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Operations management
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OPEraTiOns ManagEMEnT
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OPERATIONS MANAGEMENT
Eighth edition
nigel slack
alistair Brandon-Jones
robert Johnston
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Pearson Education Limited
Edinburgh Gate
Harlow CM20 2JE
United Kingdom
Tel: +44 (0)1279 623623
Web: www.pearson.com/uk
First published under the Pitman Publishing imprint 1995 (print)
Second edition (Pitman Publishing) 1998 (print)
Third edition 2001 (print)
Fourth edition 2004 (print)
Fifth edition 2007 (print)
Sixth edition 2010 (print)
Seventh edition 2013 (print and electronic)
Eighth edition published 2016 (print and electronic)
© Nigel Slack, Stuart Chambers, Christine Harland, Alan Harrison, Robert Johnston 1995, 1998 (print)
© Nigel Slack, Stuart Chambers, Robert Johnston 2001, 2004, 2007, 2010 (print)
© Nigel Slack, Alistair Brandon-Jones, Robert Johnston 2013, 2016 (print and electronic)
The rights of Nigel Slack, Alistair Brandon-Jones and Robert Johnston to be identified as authors of this
work have been asserted by them in accordance with the Copyright, Designs and Patents Act 1988.
The print publication is protected by copyright. Prior to any prohibited reproduction, storage in a retrieval
system, distribution or transmission in any form or by any means, electronic, mechanical, recording or
otherwise, permission should be obtained from the publisher or, where applicable, a licence permitting
restricted copying in the United Kingdom should be obtained from the Copyright Licensing Agency Ltd,
Barnard’s Inn, 86 Fetter Lane, London EC4A 1EN.
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Pearson Education is not responsible for the content of third-party internet sites.
ISBN: 978 1 292 09867 8 (print)
978 1 292 09871 5 (PDF)
978 1 292 17190 6 (ePub)
British Library Cataloguing-in-Publication Data
A catalogue record for the print edition is available from the British Library
Library of Congress Cataloging-in-Publication Data
A catalog record for the print edition is available from the Library of Congress
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16
Cover image © Karin Hildebrand Lau / Alamy Stock Photo
Print edition typeset in 9.25/12 Charter ITC Std by 76
Printed in Slovakia by Neografia
NOTE THAT ANY PAGE CROSS REFERENCES REFER TO THE PRINT EDITION
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v
Guide to ‘operations in practice’, examples,
short cases and case studies xii
Preface xvi
To the Instructor. . . xviii
To the Student. . . xix
Ten steps to getting a better grade in
operations management xx
About the authors xxi
Acknowledgements xxii
Publisher’s acknowledgements xxiv
Part One
DirECTing ThE OPEraTiOn 3
1 Operations management 4
2 Operations performance 38
3 Operations strategy 74
4 Product and service innovation 109
5 The structure and scope of operations 140
Supplement to Chapter 5 — Forecasting 170
Part Two
DEsigning ThE OPEraTiOn 181
6 Process design 182
7 Layout and flow 216
8 Process technology 246
9 People in operations 276
Supplement to Chapter 9 — Work study 306
Part Three
DELivEr 315
10 Planning and control 317
11 Capacity management 350
Supplement to Chapter 11 —
Analytical queuing models 391
12 Supply chain management 398
13 Inventory management 432
14 Planning and control systems 468
Supplement to Chapter 14 — Materials
requirements planning (MRP) 491
15 Lean operations 498
Part Four
DEvELOPMEnT 531
16 Operations improvement 532
17 Quality management 572
Supplement to Chapter 17 — Statistical
process control 603
18 Managing risk and recovery 616
19 Project management 646
Notes on chapters 681
Useful websites 689
Glossary 691
Index 704
Brief contents
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vii
How is operations performance judged
at an operational level? 48
How can operations performance be
measured? 63
How do performance objectives trade off
against each other? 66
Summary answers to key questions 68
Case study : Operations objectives at the
Penang Mutiara 70
Problems and applications 72
Selected further reading 73
Chapter 3:
Operations strategy 74
Introduction 74
What is strategy and what is operations
strategy? 76
What is the difference between a ‘top-down’
and ‘bottom-up’ view of operations
strategy? 80
What is the difference between a ‘market
requirements’ and an ‘operations
resources’ view of operations strategy? 84
How can operations strategy form the basis
for operations improvement? 92
How can an operations strategy be put together?
