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A-Level Revise Aid: This resource is designed to support your revision and may contain errors. If you find a discrepancy with your class teaching, your teacher is correct -- please let us know at alevelrevise@scott.scottrix.co.uk.

Operations Management

Year 1 / ASYear 2 / A-Level All Boards (AQA, Edexcel, OCR, WJEC, CCEA) AQA

A-Level Business Studies revision: Operations Management. Learning objectives, key points, worked examples and practice questions across AQA, Edexcel, OCR, WJEC and CCEA.

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📌 Key Points

Key Fact: Job: one-off, high skill, high cost; Batch: groups, flexible; Flow: continuous, high volume, low variety; Cell: U-shape, multi-skilled; Mass custom: flow + flexibility
Key Fact: QC (inspection) vs QA (prevention); TQM: culture, continuous improvement; Kaizen: small incremental; Six Sigma: DMAIC, 3.4 defects/million; Benchmarking: best practice
Key Fact: Capacity utilisation = actual/max x100%; Efficiency = standard hours/actual hours; Productivity = output/input
Key Fact: Lean: eliminate Muda (overproduction, waiting, transport, over-processing, inventory, motion, defects); JIT: pull system; Kanban: visual signal; 5S: Sort, Set, Shine, Standardise, Sustain
Key Fact: Supply chain: procurement (supplier selection), logistics (transport, warehousing), outsourcing (core vs non-core), supplier development
Key Fact: Industry 4.0: cyber-physical systems, IoT, big data, AI, additive manufacturing, digital twins

🎯 Learning Objectives

  • Compare production methods: job, batch, flow, cell, mass customisation
  • Evaluate quality management: QC vs QA, TQM, Kaizen, Six Sigma, benchmarking
  • Analyse capacity utilisation, efficiency, productivity
  • Understand lean production: JIT, Kanban, waste reduction (Muda), 5S
  • Analyse supply chain: procurement, logistics, outsourcing, supplier relationships
  • Evaluate technology impact: automation, AI, IoT, Industry 4.0

💡 Worked Example

Exam-Style Question

Question: A furniture maker switches from batch to flow production. Analyse implications for cost, quality, flexibility

Model Answer:

Cost: lower unit cost (economies of scale, less setup), but high capital investment. Quality: more consistent (standardised), but defects affect large volumes. Flexibility: reduced (dedicated line), harder to customise. Workforce: deskilling, potential redundancy. Inventory: lower WIP with JIT

❓ Practice Questions

Questions:

  • Compare job vs flow for bespoke vs standard products
  • Explain DMAIC in Six Sigma
  • Calculate capacity utilisation: actual 800, max 1000
  • List 7 wastes (Muda) with examples
  • Evaluate outsourcing IT support

🎬 Video Resources

📄 Past Papers & Exam Resources

🔗 Further Reading & Resources