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hotel operations management
Operations Management For Competitive Advantage 11th Edition Richard B. Chase, F. Robert Jacobs - Solutions
3 What would you do to ensure that the operators were kept busy? Value stream mapping involves first developing a baseline map of the current situation of a company's external and/or internal operations and, then, applying lean concepts,developing a future state map that shows improved operations.
2 How do you think the machine operators would react to the change? Value stream mapping involves first developing a baseline map of the current situation of a company's external and/or internal operations and, then, applying lean concepts,developing a future state map that shows improved
1 Eliminating the queue of work dramatically quickens the time it takes a part to flow through the system. What are the disadvantages of removing those queues? Value stream mapping involves first developing a baseline map of the current situation of a company's external and/or internal operations
4 Outline a plan for introducing lean at Quality Parts Company.Quality Parts Company supplies gizmos for a com- puter manufacturer located a few miles away. The company pro- duces two different models of gizmos in production runs ranging from 100 to 300 units. The production flow of models X and Y
3 Sketch the operation of a pull system for quality for Quality Parts Company's current system. Quality Parts Company supplies gizmos for a com- puter manufacturer located a few miles away. The company pro- duces two different models of gizmos in production runs ranging from 100 to 300 units. The
2 Make recommendations for lean improvements in such areas as scheduling, layout, kanban, task groupings, and inventory. Use quantitative data as much as possible; state necessary assumptions. Quality Parts Company supplies gizmos for a com- puter manufacturer located a few miles away. The company
1 Which of the changes being considered by the manager of Quality Parts Company are counter to the lean philosophy? Quality Parts Company supplies gizmos for a com- puter manufacturer located a few miles away. The company pro- duces two different models of gizmos in production runs ranging from 100
3 A major reason for the differences in opinions may be the difference in what Toyota considers "competitive" components. These are the components that would mostly be bought using the Internet trading sites. Who is right? Are steering wheels and wire connectors competitive components? It is
2 Rather than having vendors compete against one another, Toyota is interested in treating suppliers as partners. Is Toyota just being old-fashioned in its views? It is interesting to see how the large automobile man- ufacturers differ in their opinions about working with suppliers and
1 GM and Ford have quickly pushed the development of large Internet sites to create an environment where suppli- ers must compete for business. Ford and GM argue that these Internet sites should reduce cost because the negotia- tions are streamlined. How do you think the suppliers view these sites?
6 Refer to Technical Note 6, "Facility Layout," page 254, Problem I regarding the Cyprus Citrus Cooperative. Use the layout provided on that page to (a) value stream map the business and its processes as they are now and (b) develop and analyze a future state mapping of how locations can be
5 Arvin Meritor is so pleased with the outcome from the consultants' previous suggestions that the consultants are invited back for more consulting work. The consultants now suggest a more complete robotic automation of the making of muffler assemblies and also a reduction in container size to
4 Refer to Example 12.1 as the basis for this problem. Arvin Meritor hires a team of consultants. The consultants suggest a partial robotic automation as well as an increase in safety stock to 0.125. Arvin Automotive implements these suggestions. The result is an increase in efficiency in both the
3 A bottling plant fills 2,400 bottles every two hours. The lead time is 40 minutes and a container accommodates 120 bottles. The safety stock is 10 percent of expected demand. How many kanban cards are needed?
2 Transmissions are delivered to the fabrication line four at a time. It takes one hour for transmis- sions to be delivered. Approximately four vehicles are produced each hour, and management has decided that 50 percent of expected demand should be maintained as safety stock. How many kanban card
1 A supplier of instrument gauge clusters uses a kanban system to control material flow. The gauge cluster housings are transported five at a time. A fabrication center produces approxi- mately 10 gauges per hour. It takes approximately two hours for the housing to be replenished. Due to variations
15 Why would a JIT advocate have a problem with the system proposed for the BMW AG's U.S. factory (discussed in the box "BMW Moves beyond Just-in-Time Production")?
14 Explain the relationship between quality and productivity under the lean philosophy.
13 Why is lean hard to implement in practice?
12 In which ways, if any, are the following systems analogous to kanban: returning empty bottles to the supermarket and picking up filled ones; running a hot dog stand at lunchtime; with- drawing money from a checking account; raking leaves into bags?