The process of operations strategy 98
Summary answers to key questions 102
Case study : McDonald's: half a century
of growth 104
Problems and applications 107
Selected further reading 108
Chapter 4:
Product and service innovation 109
Introduction 109
What is product and service innovation? 110
What is the strategic role of product
and service innovation? 114
What are the stages of product and
service innovation? 119
What are the benefits of interactive
product and service innovation? 130
Summary answers to key questions 134
Contents
Guide to ‘operations in practice’,
examples, short cases and case studies xii
Preface xvi
To the Instructor. . . xviii
To the Student. . . xix
Ten steps to getting a better grade
in operations management xx
About the authors xxi
Acknowledgements xxii
Publisher’s acknowledgements xxiv
Part One
DirECTing ThE OPEraTiOn 3
Chapter 1:
Operations management 4
Introduction 4
What is operations management? 5
Why is operations management important
in all types of organization? 8
What is the input–transformation–output
process? 13
What is the process hierarchy? 19
How do operations and processes differ? 22
What do operations managers do? 27
Summary answers to key questions 31
Case study : Design house partnerships at
Concept Design Services 33
Problems and applications 36
Selected further reading 36
Chapter 2:
Operations performance 38
Introduction 38
Why is operations performance vital
in any organization? 39
How is operations performance judged
at a societal level? 41
How is operations performance judged
at a strategic level? 46
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viii
Case study: Developing ‘Savory Rosti-crisps’
at Dreddo Dan’s 136
Problems and applications 138
Selected further reading 139
Chapter 5:
The structure and scope
of operations 140
Introduction 140
What do we mean by the ‘structure’
and ‘scope’ of operations’ supply
networks? 141
What configuration should a supply
network have? 145
How much capacity should operations
plan to have? 149
Where should operations be located? 154
How vertically integrated should an
operation’s network be? 156
How do operations decide what to do
in-house and what to outsource? 161
Summary answers to key questions 164
Case study: Aarens Electronic 166
Problems and applications 168
Selected further reading 169
Supplement to Chapter 5:
Forecasting 170
Introduction 170
Forecasting – knowing the options 170
In essence forecasting is simple 171
Approaches to forecasting 172
Selected further reading 178
Summary answers to key questions 211
Case study: The Action Response Applications
Processing Unit (ARAPU) 212
Problems and applications 214
Selected further reading 214
Chapter 7:
Layout and flow 216
Introduction 216
What is layout and how can it influence
performance? 217
What are the basic layout types used
in operations? 220
How does the appearance of an
operation affect its performance? 231
How should each basic layout type
be designed in detail? 234
Summary answers to key questions 240
Case study: The event hub 241
Problems and applications 244
Selected further reading 244
Chapter 8:
Process technology 246
Introduction 246
What is process technology? 247
What do operations managers need to
know about process technology? 251
How are process technologies evaluated? 258
How are process technologies
implemented? 264
Summary answers to key questions 271
Case study: Rochem Ltd 272
Problems and applications 274
Selected further reading 274
Chapter 9:
People in operations 276
Introduction 276
Why are people so important in operations
management? 277
How do operations managers contribute
to human resource strategy? 279
How can the operations function be
organized? 281
How do we go about designing jobs? 286
How are work times allocated? 300
Summary answers to key questions 301
Case study: Grace faces (three) problems 302
Part Two
Designing the Operation 181
Chapter 6:
Process design 182
Introduction 182
What is process design? 183
What should be the objectives of
process design? 185
How do volume and variety affect
process design? 189
How are processes designed in detail? 195
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ix
Problems and applications 304
Selected further reading 305
Supplement to Chapter 9:
Work study 306
Introduction 306
Method study in job design 306
Work measurement in job design 309
Supplement to Chapter 11:
Analytical queuing models 391
Introduction 391
Notation 391
Variability 391
Incorporating Little’s law 393
Types of queuing system 393
Chapter 12:
Supply chain management 398
Introduction 398
What is supply chain management? 399
How should supply chains compete? 402
How should relationships in supply chains
be managed? 407
How is the supply side managed? 412
How is the demand side managed? 419
What are the dynamics of supply chains? 423
Summary answers to key questions 426
Case study: Supplying fast fashion 428
Problems and applications 430
Selected further reading 431
Chapter 13:
