Operational processes

A typical operating process

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In consulting, we seek to represent and simplify in an attempt to answer questions and define priorities and urgencies. When we look at an operational process as a whole, we can summarize it in major phases or views. Each one has a specific purpose.

This approach is taken from the aeronautics industry, which describes the complexity of its operational processes in terms of views. This enables the many people involved to converge and make the right decisions when executing tasks.

The main views are :

• The "as-sold" view, this phase, which is the responsibility of the sales teams, defines and documents the product's requirements and physical characteristics. Example: The motor must be able to start at -30 C and +45 C. If the product does not meet this requirement, it will not be accepted by the buyer, and the seller will certainly incur penalties.
   

• The "as-designed" view, this phase defines in detail the studies carried out by engineers to design the purchased product. The 3D or 2D modeling of the product, its simulation in linear, non-linear, fluidic, magnetic resistance... and the documentation of the study results lead to the stage of preparation for manufacturing. Obviously, this is a little more complicated, and many disciplines are involved in the product. They all need a collaborative platform to consolidate their studies and confirm that the work is fully completed and compliant with customer expectations and current regulations.
   

• The "as-planned" view, this phase consists of production planning, and is carried out by a methods office under the responsibility of production. The information supplied by the design office is taken into account. Drawings are adapted for use in production, and the necessary resources are defined. Build assembly lines. List the tools and materials required. Select the plant and cells required for machining or assembly. We use software to simulate the operation of the whole system and anticipate potential problems. We simulate working conditions to maximize productivity. We refine budgets and feed forecast orders into purchasing. We inform human resources of specific skill requirements. Identify risks and propose crisis management plans.
   

• The "as-built" view, this phase consists of manufacturing and demonstrating compliance with the instructions in the construction/assembly schedule. Materials are received. We number them after inspection. Everything is listed in the manufacturing bill of materials. Quality is tracked to ensure that every weld, bolt and rivet has been placed as agreed, using the correct technique and/or torque. Over time, certain parts are improved (we try to make them lighter, change the material, etc.). However, we need to be able to return at any time to a particular configuration delivered to a customer in the past... so that we can perhaps manufacture to order a part that has reached the end of its life.
   

• The "as-shipped" view, this phase consists of defining the product's shipping conditions. Here we define the packages (wooden, foam and plastic crates, user documentation, maintenance documentation, etc.) that must accompany the product, as well as the specific requirements for certain regions or countries.
   

• The "as delivered" view, this phase enables you to trace the conditions of delivery and receipt of the product. It may also be necessary to carry out commissioning for the customer, and to train the customer. Delivery is therefore the set of services that accompany the delivered product. It may also be agreed in the "as-sold" view that an advanced level of maintenance will be provided by the seller, and therefore the seller may seek to capture information relating to the location and conditions of use of the product.
   

• The "as-maintained" view, this phase involves managing difficulties in use, replacing end-of-life parts, preventing breakdowns and maximizing product productivity. During the design phase, the engineering department not only designs the product, it must also design it so that it can be manufactured and maintained. Sometimes, it produces specific tools that will be useful for maintenance. He always provides maintenance instructions. The customer (if he does not have a maintenance contract with the vendor), will have to ensure compliance with updates and replacement of parts according to the vendor's recommendations. As modifications are made, the product documentation must also be updated, as its configuration has changed... new parts have been added.
   

• The "as-recycled" view, this final phase of the operational process addresses product obsolescence and component recycling. It includes teams and specific instructions for disassembling products and recycling components... Think of a nuclear power plant: at the end of its life, special tools and machines are needed, as well as protection for the workers, to dismantle the plant and isolate the components. They will all follow a circuit for cleaning and recycling... or storage for decontamination.