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operations management
Operations Management Managing Global Supply Chains 1st edition Ray R. Venkataraman, Jeffrey K. Pinto - Solutions
How does the master scheduling process differ for the various production environments?
An air compressor assembly department has four employees who each work 40 hours a week. The processing time for assembling an air compressor is 3 hours. Given the information provided in the following table:1. Determine the available capacity and develop a load profile for the air compressor
Discuss briefly the common modules included in an ERP system.
Describe the time fencing concept used to achieve stability in the master schedule.
The manufacturing sequence for two products that a company produces involves fabrication, assembly, and painting operations. Each operation requires 2 days to completely process a production lot before it can be moved to the next department. The processing times (in hours per unit) for both
What are some key features of an ERP system?
Draw a product structure tree for a rolling cart using the low-level coding scheme. Item Components Rolling Cart Top Top, leg assembly, frame Sheet steel Sheet steel Leg Assembly Legs (4), casters (4) Legs Casters Wheel, ball bearing, axle, caster frame • Wheel • Ball Bearing • Axle •
Given the product structure tree below for end-product P,1. Determine the number of units of S, T, U, and V needed if 10 units of end product P are to be assembled.2. What is the low-level code for T? Q (3) R (2) S (4) T (2) U (3) V (4) P.
Discuss briefly the different functions of the master schedule.
Nerula Bakeries, a fictional bakery, has the following demand requirements for its specialty cakes in the month of June.The labor skill requirements for making specialty cakes are high, and the process involves two critical operations€”baking and decorating. The time required for each
Describe the differences among MRP, MRP II, and ERP systems.
Complete the master production schedule based on the following information:Additional Information:On-hand inventory: 600Schedule production whenever projected on-hand inventory drops below 30MPS lot size: 300Production lead time or lead time for MPS releases: 1 week Week 1 Forecast 320 100 110 40
Define available-to-promise (ATP).
Firebird Bicycle Company, a fictional company, produces three brands of bicycles: Racing, Mountain, and Cruiser bicycles. The master schedule in the following table shows the demand requirements for the month of March for the three brands of bicycles. The standard labor hours per unit required for
Describe briefly how the capacity planning process works.
What are the outputs from the master scheduling process?
Orion Manufacturing Inc., a fictional company, has scheduled production of the following three of its products for the 4 weeks of January as shown in the following table:The two key work centers for producing these three products are fabrication and assembly. The fabrication work station has
What are the key inputs and outputs of the capacity requirements planning system?
1. How would materials management allow Amy and her partner to better organize and coordinate deliveries and maintain critical stocks of food for service?2. Construct a hypothetical product structure tree and bill of materials file for a single restaurant dish (e.g., a turkey dinner with mashed
Visual Optics Inc. (a fictitious company) produces a premium line of women€™s sunglasses. The company has prepared a 10-week forecast for these sunglasses, given in the following table. In addition, the company has actual customer orders of 120, 90, 60, and 30 units for the first four
Refer to Example 17.1. Suppose process reengineering initiatives have enabled the company to reduce the number of worker hours required to produce a pair of skis to 3 hours. Develop a least-cost sales and operations plan using a level strategy of regular time production of 3,000 units per month.
What are some of the unique challenges and requirements of global sales and operations planning?
The manager of a company that produces compressors for refrigerators has developed the following forecast for compressor demand:
What are the benefits of coordinating a company’s S&OP process with its supply chain partners? What are the challenges?
Refer to the data in problem 6. If backorders are allowed, determine the total cost of a plan if overtime is limited to 40 units per month and subcontracting is limited to 20 units per month. Backordering costs are $30 per unit.Data from problem 6Given the following forecast and cost information,
Discuss some of the S&OP strategies that service companies can use.
Holding inventories is not an option for many service businesses. How does this impact sales and operations planning for these businesses?
Daily demand for automotive batteries in an automobile repair shop is normally distributed with a mean of 10 batteries and a standard deviation of 1 battery. The cost of a dissatisfied customer, expedited ordering, and equipment downtime as a result of running out-of-stock is US$400 per battery.
A French restaurant’s daily demand for pinot noir wine is normally distributed with a mean of 20 bottles and a standard deviation of 3 bottles. The restaurant manager checks its supply every 15 days. The lead time for wine is 5 days and is reasonably constant. A recent periodic review at the
An automobile service station uses 900 cases of motor oil annually. The station operates 300 days a year. The order replenishment lead time for motor oil is 4 days with a standard deviation of 4 cases per day. The station has specified an annual service level of 97%:1. What is the level of safety
A large law firm uses a constant 50 reams of copier paper per day. The lead time for the paper is approximately normal, averages 9 days, and has a standard deviation of 3 days. What reorder point provides a service level of 90%?
The desired service level for a sporting good store’s inventory of string bathing suits is 85%. The average demand during the replenishment period is 180 suits with a standard deviation of 30 suits:1. What is the reorder point?2. If the store wants to increase its service level to 91% for the
The demand for frozen yogurt at the fictional Garland Ice Cream and Dairy store can be approximated by a normal distribution with a mean of 50 gallons per day and a standard deviation of 6 gallons per day. The lead time from the supplier is a constant 4 days. If the store replenishes its supply of
The daily demand for integrated circuit boards by mythical Reliance Computers, which assembles computers, is 80 units. The daily demand is normally distributed and has a standard deviation of 6 units. The lead time from the supplier is a constant 9 days. If Reliance Computers is willing to accept a
Cheryl Hunter is responsible for maintaining adequate hospital supplies at fictional St. Thomas Hospital. The demand and lead times for syringes are assumed to be constant. During the past year, the daily demand for syringes was 80 units and the lead time from the supplier was 4 days. What is the
Emily Larson is in charge of purchasing surgical supplies for a county hospital. Emily is evaluating two suppliers (suppliers A and B) to purchase forceps for the hospital€™s surgical use. The quantity€“price schedules of both suppliers are given in the following table. The
A U.S. company that orders brass couplings from a supplier in China noted that the cost of the couplings increases significantly at each reorder cycle. The company uses the EOQ model to determine its order quantity. What alternative approach would you advise the company to consider to determine the
In the EOQ model, how do we determine the optimum order quantity?