11 Explain how cards are used in a kanban system.
10 What are the roles of suppliers and customers in a lean system?
9 What are the implications for cost accounting of lean production?
8 What objections might a marketing manager have to uniform plant loading?
7 Discuss ways to use lean to improve one of the following: a pizza restaurant, a hospital, or an auto dealership.
6 Will lean work in service environments? Why or why not?
5 Why must lean have a stable schedule?
4 Discuss lean in a job shop layout and in a line layout.
3 Stopping waste is a vital part of lean. Using value stream mapping, identify some sources of waste in your home or dom and discuss how they may be eliminated.
2 Is it possible to achieve zero inventories? Why or why not?
1 What lean principles are being used by Arvin Meritor (see the box on pages 482 and 483)? Use the categories in Exhibit 12.8 to develop your answer.
A local hospital wants to set up a kanban system to manage its supply of blood with the regional blood bank. The regional blood bank delivers blood to the hospital each day with a one-day order lead time (an order placed by 6 P.M. today will be delivered tomorrow aftemoon). Interally, the hospital
Arvin Automotive, a company that makes muffler assemblies for the Big Three, is committed to the use of kanban to pull material through its manufacturing cells. Arvin has designed each cell to fabricate a specific family of muffler products. Fabricating a muffler assembly involves cutting and
Recall from Chapter 5 that a process usually consists of (1) a set of tasks, (2) a flow of material and information that connects the set of tasks, and (3) storage of material and information. 1. Each task in a process accomplishes, to a certain degree, the transformation of input into the desired
9 How would you characterize the most important difference for the following issues when com- paring a job shop and a flow shop? ISSUE Number of changeovers Labor content of product Flexibility JOB SHOP FLOW SHOP
10 The diagram below represents a process where two components are made at stations A1 and A2 (one component is made at Al and the other at A2). These components are then assembled at station B and moved through the rest of the process, where some additional work is completed at stations C, D, and
12 The product-process matrix is a convenient way of characterizing the relationship between product volumes (one-of-a-kind to continuous) and the processing system employed by a firm at a particular location. In the boxes presented below, describe the nature of the intersection between the type of
A university advising office has four rooms, each dedicated to specific problems: petitions (Room A), schedule advising (Room B), grade complaints (Room C), and student counseling (Room D). The office is 80 feet long and 20 feet wide. Each room is 20 feet by 20 feet. The present loca- tion of rooms
The following tasks must be performed on an assembly line in the sequence and times specified:a. Draw the schematic diagram.b. What is the theoretical minimum number of stations required to meet a forecast demand of 400 units per eight-hour day?c. Use the longest-task-time rule and balance the line
The manufacturing engineers at Suny Manufacturing were working on a new remote controlled toy Monster Truck. They hired a production consultant to help them determine the best type of produc- tion process to meet the forecasted demand for this new product. The consultant recommended that they use
1 The Cyprus Citrus Cooperative ships a high volume of individual orders for oranges to north- em Europe. The paperwork for the shipping notices is done in the accompanying layout. Revise the layout to improve the flow and conserve space if possible. Typist Price and extension clerk Files Billing
3 An assembly line is to operate eight hours per day with a desired output of 240 units per day. The following table contains information on this product's task times and precedence relationships:a. Draw the precedence diagram.b. What is the workstation cycle time?c. Balance this line using the
4 The desired daily output for an assembly line is 360 units. This assembly line will operate 450 minutes per day. The following table contains information on this product's task times and precedence relationships:a. Draw the precedence diagram.b. What is the workstation cycle time?c. Balance this
5 Some tasks and the order in which they must be performed according to their assembly requirements are shown in the following table. These are to be combined into workstations to create an assembly line. The assembly line operates 7 hours per day. The output requirement is 1,000 units per day.a.
