery and equipment, process equipment, raw materials, parts, energy) and information (plans, process drawings, intelligence, etc.)
It is a prerequisite for engaging in production activities and a guarantee for achieving production management goals.
Production factors should meet the requirements of the production process in terms of quality, quantity, and time, so as to be effectively combined to form an organic whole
production operation process
That is, the formation process of products or the provision of services is also a consumption process of human, material and financial resources.
Enterprises achieve production operation management goals through the production operation process, make specific plans for product variety, quantity, quality, cost, and delivery time in the most economical production method, and ensure implementation
feedback
It is to return the output information of the production operation process to the input end in order to provide timely basis for the control of the production operation process and ensure the normal progress of the production operation process and the completion of the production plan tasks.
The status and role of production operations management
Production operation management is the basis for the operation of other management activities
relationship with business decisions
Business decision-making is in the decision-making position at the upper level of the enterprise and determines the enterprise's goals, policies, strategies and plans.
Production operation management is located at the middle level of the enterprise and is in an executive position. It organizes production activities and ensures implementation according to the specific tasks assigned by business decisions.
The relationship between decision-making and execution
Relationship with technology development management
Technology development provides design drawings, advanced production technology, advanced manufacturing materials, etc. for production and operation management, and is the technical guarantee and backing for production and operation management.
Production operations management provides information and equipment for scientific experiments conducted by technology development management.
are in an executive position and maintain a close collaborative relationship
Relationship with sales management
Production operation management provides the sales department with marketable products and parts, and plays a protective role in sales management.
Sales management provides market information for production and is the guarantee for product value realization in production operation management.
are in a productive position and have a close collaborative relationship
Production operation management determines the realization of enterprise competitive advantage
Enterprise market competitiveness factors TQCSE are closely connected with production operation management
T time control ability
QExcellent product and service quality and performance
C lowest cost and price
S best user service
E meets ecological and environmental protection requirements
Whether an enterprise has advantages in market competition factors such as time to quickly respond to the market and adapt to market changes, cost and price levels, quality, service, and ecological environmental protection are closely related to production management conditions. These market competition factors all depend on the methods and efficiency of production management.
The practicality and complexity of the production operation process and its management activities make it the birthplace of new methods, new technologies and new theories.
The production operation process is the actual place where products are manufactured or services are provided. It is the main area for creating social material wealth. The production operation process and its management activities are practical, complex and arduous, making it a laboratory for new ideas and methods. The forefront of application and development of new technologies and the birthplace of new theories
Tasks and contents of production operations management
Task
Use functions such as organization, planning, and control to effectively combine various production factors input into the production process to form an organic system and produce products that meet social needs according to the most economical production methods.
content
production operations strategy
It is a functional strategy under the overall corporate strategy
According to the enterprise's goals and overall strategy, make an overall and long-term plan for the production operation management system, determine the plans, contents and procedures that should be followed for production operation management, and form the enterprise's production operation management model.
Research, development and production operation technology selection
It refers to the material preparation, technical preparation and organizational work of production, including facility location selection, factory and workshop layout, product research, development and design, production process organization, material management, equipment management, etc.
production operation plan
It is the essence of production operation management, which refers to product-related production planning work and load distribution work, including production planning, process planning, production operation planning, material planning, human resource planning and load distribution planning, etc.
Production operation control
Refers to the inspection and adjustment management work carried out around the completion of planned tasks, including progress control, inventory control, quality control, cost control and enterprise standardization work
Research and adoption of advanced production and operation models
The use of advanced information technology means to realize the integration of production and operations and enhance the enterprise's adaptability and service level is a hot topic in modern production operation management.
Production and operation strategic decisions
concept
Production and operation strategy refers to deciding how to achieve the company's strategic goals through production and operation activities within the overall framework of the company's business strategy.
