Using Operations Data (AQA A Level Business): Revision Note

Exam code: 7132

Lisa Eades

Written by: Lisa Eades

Reviewed by: Steve Vorster

Updated on

Effectively using operations data

  • A range of operations data can be used to assess how well a business is performing

    • Data can be analysed over time to determine whether performance is improving or worsening

    • They may also be compared with the performance of similar firms

Case Study

JetCool Manufacturing Ltd

Business Overview
JetCool is a UK-based manufacturer of energy-efficient air conditioning units. It operates a single large factory in Leeds and supplies retail chains and construction firms across the UK and Ireland

Scenario

In early 2024, JetCool’s senior managers noticed that profit margins were shrinking despite stable sales revenue. To investigate, the operations team analysed key performance data:

Table titled "Identifying Operational Weaknesses" shows metrics for Q1 2023 vs. Q1 2024: Labour productivity fell, defect rate doubled, capacity utilisation dropped.

Analysis

  • The drop in labour productivity indicated inefficiencies on the production line. On further inspection, the company found that new employees hired in late 2023 had not completed full training

  • The rising defect rate led to increased returns and warranty claims, damaging customer satisfaction and raising repair costs

  • Lower capacity utilisation suggested that the factory was underused, possibly due to slower production and more rework time per unit

Business response

  • JetCool introduced a refreshed training program for all floor staff, focusing on quality control and assembly speed

  • It installed a real-time monitoring system to track defects and trigger line adjustments mid-shift

  • The production schedule was adjusted to focus on the company’s fastest-selling model to improve throughput and boost capacity utilisation

Outcomes within 3 months

  • Labour productivity improved by 9%

  • Defect rate dropped to 2.8%

  • Capacity utilisation recovered to 76%

  • Warranty costs fell by £22,000 compared to the previous quarter

Using productivity data

  • Productivity measures how well a business uses its resources to produce output

Illustration comparing labour productivity, represented by a person with a tablet, to capital productivity, depicted by a machine.
Productivity of labour and capital can be analysed to measure operations performance
  • Higher levels of productivity are likely to lead to lower unit costs as fixed costs are spread across more units of output

    • This can allow a business to lower selling prices to achieve an important competitive advantage over rivals, especially those with lower levels of output

  • Comparing labour productivity can reveal a range of issues

    • When each employee delivers more output, profit should rise without the need to recruit more staff

    • Rising labour productivity also suggests training, motivation techniques or new technology is working, encouraging a business to make further such investments

  • Similarly, comparing capital productivity can provide some useful insights

    • High capital productivity shows the firm is getting strong returns from its investments, so it needs less new spending to grow

    • Investors look at output per £1 of capital employed to judge whether the company is making good use of its funds

    • Measuring capital productivity helps managers decide whether to upgrade, sell off underused assets or invest in new technology

  • Labour productivity and capital productivity calculations are covered in depth here

Using quality data

1. The defect rate

  • The proportion of output that is judged to be substandard in a given time period

    • It is expressed as a percentage and calculated using the formula

Defect space rate space equals space fraction numerator Number space of space defective space items over denominator Total space output end fraction space cross times space 100

Worked Example

HomeFlex manufactures high-strength universal charging cables for mobile phones. In 2022 it manufactured and tested 14,220 cables of which 213 were found to be defective 

Calculate Homeflex's defect rate in 2022.

[2]

Step 1: Divide the number of defects by the total output

equals space fraction numerator 213 space cables over denominator 14220 space cables end fraction space

equals space 0.015 (1)

Step 2: Multiply the outcome by 100 and express as a percentage

equals space 0.015 space cross times space 100

equals space 1.50 percent sign (1)

2. The returns rate

  • The proportion of output that is returned by customers in a given time period

    • It is expressed as a percentage and calculated using the formula

Returns space rate space equals space fraction numerator Number space of space returned space items over denominator Total space sales end fraction space cross times space 100

  • Businesses take steps to reduce the defect rate and returns rate for several reasons

    • Avoid loss of revenue as faulty products or those that have been returned can rarely be sold

    • Customers will likely complain about substandard products which causes dissatisfaction and impacts business reputation

    • Unsafe products may harm customers and could lead to legal issues

    • Returned products require refunds, processing and disposal

3. The wastage rate

  • The proportion of materials and components wasted in production in a given time period

