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business
operations management

Questions and Answers of Operations Management

How do the demand and the lead time affect reorder points in a continuous review system?
You’re a buyer for fictional Quality Kitchen Appliances. The store has a demand for 1,000 toaster ovens per year. The cost of each toaster oven is US$78. The ordering cost is US$100 per order. The
What are the differences between the EPQ and the EOQ model?
The Burlap Tire Company is a mythical producer of a brand of tires known as the Snowgrip. The annual demand for this brand of tires at its distribution center is 14,000. The cost of ordering these
In the EPQ model, what would be the effect if the production rate and the demand rate are equal?
When quantity discounts are offered, what factors other than price should be considered?
A company manufactures vacuum cleaners. Although the company buys many of the components from outside vendors, it produces in-house HEPA filters at the rate of 600 per day. Vacuum cleaners are
How is the service level related to safety stock?
Park Sung Inc. is a fictional South Korean manufacturer of refrigerators. The company produces at its manufacturing plant in Busan subcomponents for its refrigerators at the rate 275 units per day.
Explain the relationship between the setup time and the average inventory level in the EPQ model. What would be the beneficial effect of reducing setup times?
The mythical Hacker Microbrewery in Rosenheim, Germany, makes a brand of beer called Golden Eagle, which it bottles and sells in cases to adjoining pubs and stores in Rosenheim. The setup cost of
In a continuous review system, how does the variability in both the demand and the lead time affect the target inventory level?
Sun International is a fictional major distributor of hand towels and wash clothes to hotel chains and restaurants. To minimize procurement costs, the company is planning to switch to a supplier
A U.S. jewelry store wishes to buy rare green amethyst gemstones. The supplier of the gemstones has announced the quantity discount schedule in the following table. The ordering cost is US$120 per
A printing company uses 2,000 reams of a certain type of paper in a year. The cost of holding one ream of paper in inventory per year US$0.60. The ordering cost per order is US$30.00. The vendor that
The mythical Owen Distributors has an annual demand of 2,000 units for its handheld security wands. The average cost of the handheld security wand is US$140. Carrying cost is 18% of the unit cost of
In single-period inventory systems, how would a high level of service affect the optimal stocking policy?
A creamery shop sells a special blend of mango and vanilla ice cream. The cost to the shop of making this ice cream is $3.00 per quart and it sells it for $4.50 per quart (in U.S. dollars). The
Refer to the data in problem 31. If the annual holding cost is a constant $3.50 per shirt per year, compute the optimal order quantity and the total annual cost.Data from problem 31Emily Ford, the
Emily Ford, the manager of a college bookstore, purchases polo shirts from a local vendor with the college name and logo printed on them. Emily purchases these t-shirts from the vendor at a cost of
A small grocery store buys one-gallon bottles of milk from a local dairy farmer. The store buys milk from the dairy farmer at a cost of $2.00 per gallon and sells it for $3.50 per gallon. The demand
A bakery must decide how many graduation cakes to prepare for the upcoming weekend. The demand for the cakes can be approximated by a normal distribution with a mean of 8 cakes per day and a standard
A local farm market buys fresh fruits and vegetables from local farmers. It buys peaches from one farmer at a cost of $0.90 per pound and sells it for $2.00 per pound. The demand for peaches during
The manager of a department store uses two types of inventory control systems to manage the inventory of stock keeping units (SKUs) in his store€”a continuous review system and a periodic
A drugstore orders at fixed intervals many of the items it stocks. The store orders a particular brand of cold medicine from a wholesale supplier. The store reviews the stock of the medicine every 25
Given the following forecast and cost information, determine the total cost of a plan that uses regular time production output of 600 units per month, overtime is used when needed up to a maximum of
A company currently uses the level strategy for implementing its sales and operations plan. The company recently introduced several new products into the market that have significantly increased the
You have been named manager for a Mexican-themed restaurant at a vacation hot spot in the Dominican Republic. Your highest volume season is typically from mid November to late March. How might you
What are the problems that S&OP planners face in an environment of high demand uncertainty? What decision options do they have in such an environment?
You have just been put in charge of a golf equipment store in the western New York region and are interested in employing some “demand influencing options” for boosting sales. Please give
The objective of S&OP is to minimize total cost. What are the major cost categories of this total cost?
