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operations and supply chain management
Operations Engineering And Management Concepts Analytics And Principles For Improvement 1st Edition Seyed Iravani - Solutions
An airline has the same number of flights every day departing its hub airport in a large city.The average number of flights that are delayed due to mechanical failure in a normal day is about
A manufacturer of plastic products produces a large plastic cart used for carrying heavy items. The main body of the cart is made using thermoforming equipment and is checked for quality issues by a quality control (QC) worker. The QC worker checks each produced body for nonconformities such as
Cashmere R Us is a firm that sells cashmere clothing and yarns. One of its product is a 2-ply yarn of cashmere and silk, which is sold in 67-yarn skein in a variety of colors. The quality control department takes random samples of 60 skeins each day and looks for nonconformities such as
Steve knows that when its injection molding machine is working properly, only 3 percent of plastic bottles produced by the machine are defective. He receives a phone call from one of its customers who complains that 12 of the 200 bottles that the customer received yesterday were defective. This
The blueberry granola cereal of H&O in Problem 6 must have at least 2 ounces of dried blueberry in each 28-ounce box. To monitor this, H&O takes samples of 40 boxes every 2 hours and measures the amount of blueberry in the box. The following table shows the number of boxes with less than 2 ounces
Healthy-&-Organic (H&O) produces a large number of breakfast cereal and granola bars.One of its popular product is blueberry granola cereal, sold in boxes that contain 28 ounces of cereal. Every 3 hours, a sample of five boxes is taken from the filling process and their weights are measured and
The weight of a professional tennis racket must be around 300 grams. When the production process that produces these rackets is set up properly, the weight of produced rackets is Normally distributed with mean of 300 grams and standard deviation of 6 grams. The production manager takes a sample of
Hospital discharge process is a complex process and thus it often takes several hours. Caroline, the manager of NMMEH hospital, has received complaints from some of her patients about the long discharge time. She decided to monitor the average discharge time each day to make sure things are in
Currently Sanjay takes samples of size 6 to monitor the average weight of cereal boxes filled by his filling process using the X chart. If Sanjay increases his sample size to 8, explain why each of the following statements is true or false:a. The control limits of the chart will become closer to
Jack wants to use two-sigma control limits for his control chart, but Jill suggests using threesigma control limits. Jill makes the following arguments to convince Jack to use three-sigma control limits. Explain why each of the arguments is true or false:a. Three-sigma control limits can detect an
Explain why each of the following statements is true or false:a. A process has just made a defective output, the process is therefore out of control.b. A process has been producing outputs that are all within design specifications, the process is therefore in control.
What is the appropriate control chart for monitoring each of the following:a. Time it takes to deliver express mail.b. Acidity of the batch of vinegar produced in each run.c. Fraction of packages delivered after their delivery guarantee dates.d. Number of packages delivered to wrong addresses in a
When taking samples for variables control charts, how many samples should be used to compute the control limits? How often a sample should be taken? What is the appropriate sample size? What about attributes control charts?
Describe the two main phases of developing and using statistical process control charts.
What is the difference between np chart and c chart, and when should each one be used?
What are the differences between variables control charts and attributes control charts?
Describe eight pattern signals of SPC charts that can signal an out-of-control process.
Describe the six control limit signals of SPC charts that can signal an out-of-control process.
What do type-I and type-II errors mean in SPC charts?
What are the control limits in SPC charts and why the three-sigma control limits are commonly used in practice?
What does it mean to have a process in statistical control, and what does an SPC chart do?
What are the differences in normal and abnormal variability in process performance? How do they correspond to the stability of a process?
What are lower specification limit (LSL) and upper specification limit (USL) and how are they determined?
Briefly describe the contribution of the following people to quality control and management:a. Walter Shewhartb. E. Edward Demingc. Joseph M. Jurand. Phillip Crosbye. Armand V. Feigenbaumf. Genichi Taguchi g. Kaoru Ishikawa
What is Deming’s wheel and what are its four main steps?
Explain two main dimensions of quality that are important to producer of a product.
What is critical to quality and how does it relate to design specifications of a product?
Describe eight dimensions of quality that are important to customers of physical goods. How do they differ for customers of services?