6 An initial solution has been given to the following process layout problem. Given the flows described and a cost of $2.00 per unit per foot, compute the total cost for the layout. Each location is 100 feet long and 50 feet wide as shown on the following figure. Use the centers of departments for
7 An assembly line is to be designed to operate 7 hours per day and supply a steady demand of 300 units per day. Here are the tasks and their performance times:a. Draw the precedence diagram.b. What is the workstation cycle time?c. What is the theoretical minimum number of workstations?d. Assign
8 S. L. P. Craft would like your help in developing a layout for a new outpatient clinic to be built in California. From analysis of another recently built clinic, she obtains the data shown in the following diagram. This includes the number of trips made by patients between departments on a
9 The following tasks are to be performed on an assembly line:The workday is seven hours long. Demand for completed product is 750 per day.a. Find the cycle time.b. What is the theoretical number of workstations?c. Draw the precedence diagram.d. Balance the line using sequential restrictions and
10 The Dorton University president has asked the OM department to assign eight biology profes- sors (A, B, C, D, E, F, G, and H) to eight offices (numbered 1 to 8 in the diagram) in the new biology building.The following distances and two-way flows are given:a. If there are no restrictions
11 The flow of materials through eight departments is shown in the table below. Even though the table shows flows into and out of the different departments, assume that the direction of flow is not impor- tant. In addition, assume that the cost of moving material depends only on the distance
13 A sheet metal shop was in moving to a new facility and wanted to create a layout for their new factory. The new building was 60 feet by 20 feet. The operations manager had looked into dif- ferent methods for developing a layout and decided to try Systematic Layout Planning (SLP). He has worked
1. Suppose a manufacturer has identified the following options for obtaining a machined part: It can buy the part at $200 per unit (including materials); it can make the part on a numerically controlled semiautomatic lathe at $75 per unit (including materials); or it can make the part on a
16 Assume that your stock of sales merchandise is maintained based on the forecast demand. If the distributor's sales personnel call on the first day of each month, compute your forecast sales by each of the three methods requested here.a. Using a simple three-month moving average, what is the
Dell Computer reported the following information in its 1999 annual report (all amounts are expressed in millions):The cost of revenue corresponds to what we call cost of goods sold. One might think that U.S. companies, at least, would use a common accounting terminology, but this is not true. The
Mike Morales is the supervisor of Legal Copy-Express, which provides copy services for downtown Los Angeles law firms. Five customers submitted their orders at the beginning of the week. Specific scheduling data are as follows: All orders require the use of the only color copy machine available;
We can approach the problem by examining a specific situation. Consider the cost of shipping from Bloomington, Indiana, to Littleton, Massachusetts. Assume that the inventory carrying cost rate is 30 percent per year of the product value. This cost rate captures the cost of capital, insurance,
A firm's sales for a product line during the 12 quarters of the past three years were as follows:The firm wants to forecast each quarter of the fourth year that is, quarters 13, 14, 15, and 16. QUARIER SALES QUARTER SALES 1 600 7 2,600 234 1550 8 2,900 1500 9 3,800 1,500 10 4.500 5 2,400 11 4,000 6
Find the economic order quantity and the reorder point, givenWhat quantity should be ordered? Annual demand (D) = 1,000 units Average daily demand (7) = 1,000/365 Ordering cost (S)= $5 per order Holding cost (H)=$1.25 per unit per year Lead time (L) 5 days Cost per unit (C)=$12.50
Joe's Auto Seat Cover and Paint Shop is bidding on a contract to do all the custom work for Smiling Ed's used car dealership. One of the main requirements in obtaining this contract is rapid delivery time, because Ed-for reasons we shall not go into here-wants the cars facelifted and back on his
The Carpet City Store in Carpenteria has kept records of its sales (in square yards) each year, along with the number of permits for new houses in its area.Carpet City's operations manager believes forecasting sales is possible if housing starts are known for that year. First, the data are plotted
The following table shows unit demand for a broiler pan over an 18-month period. (Try to guess what demand might be for July, August, and September this year, and compare your guess to the actual data presented later.) LAST YEAR THIS YEAR LAST YEAR THIS YEAR January 6 72 July 167 February 212 90
Sunrise Baking Company markets doughnuts through a chain of food stores. It has been experienc- ing over- and underproduction because of forecasting errors. The following data are its demand in dozens of doughnuts for the past four weeks. Doughnuts are made for the following day; for example,
Here are the actual demands for a product for the past six quarters. Using focus forecasting rules 1 through 5, find the best rule to use in predicting the third quarter of this year. QUARTER - I II III IV Last year 1,900 700 900 1,100 This year 1400 1,000
