The Stage

The Stage

April 28, 2020
how-to-change

In order to analyze thoroughly the Stage of the Process, we should consider the production flows that results in the final Product for the consumer.

The Production Flow

Although the following example shows a manufacturing process, these flows can also be applied to generic environments where resources are used for tasks that require skills, to achieve a goal.

In order to extract a process sample, the P&Q Factory, shown below, will be used as an example.

graph LR PP[P-Part $5/u] --> D1[D 15min/u] --> P[P $90/u 100u/wk] RM1[RM1 $20/u] --> A1[A 15min/u] --> C1[C 10min/u] --> D1 RM2[RM2 $20/u] --> B2[B 15min/u] --> C2[C 5min/u] --> D1 C2 --> D2[D] RM3[RM3 $20/u] --> A3[A 10min/u] --> B3[B 15min/u] --> D2[D 5min/u] --> Q[Q $100/U 50u/wk]

Initially, the partial elements shown below represent RM1 being processed by A for 15 minutes. This means that something happens to the raw material RM1, causing its exit from A in a different state. This new asset is actually a fragment, known by the generic term work-in-process (WiP).

graph LR RM1[RM1 $20/u]-- raw material --> A1[A 15min/u]-- work-in-process --> C1[C 10min/u]

Then, C processes the WiP for 10 minutes. Please note that the C input is not RM1 anymore, since it was already transformed by A. It is also implied in the production flow diagram that:

  • RM1 is a resource to A, and WiP is a resource to C as well.
  • RM1 is an external asset, since it comes from outside the process.
  • WiP is an internal asset, i.e. an intermediary result inside the process.
  • The transformation in RM1 is a task that requires 15 minutes of A’s work.
  • Similarly, the WiP is processed by a task that requires 10 minutes from C.
  • A and C are combination of people/tools with specific skills.
  • It is convenient to organize people/tools based on its skills.
  • Actually the task is a Stage that requires a skill.
  • A person may be a resource with a skill to accomplish the job.
  • A tool with a skill is another resource that can also be used.
  • The skills may be combined, for example, a person commands a group of robots.

We can also assure that the resources come from different sources:

  • RM and WiP are resources related to the Cyclo.
  • People, tools, energy, shop floor area, etc. are resources deployed across a Facility.

The Stage Model

Then, we have the following modeling that includes the Stage:

classDiagram Planet --> "1..n" Product : has Product --> "1..n" Process : made by Process --> "1..n" Stage : has Stage --> "1..n" Skill : requires Stage --> "1..n" Resource : uses Stage --> Stage : previous_next Worker --> "1..n" Skill : has Worker --> "0..n" Tool : command Tool --> "0..n" Tool : command Tool --> "1..n" Skill : has Resource <|-- Cyclo Resource <|-- Facility Cyclo <|-- RM : external Cyclo <|-- WiP : internal Facility <|-- Worker Facility <|-- Tool Facility <|-- Energy Facility <|-- Area

The Stage model highlights the following features:

  • The Planet has at least one Product.
  • Each Product has at least one Process that leads to its creation.
  • Each Process has at least one Stage to be executed.
  • The Stage must use at least one Resource.
  • The Stage proceeds to one or more Stages, until a consumer Product is reached.
  • The consumer Product is the final and more important Stage.
  • The Resource is related to the Cyclo or to the Facility.
  • The Cyclo Resource may be Raw Material (RM) or Work in Process (WiP).
  • RM is an external resource, and it is also a Product coming from another Process.
  • WiP is an internal Process resource, still subject to transformation.
  • The Facility resources are Worker, Tool, Area, and Energy, among others.
  • Both Worker and Tool have at least one Skill.
  • Worker & Tool may handle a Tool with a Command, but this is not mandatory.
  • The Stage requires at least one Skill, to be satisfied by Worker and/or Tool resources.

At run time, it is necessary to audit the Process and certify that the Cyclo is able to run. Every Stage Skill demanded by the Process specification should be satisfied in due time by the Facility implementation. Worker and Tool resources must permanently comply with the required Stage expertise, in order the Process may keep running, and generating Gain.

Published in Business Amplifier, also e-book and Amplificador de Negócios.