A manufacturer produces three different types of microwave ovens, namely, solo microwave ovens (S ovens), grill microwave ovens (G ovens), and convection microwave ovens (C ovens). The monthly demand for these products has been steady and is about 2250, 750, and 1500 a month, respectively, for S
Consider the CNC drill in Problem 4 and assume that repairing the CNC drill costs about$1200. This includes the cost of labor, material, and parts and the cost of losing production.The cost of the 20-minute preventive maintenance, however, is about $350 each time it is performed. Develop a
A CNC drill is the bottleneck of a Tool and Die shop. The drill is used in the production of a variety of products. The average time it takes to drill a part is about 3 minutes. Because the drill works constantly in three working shifts (24 hours a day), it often breaks down and requires some
Explain why each of the following statements is true or false:a. Pull systems generate higher throughput than push systems.b. For a given inventory level, pull systems generate higher throughput because they increase theoretical capacity of the process.c. Pull systems can generate the same
Consider the five-station serial line in Problem 1, and suppose that the line is run as a single Kanban system. All stations have five Kanban cards, except the bottleneck station that has eight Kanban cards. Explain why each of the following statements is true or false:a. Reducing the number of
A five-station serial push line has a throughput of 10 jobs an hour. If the line is run like a Kanban system such that it also produces 10 jobs an hour, explain why each of the following statements is true or false:a. The average inventory in each station of the push line is larger than that in the
Provide three examples of service firms that have used the principles of lean operations to improve performance. Which lean tool (or tools) did they use?
How does Toyota make its suppliers a part of its firm?
What are the six principles that Toyota uses to build a close relationship with its suppliers?
How do teams in lean operations function? Describe responsibilities of team members, team leaders, and group leaders in Toyota Production System.
What are 5S and 5-why practices in lean operations?
What are the four main components of a visual workplace? Provide an example for each component.
Define visual workplace and describe three major benefits of a visual workplace.
Describe what value stream and value stream mapping (VSM) are. How does VSM relate to lean operations?
What are Kaizen and Kaizen Blitz? Why is worker involvement essential in Kaizen and why does Kaizen focus on small and gradual improvements?
What is Heijunka and what are the two steps of implementing Heijunka? Also, describe the three main benefits of Heijunka.
How does Toyota Production System define Muda, Muri, and Mura?
What is work sequencing in lean operations and what are its six benefits?
What is takt time? and what is its role in minimizing inventory?
What is the difference between autonomous maintenance and preventive maintenance, and what are the advantages of each?
What is TPM? What are its goals and how does it achieve those goals?
What is an Andon system in lean operations?
What is Poka-Yoke? Present two examples of Poka-Yoke in manufacturing and service systems.
What are the four practices in lean operations that help rapid resolution of quality problems?
Describe four different ways in lean operations that help early detection of quality problems.
What are the two main approaches that lean operations use that can prevent quality problems from occurring?
What is river analogy and how is it analogous to continuous improvement in lean operations?
Describe seven benefits of pull production systems.
Describe how Kanban systems work.
Explain the differences between pull and push production systems from the following three perspectives: job release, control, and production authorization.
Describe four different ways that cellular layout can eliminate wastes.
Explain how using flexible resources helps reduce waste in lean operations.
Describe four major benefits of smaller batch sizes in operations systems.
What is SMED? Describe six principles that help achieve SMED.
How was Toyota’s approach different from Ford’s approach in dealing with setup time of their stamping plants?
What are the particular actions that Toyota has taken to mitigate the impact of variability in demand?
What are the seven sources of waste in lean operations?
How was Toyota’s approach to eliminating waste different from traditional scientific management approach?
What are the main four goals of lean operations?
Lean operations is a customer-focused process. Describe the three capabilities that lean operations must have to become a customer-focused process.
Explain what Jidoka means and how it is evolved into several practices in lean operations.
What does Genchi Genbutsu refer to in Toyota Production System?
Dell Computers is one of the pioneer companies that uses modular components to reduce its inventory costs. A personal computer (PC) is made of three main components: microprocessor (CPU), hard drive (HD), and random access memory (RAM). Now consider the case when Dell produces 30 different models
Fast-&-Easy Loans (F&E Loans) is a financial institution that offers loans to home buyers.F&E works 8 hours a day (from 8:00 am to 5:00 pm with lunch break from 12:00 to 1:00), and 5 days a week. Figure 14.14 shows the process-flow chart of the loan approval process at F&E.All applications are
Hampptton Phones makes two types of phones—standard and customized—on two different production lines in its assembly department. Each production line has five workstations, and each workstation has one worker, see Fig. 14.13. The assembly department works three shifts, 24 hours a day, 7 days a
About 60 percent of customers who come to Café Minoo order drink, about 10 percent of customers order sandwich, and the remaining 30 percent order sandwich and drink. Upon arrival, a customer first places the order with the cashier—Henry—and pays for it. The cashier asks the name of the
Office Support Equipment (OSE) is a firm that leases copiers to four major institutions in Chicago, namely, private firms, government offices, educational institutions, and small copy centers. OSE has a repair and maintenance crew with four technicians: Bill, Chad, Dan, and Paul, who provide repair
What is the maximum capacity of Leather Office Furniture (LOF) in Sec. 14.5 if all four workers can be cross-trained to work in all four stations?