Suppose you were in charge of product purchasing for the men’s sportswear department of a large department store in the suburbs of Chicago. How might you use top-down and bottom-up planning for
List some industries or situations where each of the three basic S&OP strategies is appropriate?
Why is demand planning so difficult for a company to perform? Use the example of a video game developer. How would they use demand planning prior to the anticipated launch of a new product? How would
What are the major differences between the level and chase S&OP planning strategies?
1. How has social media made the S&OP process more complex?2. How can e-commerce help and hurt the coordination of sales and operations planning forecasts?3. Why is the challenge of managing
Sales and operations planning (S&OP) has been referred to as the means for bringing together a company’s marketing, finance, sales, and operations departments for fully integrated business
What is sales and operations planning (S&OP), and why is it important to companies in many industries?
Develop a level production plan for the compressor demand forecast in problem 9 by using overtime, inventory, and backlogs to absorb demand fluctuations. Inventory holding costs are $10 per month per
What are some of the issues that companies should address in implementing a global sales and operations plan?
Refer to Example 17.1. Suppose the company€™s manufacturing plant was shut down during February and March due to a labor strike. Nonetheless, demand for those 2 months still had to be met.
What is sales carbon operations planning (SCOP)? How is it different from the typical S&OP process?
Refer to Solved Problem 17.1. Suppose Cool Air Inc. has a maximum regular time production capacity of 900 air conditioners per month for the months of January through October and only 600 air
Refer to Solved Problem 17.1. Use a chase production strategy. Yet, the number of full-time employees hired or fired is restricted to 5 employees per month. During peak demand periods, the company
PharmaTech, Inc., a fictional manufacturer of pharmaceutical products and medical supplies located in Zurich, Switzerland, uses sales and operations planning to set production, workforce, and
Excelsior Clay Works, a fictional manufacturer of a variety of high-quality glazed clay roof tiles in Kerala, India, has the following composite demand forecasts (in hundreds of units):Additional
Kate Russell, the plant manager of a furniture manufacturing company, is in the process of developing a sales and operations plan for the upcoming year. She has obtained a forecast of expected demand
Medaas Electronics is a fictional producer of laser printers. The company€™s production planner, Christian Medaas, has developed the following cost data (in U.S. dollars):Regular time cost:
Reagan Health Foods Inc. is a fictional producer of protein drinks. The company’s production planner has developed the following demand forecast (in cases) for the first 6 months of 2016: 3,500;
Montague Furniture Corporation is a fictional chair manufacturer located in Pampanga, Philippines. They make two types of rattan bamboo chairs€”Rocking Chair and Windsor Chair. Both chairs
A company€™s production planner for the company€™s popular product has developed the following demand forecast and the perunit regular time production cost information for the
A company that manufactures roofing materials for houses has the following demand forecasts for the next 4 weeks.The company€™s available capacities for labor and machines and their
What are the immediate inputs to the master scheduling process?
1. Enterprise training represents just one more example of the types of enterprise-wide initiatives companies use their ERP systems to support. Can you think of other types of enterprise wide
A work center has two machines and two operators. The work center operates on two shifts and each operator works one shift at 8 hours per shift. The efficiency and utilization rates of the two
Dickinson Sports Equipment Inc. is a mythical manufacturer of a variety of sports goods. The bill of materials for one of its popular products, a sidewalk skateboard, is made up of a fiberglass board
How can ERP contribute to sustainable business practices?
Given the following product structure tree, master production schedule, and routing and work standards information:1. Develop a load projection report for each of the five work stations.2. Balance
Refer to problem 8. You are the production planner at Dickinson Sports Equipment Inc. The lead times for assembling the skateboard and for assembling or acquiring the various subassemblies and
Given the following product structure tree, master production schedule, and routing and work standards information:1. Develop a load projection report for each of the three work stations.2. Balance
Describe the time phasing logic in MRP.
Refer to the following product structure tree. At the beginning of week 7, 100 units of P are to be assembled. Component S is ordered in lot sizes of 300 units, and one such order is scheduled to
Describe the process of MRP explosion.
Refer to problems 8 and 9. If the master schedule calls for 70 sidewalk skateboards to be assembled at the beginning of week 10, prepare a material requirements plan for all subassemblies and
Explain the pegging capability of the MRP system.
What are the key outputs from the MRP process?