A specific forecasting model was used to forecast demand for a product. The forecasts and the cor- responding demand that subsequently occurred are shown below. Use the MAD and tracking signal technique to evaluate the accuracy of the forecasting model. ACTUAL FORECAST October 700 660 November 760
Here are quarterly data for the past two years. From these data, prepare a forecast for the upcoming year using decomposition. PERIOD ACTUAL PERIOD ACTUAL 1 300 234 540 885 580 56200 7 1191 8 760 416 760
A product is priced to sell at $100 per unit, and its cost is constant at $70 per unit. Each unsold unit has a salvage value of $20. Demand is expected to range between 35 and 40 units for the period; 35 definitely can be sold and no units over 40 will be sold. The demand probabilities and the
1 AlwaysRain Irrigation, Inc., would like to determine capacity requirements for the next four years. Currently two production lines are in place for bronze and plastic sprinklers. Three types of sprinklers are available in both bronze and plastic: 90-degree nozzle sprinklers, 180-degree nozzle
1 Semans is a manufacturer that produces bracket assemblies. Demand for bracket assemblies (X) is 130 units. The following is the BOM in indented form:Below is a table indicating current inventory levels:a. Using Excel, create the MRP using the product tree structure.b. What are the net
1 Calculate the break-even product value of using Express Mail (overnight delivery) versus Parcel Post (three-day delivery) for sending a package from Peoria, Illinois, to Memphis, Tennessee. The following table contains the appropriate costs. Assume that inventory carrying cost is 25 per- cent per
2 Suppose that Always Rain Imigation's marketing department will undertake an intense ad campaign for the bronze sprinklers, which are more expensive but also more durable than the plastic ones. Forecast demand for the next four years isWhat are the capacity implications of the marketing campaign?
2 In the following MRP planning schedule for Item J, indicate the correct net requirements, planned order receipts, and planned order releases to meet the gross requirements. Lead time is one week. HEM J Gross requirements On-hand Net requirements Planned order receipt Planned order release WEEK
1 Christine has three cars that must be overhauled by her ace mechanic, Megan. Given the following data about the cars, use least slack per remaining operation to determine Megan's scheduling priority for each: CAR ABC REMAINING OVERHAUL CUSTOMER PICK-UP TIME (HOURS HENCE) TIME (HOURS) 10 4 17 5 15
6 DAT, Inc., needs to develop an aggregate plan for its product line. Relevant data areThe forecast for next year isManagement prefers to keep a constant workforce and production level, absorbing variations in demand through inventory excesses and shortages. Demand not met is carried over to the
4. The U.S. Airfilter company has hired you as a supply chain consultant. The company makes air filters for residential heating and air-conditioning systems. These filters are made in a single plant located in Louisville, Kentucky, in the United States. They are distributed to retailers through
5 Note: For Problems 5 through 10, to simplify data handling to include the receipt of orders that have actually been placed in previous periods, the following six-level scheme can be used. (A number of different techniques are used in practice, but the important issue is to keep track of what is
2 A hotel has to schedule its receptionists according to hourly loads. Management has identified the number of receptionists needed to meet the hourly requirement, which changes from day to day. Assume each receptionist works a four-hour shift. Given the following staffing requirement in a certain
7 Old Pueblo Engineering Contractors creates six-month "rolling" schedules, which are recom- puted monthly. For competitive reasons (they would need to divulge proprietary design criteria, methods, and so on), Old Pueblo does not subcontract. Therefore, its only options to meet cus- tomer
3 Seven jobs must be processed in two operations: A and B. All seven jobs must go through A and B in that sequence-A first, then B. Determine the optimal order in which the jobs should be sequenced through the process using these times: JOB PROCESS A TIME PROCESS B TIME 1 9 8 234567 7 6 1 2 4
5 What are the differences between high and low customer contact service (CCS) businesses, in general, for the dimensions listed below? (Example-Facility Layout: in a high CCS, the facility would be designed to enhance the feelings and comfort of the customer while in a low CCS, the facility would
8 Alan Industries is expanding its product line to include new models: Model A, Model B, and Model C. These are to be produced on the same production equipment, and the objective is to meet the demands for the three products using overtime where necessary. The demand forecast for the next four
4 Jumbo's Restaurant is trying to create a consecutive-days-off schedule that uses the fewest workers. Use the following information to create a five-days-on, two-days-off schedule: DAY M TU W TH F S SU Requirements 2 2 1 3 3 4 2
9 Shoney Video Concepts produces a line of videodisc players to be linked to personal computers for video games. Videodiscs have much faster access time than tape. With such a computer/video link, the game becomes a very realistic experience. In a simple driving game where the joystick steers the