Specifically, it is to determine the guiding ideology and decision-making principles of some basic issues in production and operation management through the analysis of various resources, elements and internal and external environments of the enterprise, as well as a series of decision-making plans, contents and principles under this guiding ideology. Procedures are an important part of corporate strategy
Influencing factors
external factors
Internal factors
Competitive strategy for production operations
Cost leadership strategy
Differentiation Strategy
centralization strategy
Research and development, technology selection of products and services
Research and development of industry and services refers to the theoretical research and development work done by enterprises on new products, technical reserves, and product production technology.
The significance of corporate research and development
It is an important factor in improving market competitiveness and the engine that promotes the sustainable development of enterprises.
It is an insurance for the future of the enterprise.
It is a creative activity that explores the mysteries and laws of nature and human beings and benefits human society. It is a difficult job that requires courage and ability, and it is also the most valued by people.
Principles for selecting production operation technology
Choice of technical status
leading position
follow status
Independent technology development
Technology introduction
Selection and application of new technologies
Advanced Manufacturing Technology
modern management techniques
Production and operation capabilities
Is the maximum output rate of a piece of equipment, a process, or an enterprise
The production and operation capability of an enterprise is the sum of personnel, equipment and management capabilities.
Production operation capacity can be measured by input or output
Facility siting
Facilities are the hardware conditions for enterprise production and operation, including factories, workshops, equipment, warehouses, office buildings, etc.
The location of the facility has a significant and long-term impact on the future layout of the facility as well as the production and operation expenses, product costs, quality, etc. after the operation is put into operation, and must be carefully decided.
level
Factory site area selection
Location selection
Influencing factors
Political Factors
military factors
legal factors
economic factors
Production process of main products, raw materials, parts and energy supply
Production costs of main products (in-factory)
Product sales market demand and competition
Cost (off-site), investment, charges, taxation and supporting infrastructure
The supply and price of human resources, attracting talents, retaining talents and other human resource costs
Local government policies and partnerships
Factors such as future development space and prospects
social factors
technical factors
natural conditions factors
How to locate facilities
weighted scoring method
center of gravity method
Facility layout
It is the location arrangement of each production operation unit in the enterprise's internal production structure.
Influence
Once the location of the facility is determined, the material flow, transportation routes and transportation methods for the company's production operations are also determined.
Type of facility layout
Arrange according to process
Arrange by product
fixed arrangement
Facility layout method
Use the From-to table to list the relative positions between facilities, and use the diagonal as the basis to calculate the relative distance between construction sites to find the layout plan that minimizes the total amount of materials.
production operation planning system
It is a system that includes demand planning, comprehensive planning (production outline), master production plan, production operation plan, material plan, capacity plan, equipment plan, new product development plan and other related planning functions, and is composed of rapid feedback connections of production control information complex system
Purpose
Make full use of the company's production capacity and other resources to ensure that the order contract is completed according to quality, quantity, variety and time limit to meet market demand, improve the economic benefits of the company and increase profits as much as possible
level
long term production plan
Strategic Plan
mid-term production plan
tactical plan
short term production operation plan
production operation plan
main indicators
Variety
Yield
quality
output value
production period
comprehensive plan
It is a general decision made about the balance between resources and needs over a long period of time in the future.
It is the overall plan of the enterprise. Its purpose is to achieve the overall business goals of the enterprise, which is different or even contrary to departmental goals.
Purpose
Minimum cost/maximum profit
Maximize customer service (meet customer needs to the greatest extent)
Minimal inventory investment
Production rate stability
Minimal changes in staffing levels
Full utilization of equipment
comprehensive planning decisions
Robust adaptability
Develop plans based on market needs
Aggressive
regulating demand patterns
master production schedule
Also known as industrial production schedule planning, it is based on the demand quantity and production period of the final product, through manual intervention and balanced arrangements, so that the master production plan volume and forecast and customer orders match the total volume within a period of time, without pursuing Each specific moment is matched to the needs, resulting in a stable and balanced plan.
prepared by
Determine production forecasts for each final project based on production planning and planning lists
Calculate total demand based on production forecast, customer orders received, parts forecast, and demand quantities for this final item as a dependent demand item
Calculate the master production plan receiving quantity and expected available quantity in each time zone based on the total demand, predetermined ordering strategy and batch size, as well as safety stock and opening inventory.