Assembling a pair of scissors requires a straight blade assembly, a bent blade assembly, and a screw. Each straight blade assembly requires a straight blade and a straight blade grip. Each bent blade
What are the differences between a regenerative and a net-change MRP system?
Complete the MRP records for component K. Component K Low-Level Code: 1 Lead Time: 2 weeks Lot Size: 200 Week 2 3 5 7 8 9. Gross Requirements 55 75 80 120 65 50 70 40 35 Scheduled Requirements 200
What is the meaning of “nervousness” in an MRP system? Describe its impact and the mitigation approaches that can be taken.
Complete the MRP records for end-product P. Week ProductP Low-Level Code:0 Lead Time: 1 week Lot Size: 2-week fixed-period ordering 3 4. 9. 10 Gross Requirements Scheduled Requirements Projected
Describe briefly the different lot-sizing approaches used in MRP.
Component X has the following weekly demand requirements:The ordering cost for this item is $50/order and holding cost is $2/unit/week (in U.S. dollars). To develop a material requirements plan for
Discuss briefly the benefits and limitations of an MRP system.
Component K has the following weekly demand requirements:The ordering cost for this item is $100/order and holding cost is $1/unit/week (in U.S. dollars). To develop a material requirements plan for
Discuss the key features and advantages of an integrated MRP–JIT system.
Explain how MRP can be applied in the following service businesses: (a) A hospital and (b) Aircraft scheduling.
The following table is a partial master schedule:1. Complete the master schedule records. Show all calculations.2. Suppose a customer cancels an order of 60 units in week 3, what effect would it have
A finished product R is assembled from two units of S and two units of Q. Production of S requires two units of K, three units of L, and one unit of M. Q is produced from two units of X and three
Suppose you were in charge of your company’s MRP system and received a memo from the CEO stating the need to “search diligently” for ways to improve manufacturing sustainability. Explain how
Refer to problem 19. Using the information provided in that problem and the following data, prepare an MRP table for finished product R.The minimum production lot size for R is 60. Assume no
Refer to problem 19. Using the information provided in that problem and the following data, prepare an MRP table for subassembly Q.The lot size for Q is in multiples of 70.There are 140 units of Q on
Refer to the product structure tree and the following data:Based on this product structure tree and the data provided, develop a gross and net requirement plan for subassemblies C and D. C (1) E (1)
Refer to problem 22. Given the data and the product structure tree provided in that problem, develop a material requirements plan for all the nine items.Data form problem 22Refer to the product
Explain the scheduling technique used when multiple products have to be scheduled in a line process.
The following table provides information on planned and actual inputs and outputs of an automotive service center in terms of standard hours of work. The beginning backlog is 14 standard hours of
1. How can you use workforce scheduling methods to schedule the umpires this coming summer?2. Can you think of other situations where workforce scheduling can be applied in your life?Ross Davis is a
Why is job-shop scheduling considerably more complex?
Given the following data on planned and actual inputs and outputs of a machine shop in terms of standard hours of work, determine the cumulative deviation and the backlog for each period. The
What is input–output control, and why is it an important scheduling technique for job shops?
Given the following data on planned and actual inputs and outputs of work center 4 of a tool and die shop in terms of standard hours of work, determine the cumulative deviation and the backlog for
Describe Gantt charts and how they are useful in job shop scheduling.
An elite logistics company wants to determine the optimum assignment of its fleet of trucks to delivery routes. The objective is to minimize total cost. The cost data in hundreds of dollars for the
Virat Kohli, the hospital administrator at mythical Trinity Hospital, wants to assign nurses beginning a shift in the oncology ward of the hospital. The time required for patient care varies from one
Refer to problem 5. Two weeks after assigning the nurses, Virat Kohli of Trinity Hospital wanted to focus on the patient satisfaction with the care they received from the nurses. Accordingly, he
List the assumptions made in the use of the five priority rules.
Susan Inskeep is the plant manager of an electronic manufacturing plant. The plant€™s current product line has five electronic components that can be processed in five machines. The
Describe briefly the three criteria used to evaluate the performance of the priority rules.
The Chief of Police, Karen Stanley, of the Make Believe Police Department needs to assign five detective squads to five pending criminal cases. Karen wants to come up with an optimum assignment that
Explain when Johnson’s rule can be used as a scheduling technique.

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