    • It is expressed as a percentage and calculated using the formula

Wastage space rate space equals space fraction numerator Cost space of space wasted space materials over denominator Total space cost space of space sales end fraction space cross times space 100

  • Businesses take steps to reduce the wastage rate for several reasons

    • Lower production costs

      • By reducing waste, a business uses fewer raw materials overall, which brings down the cost of making each unit

    • Higher profit margins

      • Every tonne of material saves reduced variable costs, increasing the profit earned on each sale

    • Improved sustainability and reputation

      • Cutting scrap reduces costs of disposal and the business's environmental impact and shows customers the business is committed to being green

4. Customer satisfaction

  • A business may carry out surveys, focus groups or interview customers to determine how happy they are with their purchase

    • Increasingly, businesses use data collected by research organisations such as Trustpilot to determine levels of customer satisfaction

5. Customer loyalty

  • Customer loyalty may be measured by reviewing the volume of repeat sales

    • Loyalty schemes, such as Tesco's Clubcard, have made gathering and analysing this information much more straightforward

Examples of industry measures of quality

Industry

Quality measure

Explanation

Hotels

  • Guest satisfaction score

  • Average rating from post-stay surveys and online review platforms

Train operators

  • Punctuality rate

  • Percentage of trains arriving or departing within a few minutes of schedule

Hospitals

  • Patient satisfaction and infection rate

  • Survey scores from patients and the number of hospital-acquired infections per 1,000 patients

Restaurants

  • Food hygiene rating

  • Score given by local health inspectors on cleanliness and food safety

Using capacity utilisation data

  • Capacity utilisation measures how effectively a business uses its assets to produce output

    • It compares current output to the maximum possible output a business can produce using all of its assets

  • High capacity utilisation is important for several reasons

    • Cost efficiency and profitability

      • Using more of a factory’s or machine’s capacity spreads fixed costs, such as rent and salaries, over more units of output, lowering the unit cost and increasing profit margins

    • Resource management

      • High capacity utilisation shows a business is making full use of its non-current assets, such as machines, buildings and labour, so it isn’t wasting money on idle capacity

    • Investment planning

      • Monitoring capacity utilisation helps managers decide when to invest or scale back capital expenditure

    • Cash‐flow forecasting

      • More output generally means more sales and cash coming in

      • A sudden drop in capacity utilisation can signal that there is likely to be an imminent shortage of cash

    • Quality and maintenance balance

      • While high utilisation is good, pushing equipment too hard can increase breakdowns and defects

      • The right rate of capacity utilisation balances the level of output with reliable, high‐quality production

  • Calculation of capacity utilisation is covered in depth here

Evaluating the use of operations data to analyse business performance

Advantages

Limitations

  • Reveals efficiency and cost control

    • Productivity and capacity utilisation rates show how well labour and capital resources are used

  • Ignores demand context

    • Low capacity utilisation may be due to weak customer demand rather than poor operations, risking misplaced blame

  • Highlights quality issues

    • Defect rates and rework figures can pinpoint production problems that drive up costs and harm reputation

  • Overlooks human factors

    • High productivity figures can mask staff burnout or low morale if workers are pushed too hard to meet targets

  • Guides investment and planning

    • Capacity data signals when to expand or scale back equipment and facilities, preventing over- or under-investment.

  • Depends on data accuracy

    • Faulty measurements or inconsistent definitions (e.g. what counts as a defect) can give a misleading picture

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Lisa Eades

Author: Lisa Eades

Expertise: Business Content Creator

Lisa has taught A Level, GCSE, BTEC and IBDP Business for over 20 years and is a senior Examiner for Edexcel. Lisa has been a successful Head of Department in Kent and has offered private Business tuition to students across the UK. Lisa loves to create imaginative and accessible resources which engage learners and build their passion for the subject.

Steve Vorster

Reviewer: Steve Vorster

Expertise: Economics & Business Subject Lead

Steve has taught A Level, GCSE, IGCSE Business and Economics - as well as IBDP Economics and Business Management. He is an IBDP Examiner and IGCSE textbook author. His students regularly achieve 90-100% in their final exams. Steve has been the Assistant Head of Sixth Form for a school in Devon, and Head of Economics at the world's largest International school in Singapore. He loves to create resources which speed up student learning and are easily accessible by all.