Mark, the inventory manager in a large warehouse, is planning to use bucket brigade line for its order picking process. Current order picking process consists of three identical lines with eight stations. Each line is assigned to a worker who works in all eight stations picking items of an order
What are modular product and modular process? Provide an example for each?
What are the three main enablers of postponement?
Provide examples of point of differentiations at the manufacturer, at the distribution center, at the retailer, and at the customer site of a supply chain.
What are the benefits of postponement and what are the reasons that postponement can provide those benefits?
Explain what “postponement” strategy and “point of differentiation” are in a production process.
What is a bucket brigade line and what types of operations are suited for implementing bucket brigade control policy?
What is a chain flexibility structure and why does it perform so well?
Explain two different ways that flexible resources can improve process-flow measures of a process.
Describe the differences between mass production and mass customization.
Call center in Problem 23 pays its full-time agents who work in its three 8-hour shifts $20 per hour. In addition to hiring new full-time agents, the manager is also considering hiring part-time agents who work for 4 consecutive hours in a day. The part-time shifts include seven 4-hour shifts with
Call center of a financial institution works from 7:00 am to 5:00 pm. The firm has a plan to offer more of its services online and through its call center, and thus expecting to have significant increase in calls to its call center. When the plan is implemented, the number of agents required to
Consider the online retailer in Problem 20 that is making a transition to a new system for order processing and sales. The consulting firm had a long negotiation and is planning to sign a contract to finish the project in 23 days. But, before doing that, they are asking your opinion about the
Consider the online retailer in Problem 20. Because the sales promotion campaign is scheduled to start on day 20, the retailer is willing to pay a bonus of $30,000 if the consulting firm can complete the transition by day 20. Suppose you work for the consulting firm and you have gathered the
A large online retailer is working with an information technology consulting firm to update its order processing and sales equipment and software. The transition from the old system to the new system consists of the following activities:a. What is the earliest time that the retailer can use the new
Consider Smaag Homes in Problem 18 and assume that because of budget considerations, Smaag Homes decided not to spend money to reduce the durations of the tasks in its current project in Problem 17. However, Smaag Homes has just got a new project from another client who requests Smaag Homes to
Smaag Homes in Problem 17 is informed that its client is willing to pay a bonus if Smaag Homes can finish the project in 40 days.The following table shows the cost of reducing the duration of each activity by a day and the maximum possible reduction:a. Develop a linear programming model to find the
Smaag Homes is a construction firm that builds houses for its clients. The following table presents the list of activities that Smaag Homes must complete for its current client’s project:a. What is the earliest time that Smaag Homes can finish the project?b. What is the earliest time that each
A firm provides cleaning services to houses in a metropolitan area. The cleaning of a house consists of two main activities: (i) cleaning bathrooms and kitchen, (ii) vacuuming the entire house, which has to be done after cleaning bathrooms and kitchen. The firm has seven houses to clean today and
Solid Foundation and Concrete (SFC) is specialized in excavation and concrete services for commercial and residential construction. SFC has two teams: (i) excavation team and (ii) concrete team. For each project, first excavation team excavates the site, making it ready for the concrete team to
Superior Games (SG), a video game design company, is in the process of designing a new video game that is expected to launch during the next 3 months. The game consists of seven software modules that can be developed independent of each other. After these modules are completed, the final step is to
You come back to school from Christmas and new year’s break on January 3rd and you realize that you have eight homework assignments that you need to submit this month. The list of the homework, the time it takes (in days) to finish each one, and their due dates are in the following table:You
Besides its plant in Detroit, JD Precision Part in Problem 11 decides to also use its plant in Indiana to process the orders. Each order can only be allocated to one of the two plants. Which order should be allocated to each plant in order to minimize the average waiting time of the manufacturers?
JD Precision Parts is a firm that supplies parts and components to auto manufacturers. Because orders received from manufacturers are for different parts, JD must set up its production process to make each order. The following table shows the list of orders that JD has received from eight different
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