Use rough capacity planning to evaluate the feasibility of master production plan alternatives, simulate and select the best, and provide a master production plan report
Material Requirements Planning (MRP)
produce
The demand for parts is different from the demand for final products. The demand for parts is a related demand.
Once the demand for the final product is determined, the demand for its raw materials and parts can be accurately calculated.
Calculation of material requirements can be completed with the help of computers
working principle
According to the product production quantity and current requirements stipulated in the master production plan, the product structure, parts and work-in-progress inventory status, lead time of each production stage (or subscription), safety stock and other information are used to calculate each part in reverse process sequence. The production quantity and deadline of components, so as to achieve minimum inventory and timely supply through precise planning and control of each production link
Decision parameter calculation
lead time
batch
safety stock
Closed Loop Material Requirements Planning
In closed-loop MRP, after the master production plan and material requirements plan are calculated, production capacity balance must be carried out through modules such as rough capacity planning and capacity requirements planning.
When preparing the master production plan, the overall capacity balance accounting work is generally carried out.
The accounting process is based on the following processing based on the parts operation plan from MRP, work center files in the production database, factory calendar, process route files, and workshop in-process task files.
Prepare process progress plan
Prepare load diagram
Load and capacity leveling
Production activity control
Manufacturing Resource Planning (MRP2)
It carries out production, planning and a series of management activities from the perspective of the entire enterprise. It makes effective planning arrangements for the enterprise's production and operation activities, and connects the scattered work centers for unified management.
It is an integrated system that integrates the production, finance, sales, procurement, technical management and other subsystems of an enterprise. Each part is interconnected and provides data to each other.
Enterprise Resource Planning (ERP)
From a functional point of view, the ERP system is still centered on the production process, and its core is MRP, which embodies the general model of the manufacturing industry.
Based on the original functions of MRP2, ERP extends in both internal and external directions.
It advocates transforming the enterprise's production management system with lean production methods internally, and adding strategic decision-making functions and supply and demand chain management functions externally.
Functional subsystem
Strategic management system that supports the overall development strategy of the enterprise
Comprehensive cost management system
new production methods
computer integrated manufacturing system
From the perspective of science, technology and creation, CIMS is a high-tech intensive technology and a highly integrated integration of systems engineering, management science, computer technology, communication network technology, software engineering and manufacturing technology.
From the perspective of manufacturing production management and operation management, CIMS is a large-scale integrated management system
From the perspective of data sharing, CIMS integrates logistics, technical information flow and management information flow, which brings data sharing in enterprises to a new level.
In terms of management technology and methods, CIMS integrates MIS, MRP2, computer-aided design, computer-aided process planning, computer-aided manufacturing, group technology and other technologies
Flexible manufacturing system
It is an automated manufacturing system that is integratedly managed and controlled by a computer and used to efficiently manufacture small and medium-sized batches of multi-variety parts.
FMS is a programmable manufacturing system that contains automatic material conveying equipment and can realize information integration and logistics integration with the support of computers. Its flexibility is reflected in the following aspects:
A variety of parts with similar physical features and processing techniques can be processed simultaneously
Ability to automatically change knives and tools
Can be easily networked and integrated with other systems
Capable of dynamic scheduling, and can dynamically reorganize logistics paths when local failures occur
Just-in-time production
It refers to producing the required products according to the required quality and quantity within the required precise time.
ideal goal
Zero defects
Zero preparation
zero inventory
Zero handling
Zero downtime
Zero lead time
batch size is one
Features
The reverse process method that changes "push" to "pull", based on the implemented orders, arranges the entire enterprise's production according to the "pull" reverse process route sequence of general assembly-component assembly-parts processing
Emphasis on "demand" and "supply", produce on time, deliver on time, and avoid backlogs
Lean production
Through changes in system structure, personnel organization, operation methods, market supply and demand, etc., the production system can quickly adapt to the changing needs of users, and all useless and redundant things in the production process can be streamlined, ultimately including the market Achieve the best results in all aspects of production, including supply and marketing
feature
Treat users as “god”
People-centered
Using "simplification" as a means
Work combination concurrent design
JIT supply method
"Zero defect" work goal
Agile manufacturing
It refers to the use of modern communication means by manufacturing enterprises to quickly allocate various resources (including technology, management and people) to respond to user needs in an effective and coordinated manner to achieve manufacturing agility.
