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3a. Factory Automation redesign - MECH_3135_redesign_to_students

3a. Factory Automation redesign - MECH_3135_redesign_to_students

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S. Venkannah Factory Automation MECH 3135 Reference : Lucas Engineering and Systems Page 1 of 22 The five step approach to business re design Step 1 : Market Analysis Step 2: Collection and Analysis of data on machines, processes, organization and procedures Step 3: Design of a system to meet average needs Step 4: Dynamic design to cope with change Step 5: Integration and Design of information and control systems Supporting Tools and Principles: A – Process flow charts to define natural cells and identify wasteful activity B- Business process definition and measurement of performance C – Input-output analysis of departments and redesigned cells D – Installation of mechanisms to make change stick and definition of ownership of new practices E- Organization management structure F – Information technology to match business processes G- Simplify job structure by skills leveling
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S. Venkannah Factory Automation MECH 3135 Reference : Lucas Engineering and Systems Page 2 of 22 H – Value chain analysis Application: Draw process flow charts for Information flows Material flows Determine ratio of non value added to value added activities Classify paperwork and reduce it Benefits: Focuses on reduction of non value added activities, waste and staff members Simplifies materials and information flows Groups staff into teams, and information flows into natural groups of cells, reducing lead time and increasing reliability Focused use of group technology techniques
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S. Venkannah Factory Automation MECH 3135 Reference : Lucas Engineering and Systems Page 3 of 22 Application: Use PFA to divide the core business into two categories Operations e.g. materials flow, management or customer, enquiry processing, support Development e.g. new products or organization redesign Benefits: Regroups specialist activities to avoid fragmenting core activities Cross functional management of core processes Teams of staff working in a “single office” need fewer offices and support staff Optimum mix of permanent and temporary staff Sets measures of performance Application: For each department. List all inputs, outputs and number and skills of staff
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S. Venkannah Factory Automation MECH 3135 Reference : Lucas Engineering and Systems Page 4 of 22 List redundant inputs, outputs and paperwork Show existing system as a network of sub systems and input-output diagrams and outputs Eliminate redundant outputs and departments. Redefine groups considering the core processes identified in business process management. Draw the new network and list the staff and work savings Benefits: Structured organization simplification Staff reductions without the risk to effectiveness Visible linking of departments Reduces number of offices With PFA and BPM, leads to the three office structure: Operations Development Support services Application:
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