The process design for his operation requires a flexible workforce and facility that is able to respond to order volume and type of product shipped. The preferable design approach is that of a Worcester. Various processes are placed in a semi circle beginning with inbound product and progressing to inventory, outbound and shipping bins for pickup. Offshoots available to further process as needed. When using human labor to move 50,000 or more units per day, minimization of movement is critical. Processes are constantly broken down into individual parts with a goal of increasing accuracy and reducing cycle time.
Single family homebuilding requires a completely different outlook on design processes, principally due to the fact that the product we build is completely handmade and built in one spot, where it will permanently set. Design considerations are less about economical movement of the product as maximizing how efficiently workers can access, work and withdraw from the product- while maintaining quality work. After designing a home that can be efficiently built and will appeal to consumers in the region, a critical path design process and plan just be implemented.
Critical path is the longest sequence of events that must take place in the construction process. Knowing that the foundation must be poured prior to the wood framing is an easy way to visualize this. Once that path is understood and set, secondary and tertiary processes can be planned for in the process. The process schedule, like all construction projects, is a chronological timeline giving an appropriate amount of time to each trade whose work is required on the home. Many builders have several houses in various stages of construction to educe their costs.
It is easier to negotiate a subcontractors price when he knows he can have his crews move from house to house as they complete their work. Each subcontractor is employed by the general contractor (the homebuilder or a company) to do a set Job for a set price. Capable managers in the field are a vital part of keeping these costs under control and holding the labor accountable. Failure of the onsite managers to manage will result in poor quality, time and cost overruns. Whether developing a design process for a product or a service, customer distractions with the result and control of costs are critical considerations.
Related article: Process Design Matrix
Though there are numerous variables in strategy, design and process, a manager who ensures those considerations are accounted for will be successful. Process Design Aspect Service Product Design focal point Minimize wait time between customer order and delivery of product. Cost effective construction with high customer appeal/price point. Strategy Production line approach. Fixed position layout addressing access and workspace requirements for various trades. Process design approach Minimize movement of personnel and material. Critical path design with emphasis on minimization of days spent building home.
Process map Focus on lean kamikaze and Just in time picking/shipping. Chronological timeline. Process Performance Measurement Accuracy in units shipped vs. labor hour. Customer satisfaction surveys, price of unconformable (change-orders) Factory location Large, industrial warehouses, based near shipping hubs. Individual neighborhood Jobless. Product (homes) often tailored to Jobbers, customer desires and climate. ) Facility layout Worcester layout. Product flows in a generally straight line, but is diverted into customer driven required processes.
Project layout- homes built in place with phased construction. Process design Lean process, always innovating. Blueprints and schedule Scheduling Lean driven scheduling driven by customer order volumes. Critical path scheduling. Production planning (Vive never heard of this- not in book either) Workforce Flexible hourly workers able to perform 3 or more Job processes Individual contractors hired at-will. Quality Poke-a-yokes throughout pick and pack process requiring units to be scanned. Weights checked at two points to further increase accurate shipping.