It relies on various modern technologies and methods, the most representative of which are the organizational methods of agile virtual enterprises (referred to as virtual enterprises) and the development methods of virtual manufacturing.
Smart manufacturing
development stage
1980s: Proposition of the concept
1990s: Development of the concept
Since the 21st century: deepening of the concept
feature
Human-machine integration
virtual reality technology
Self-organization and ultra-flexibility
Learning ability and self-maintenance ability
Cause changes in production management
Change the direct management objects of enterprise production from humans to machines
Make enterprise production modular
The application of intelligent manufacturing will bring about "cloud-style" virtual production enterprises
Equipment Management and Technology Management Overview
Equipment management is based on the production and operation objectives of the enterprise and through a series of technical, economic and organizational measures, the planning, design, manufacturing, selection, purchase, installation, use, maintenance, repair, transformation, updating and scrapping of equipment Scientific management throughout the entire process
Stages of device management
Post-maintenance stage
preventive maintenance phase
Equipment comprehensive management stage
Technical management problems can be divided into
encourage invention
Innovative Success Management
Equipment selection, evaluation and use
Concepts and types of equipment
Equipment is a general term for various machinery, machines, devices, vehicles, ships, tools, instruments, and meters that are fixed assets. It is an important material and technical basis for modern enterprises to carry out production and operations.
type
Production process equipment
Power plant
conduction equipment
Lifting and transporting equipment
Scientific research equipment
Manage devices
Living welfare and educational equipment
Equipment selection
It is the primary link in enterprise equipment management.
Factors that must be considered when selecting equipment
Equipment productivity
Equipment reliability
Maintainability of equipment
Environmental protection of equipment
Equipment matching
Equipment energy saving
Evaluation method for equipment selection
payback period method
cost conversion method
present value method
Equipment maintenance and comprehensive management
Technical and economic indicators for equipment maintenance and management
Equipment maintenance and management should achieve two results
The technical status of the equipment is the best, usually measured by equipment integrity rate and failure rate.
Maintenance and management costs are the most economical, usually measured by the maintenance expense rate
Equipment maintenance organization and management
The organization method of equipment repair should be determined according to the size of the enterprise, production characteristics and the complexity of equipment repair.
centralized repair
distributed repair
hybrid repair
Advanced organizational methods for equipment repair
parts repair method
Partial repair method
simultaneous repair method
plan review method
All-staff production and maintenance system
full efficiency
The whole process
All members participate
Equipment life
Equipment life
Refers to the time that elapses from the time the equipment is put into production, through physical wear and tear, until it is technically or economically unsuitable for continued use and needs to be updated.
material life span
The service life determined based on the physical wear and tear of the equipment, that is, the time that elapses from the beginning of the equipment's use to the time it is scrapped.
technical life
It refers to the time that elapses from when the equipment is put into use until due to the development of science and technology, equipment with superior technical performance appears and is eliminated before the end of the material life of the equipment.
economic life
The life of the equipment is determined by the cost of using the equipment
Comprehensive equipment management
Also called comprehensive equipment management, it is the application of a system perspective in equipment management.
Comprehensive equipment engineering
All-staff production and maintenance system
Technology and new product development management
Technology and new product development are based on technological innovation. The higher the technical content, the more advantageous the product will be, and the more it will create greater competitive opportunities and commercial value for the company.
program
Strategic Plan
Concept generation and evaluation
filter
Develop a plan or establish a project
develop
Value engineering and technological transformation
It refers to a technical and economic method that uses collective wisdom to carry out organized activities, focuses on the functional analysis of products (or operations), and realizes the necessary functions of the product (industry) at the lowest life cycle cost, thereby increasing the value of the product (or operation).
Function
life cycle cost
value
technological transformation
Technical transformation in a narrow sense
Equipment renovation
Process reform