Inventory management 432
Introduction 432
What is inventory? 434
Why should there be any inventory? 437
How much to order? The volume decision 442
When to place an order? The timing decision 452
How can inventory be controlled? 458
Summary answers to key questions 463
Case study: supplies4medics.com 465
Problems and applications 466
Selected further reading 467
Chapter 14:
Planning and control systems 468
Introduction 468
What are planning and control systems? 469
What is enterprise resource planning and
how did it develop into the most common
planning and control system? 475
How should planning and control systems
be implemented? 483
Summary answers to key questions 486
Deliver 315
Chapter 10:
Planning and control 317
Introduction 317
What is planning and control? 318
What is the difference between planning
and control? 319
How do supply and demand affect planning
and control? 321
What are the activities of planning and control? 327
Summary answers to key questions 345
Case study: subText Studios Singapore 346
Problems and applications 348
Selected further reading 349
Chapter 11:
Capacity management 350
Introduction 350
What is capacity management? 351
How are demand and capacity
measured? 354
How should the operation’s base capacity
be set? 364
What are the ways of coping with
mismatches between demand
and capacity? 366
How can operations understand the
consequences of their capacity
decisions? 373
Summary answers to key questions 382
Case study: Blackberry Hill Farm 384
Problems and applications 388
Selected further reading 389
Part Three
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x
Case study: Psycho Sports Ltd 487
Problems and applications 489
Selected further reading 490
Supplement to Chapter 14:
Materials requirements
planning (MRP) 491
Introduction 491
Master production schedule 491
The bill of materials (BOM) 492
Inventory records 494
The MRP netting process 494
MRP capacity checks 497
Summary 497
Chapter 15:
Lean operations 498
Introduction 498
What is lean? 499
How does lean eliminate waste? 506
How does lean apply throughout the
supply network? 519
How does lean compare with other
approaches? 521
Summary answers to key questions 524
Case study: Saint Bridget’s Hospital 525
Problems and applications 527
Selected further reading 528
Summary answers to key questions 566
Case study: Reinventing Singapore’s
libraries 568
Problems and applications 569
Selected further reading 570
Chapter 17:
Quality management 572
Introduction 572
What is quality and why is it
so important? 573
What steps lead towards conformance
to specification? 580
What is total quality management (TQM)? 587
Summary answers to key questions 597
Case study: Turnaround at the
Preston plant 599
Problems and applications 601
Selected further reading 602
Supplement to Chapter 17:
Statistical process control 603
Introduction 603
Control charts 603
Variation in process quality 604
Control charts for attributes 608
Control chart for variables 610
Summary of supplement 615
Selected further reading 615
Chapter 18:
Managing risk and recovery 616
Introduction 616
What is risk management? 617
How can operations assess the
potential causes and consequences
of failure? 619
How can failures be prevented? 632
How can operations mitigate the effects
of failure? 637
How can operations recover from the
effects of failure? 639
Summary answers to key questions 642
Case study: Slagelse Industrial
Services (SIS) 643
Problems and applications 645
Selected further reading 645
Part Four
Development 531
Chapter 16:
Operations improvement 532
Introduction 532
Why is improvement so important in
operations management? 533
What are the key elements of operations
improvement? 540
What are the broad approaches to
improvement? 545
What techniques can be used for
improvement? 554
How can the improvement process
be managed? 559
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xi
Chapter 19:
Project management 646
Introduction 646
What is project management? 647
How are projects planned? 653
How are projects controlled? 669
Summary answers to key questions 674
Case study: United Photonics Malaysia Sdn Bhd 675
Problems and applications 679
Selected further reading 680
Notes on chapters 681
Useful websites 689
Glossary 691
Index 704
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xii
guide to ‘operations in practice’, examples, short
cases and case studies
Chapter Location Company/example Region Sector/activity Company size
1 Operations
management
Lego Europe Manufacturing Large
Torchbox UK Web design Small
MSF Global Charity Large
Pret a Manger Global Hospitality Medium
Formule 1 Europe Hospitality Large
Ski Verbier Exclusive Europe Hospitality Small
Hewlet Packard Manufacturing Large
To be a great operations
manager…
Global N/A N/A
Concept design services General Design/manufacturing/distribution
Medium
2 Operations
performance
Novozymes Europe Pharmaceutical Large
Patagonia Global Garments Large