5 The following list of jobs in a critical department includes estimates of their required times:a. Use the shortest operation time rule to schedule these jobs. What is the schedule? What is the mean flow time?b. The boss does not like the schedule ina. Jobs E and G must be done first, for obvious
1 For the four basic configurations that follow, assume that the market is demanding product that must be processed by both Resource X and Resource Y for Cases I, II, and III. For Case IV, both resources supply separate but dependent markets; that is, the number of units of output from both X and Y
6 The following matrix shows the costs in thousands of dollars for assigning Individuals A, B, C, and D to Jobs 1, 2, 3, and 4. Solve the problem showing your final assignments in order to min- imize cost. JOBS INDIVIDUALS 1 2 3 4 734 ABCD 9 11 5 376 5 6 2 5 9 10 12
2 Following are the process flow sequences for three products: A, B, and C. There are two bot- tleneck operations on the first leg and fourth leg-marked with an X. Boxes represent process- es, which may be either machine or manual. Suggest the location of the drum, buffer, and ropes. Final product
11 Helter Industries, a company that produces a line of women's bathing suits, hires temporaries to help produce its summer product demand. For the current four-month rolling schedule, there are three temps on staff and 12 full-time employees. The temps can be hired when needed and can be used as
7 A manufacturing facility has five jobs to be scheduled into production. The following table gives the processing times plus the necessary wait times and other necessary delays for each of the jobs. Assume that today is April 3 and the jobs are due on the dates shown:Determine two schedules,
3 The accompanying figure shows a production network model with the parts and processing sequences. State clearly on the figure (1) where you would place inventory; (2) where you would perform inspection; and (3) where you would emphasize high-quality output. (Note: Operations may be shown either
1 Prepare an aggregate plan for the coming year, assuming that the sales forecast is perfect. Use the spreadsheet "Bradford Manufacturing" from this book's DVD. In the spreadsheet an area has been designated for your aggregate plan solution. Supply the number of packaging lines to run and the
11 The MRP gross requirements for Item A are shown here for the next 10 weeks. Lead time for A is three weeks and setup cost is $10. There is a carrying cost of $0.01 per unit per week. Beginning inventory is 90 units.Use the least total cost or the least unit cost lot-sizing method to determine
4 The following production flow shows Parts E, I, and N; Subassembly O; and final assembly for Product P:B involves a bottleneck operation, and M involves a CCR.a. Draw the process flow.b. Where would you locate buffer inventories?c. Where would you place inspection points?d. Where would you stress
2 Review your solution carefully and be prepared to defend it. Bring a printout of your solution to class. If you have a note- book computer, bring it to class with a copy of your com- pleted spreadsheet. Your instructor may run a simulation in class using your solution.THE SITUATION You are the
11 What kind of policy or procedure would you recommend to improve the inventory operation in a department store? What advantages and disadvantages does your system have vis--vis the department store inventory operation described in this chapter? 1 The local supermarket buys lettuce each day to
12 (This problem is intended as a very simple exercise to go from the aggregate plan to the mas- ter schedule to the MRP.) Gigamemory Storage Devices, Inc., produces CD-ROMs (read only memory) and WORMS (write once read many) for the computer market. Aggregate demand for the WORMS for the next two
9 The Glendale Electronics Store employs five people. Customer traffic is highest on the week- end and is lowest during midweek. Accordingly, demand for employee help is given in the fol- lowing table. Make an employee work schedule that will meet staffing requirements and guar- antee each employee
5 Here are average process cycle times for several work centers. State which are bottlenecks, nonbottlenecks, and capacity-constrained resources. Processing time Processing time Setup Idle Processing time Setup Processing time Setup Processing time Setup Idle Idle Setup time Idle
10 Jobs A, B, C, D, and E must go through Processes I and II in that sequence (Process I first, then Process II). Use Johnson's rule to determine the optimal sequence in which to schedule the jobs to minimize the total required time. REQUIRED PROCESSING REQUIRED PROCESSING TIME ON I TIME ON II A 4
6 The following diagram shows the flow process, raw material costs, and machine processing time for three products: A, B, and C. There are three machines (W,X, and Y) used in the production of these products; the times shown are in required minutes of production per unit. Raw material costs are
11 In a job shop, six machinists were uniquely qualified to operate any one of the five machines in the shop. The job shop had considerable backlog, and all five machines were kept busy at all times. The one machinist not operating a machine was usually occupied doing clerical or rou- tine
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