Holcim Global Cement/aggregates Large
Quality Street Global Confectionary Large
The Golden Hour General Healthcare N/A
UPS Global Distribution Large
Mymusli German Web retail Small
Aldi Europe Retail Large
Foxconn Taiwan Manufacturing Large
The Penang Mutiara Malaysia Hospitality Medium
3 Operations
strategy
SSTL UK/ Space Aerospace Medium
Apple retail Global Retail Large
Amazon Global Web retail Large
Apple supply operations Global Manufacturing Large
Nokia Global Telecomm Large
Sometimes any plan is better
than no plan
Europe Military Large
McDonalds Global Hospitality Large
4 Product and
service innovation
Apple iPhone Global Design Large
Kodak Global Manufacturing Smaller
Square watermelons Global Agriculture Various
IKEA Global Design/ Retail Large
Dyson Global Manufacturing Large
The circular economy Global Sustainability Various
Dreddo Dan’s Global Snack food Large
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xiii
Chapter Location Company/example Region Sector/activity Company size
5 The structure
and scope of
operations
ARM and Intel Global Design and Design/
manufacturing
Large
Hollywood studios USA Creative Large
Surgery and shipping India/Global Healthcare/transportation
Large
Counting clusters Various Various Various
HTC Taiwan Design/manufacturing Large
Samsun Korea Manufacturing Large
Aarens Electronic Netherlands Manufacturing Medium
6 Process
design
Changi airport Singapore Air travel Large
Fast food Global Hospitality Large
Ecover Europe Manufacturing Large
Sands Film Studio UK Creative Small
Space4 housing UK Construction Medium
Sainsbury’s UK Retail Large
Shouldice hospital Canada Healthcare Small
Action response UK Charity Small
7 Layout and
flow
Volkswagen Germany Manufacturing Large
Google USA Technology Large
Factory flow helps surgery UK Healthcare Medium
Apple’s shop UK Retail Large
Cadbury’s UK Manufacturing/ entertainment
Large
Nestlé Global Manufacturing Large
Office cubicles Various Design Various
Zodiac France /
Global
Manufacturing Medium
The Event Hub UK Policing Medium
8 Process
technology
I Robot Global Various Various
Technology or people? Various Various Various
QB house Asia Hairdressing Medium
Marmite UK Food Large
Technology failures UK Technology Large
Who’s in the cockpit? Global Various Airlines Various
Rochem UK Food processing Medium
9 People in
operations
W L Gore Global Manufacturing Large
High customer contact jobs USA Air travel Large
McDonald’s Global Hospitality Large
Yahoo USA Technology Large
Music while you work Global Various Various
Grace faces (three) problems UK Legal Medium
10 Planning
and control
Joanne manages the
schedule
UK Retail Medium
Operations control at Air
France
Global Airline Large
Uber Global Technology platform Large
Can airline passengers be
sequenced?
General Airports Various
The hospital triage system Global Healthcare Various
The life and times of a
chicken sandwich (part 1)
UK Food processing Medium
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xiv
Chapter Location Company/example Region Sector/activity Company size
11 Capacity
management
Heathrow UK Airports Large
Panettone Italy Food processing Large
Amazon Global Retail Large
Lowaters UK Horticulture Medium
Demand management USA Public Large
Baseball games USA Leisure Medium
Blackberry hill farm UK Leisure Small
12 Supply chain
management
Ocado UK Retail Large
The North Face Global Garment manufacture Large
Apple Global Technology Large
The tsunami effect Asia Various Various
Levi Strauss Global Garment manufacture Large
Seven-Eleven Japan Japan Retail Large
Supplying fast fashion Global Garment design/
manufacture/ retail
Large
13 Inventory
management
National Health Service
Blood and Transplant service
UK Public sector Large
Energy inventory Global Power generation Large
Treasury wines Australia Wine production Large
Gritting roads Europe Public sector Large
Flame electrical South Africa Wholesale Small
Amazon Global Retail Large
Supplies4medics Europe Retail Medium
14 Planning
and control
systems
Butchers pet care UK (Dog) food production Medium
SAP and its partners Global Systems developers
The life and times of a chicken salad sandwich (part 2)
UK Food production Medium
What a waste USA Recycling Large
Psycho sports N/A Manufacturing Small
15 Lean
operations
Jamie’s lean meals UK Domestic food
preparation
N/A
Pixar adopts lean USA Creative Large
Toyota Global Auto production Large
Waste reduction in airline
maintenance
N/A Air transport N/A
Andon’s in Amazon Global Retail Large
Torchbox UK Web design Small
St Bridget’s Hospital Sweden Healthcare Medium
16 Improvement
Sonae Corporation Portugal Retail Large
The checklist manifesto N/A Healthcare Various
6Wonderkinder Germany App developer Small
Improvement at Heineken Netherlands Brewer Large
6Sigma at Wipro India Outsourcers Large
Learning from Formula 1 UK Transport Various
Reinventing Singapore’s
libraries
Singapore Public sector Medium
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