1. What does the public’s reaction to Wal-Mart’s Project Impact suggest about expectations for discount stores?2. What are the inventory control implications for making drastic changes like Wal-Mart undertook?3. React to the following statement: “Crowded and cluttered stores send a signal to
Why must companies carry inventory?
A manager of a home improvement store has been using the linear trend multiplicative model to predict the demand for his lawn mowers. The quarterly seasonal indices are S1= 0.85, S2= 0.90, S3= 1.10, and S4= 1.00. The linear trend equation that the manager developed is: Yt= 15 + 6t. The following
Orion Electronics, a fictitious chain of electronics stores, operates a website to encourage potential customer to buy its products online. Because the website is expensive to maintain, the VP of Marketing is unsure if the online sales of the company€™s products is directly related to the
Refer to problem 26.1. Using Excel, develop a linear regression model for predicting maintenance cost as a function of age of the trucks. Forecast maintenance cost if the age of the truck is 7 years.2. Using Excel, develop a linear regression model for predicting maintenance cost as a function of
The chancellor of a small regional college is concerned about the declining freshmen enrollment at his college. A number of factors have contributed to the decline, but the chancellor believes it is directly related to annual tuition increases. He has collected the following data for the past 8
A home improvement store has the following actual quarterly sales for its lawn mowers for the past 2 years. Quarterly seasonal indices for quarters 1, 2, 3, and 4 are S1= 1.0, S2= 1.2, S3= 0.96, and S4= 0.85:Predict the sales for the second quarter of 2016. Quarter 1 Year Quarter 2 Quarter 3
Use the seasonal indices developed for problem 12 and the centered moving average method to:1. Deseasonalize the ice cream sales data.2. Develop a linear trend equation using the deseasonalized data.3. Develop a trend forecast for the first quarter of year 5.4. Develop a seasonalized forecast for
A BMW car dealer in Sicilia, Italy, has the following monthly new car sales data for January through December 2014. The dealer believes that new car sales follow a monthly seasonal pattern and computed the seasonal indices for each of the 12 months, which are also given in the following table:1.
The fictitious Haskin & Collins Ice Cream Store needs an accurate estimate of demand. The owner of the store believes that the demand for ice cream has a quarterly seasonal pattern. To analyze the pattern, the owner gathered the following quarterly ice cream sales data in gallons for the last 4
The director of an emergency room, Simran Kaur, has observed that patient traffic at the emergency room follows a seasonal pattern with a higher patient traffic during weekends than weekdays. She has gathered the following data on daily patient admissions during the last 4 weeks:Given this
In the busy port of Chennai, India, the number of containers loaded onto ships during a 15-week period is as follows:1. Develop a linear trend equation to forecast container loadings.2. Using the equation, forecast the number of containers that will be loaded in weeks 15 and 16.3. The current
Martin Guenther, the manager of Lloyd€™s Savings Bank (fictitious) in Hamburg, Germany, wants to forecast the number of new checking accounts that will be opened in the next 2 months. He has data for the past 12 months on new checking accounts opened, which is shown in the following
St. Xavier College, a fictional educational institution, wants to forecast the enrollment in its business department for the next academic year. The combined enrollment for full-time and parttime students expressed in full-time equivalents (FTE) for the past 10 semesters are:1. Plot the data. Does
The marketing manager of a shoe store has developed the following linear trend equation to predict monthly sales for the store’s popular brand of ladies shoes.Ft = 220 + 27 x t, whereFt is monthly sales (in 00s), and t is in months.1. By how much do monthly sales increase or decrease?2. Using the
Bear Creek Ski Resort in Vail, Colorado, had the following guest occupancy for the 8 weeks of November and December of 2014. Forecast the number of guests for January 2015 using trendadjusted simple exponential smoothing with α = 0.5 and β = 0.3. Assume that the forecast
Calangute Beach Resort, a fictional sea-side luxury hotel in Goa, India, had the following occupancy rates for 12 months of 2014:1. Forecast the occupancy rate for January 2015 using simple exponential smoothing with α = 0.4. Assume that the forecast for month 2 (F2) is 65%.2.
Trinity General Hospital had the following number of patient admissions during the past 8 weeks:1. Develop a 3-week weighted average forecast for week 4 through 9 with weights of W1 = 0.5, W2 = 0.3, and W3 = 0.2.2. Forecast patient admissions for week 9 using simple exponential smoothing with
James Triton, owner of the fictitious Triton Auto Parts, wants to use simple exponential smoothing to forecast the demand for automobile batteries for his store. He has collected the following data from his store for the past 6 months:1. Forecast the sales for July using simple exponential
Vidhya Balan is planning to liquidate her investments in mutual funds and invest in real estate. Before making the change in her investment strategy, Vidhya wants to forecast the price of mutual funds for the next 2 months. She has collected the following data on the average fund prices for the
1. Given the role that “Mother Nature” plays in forecasting Super Bowl ticket prices, how might you adjust your expectations for ticket costs from year to year, given the location of the event?2. Consider this case from an ethics perspective. Do you see anything “unethical” with large-block
The demand for automobiles at Crescent Auto Dealers for the last 8 weeks is as follows:1. Develop a 3-week moving average forecast for weeks 4 through 9.2. Develop a 3-week weighted average forecast for weeks 4 through 9 with weights of W1 = 0.6, W2 = 0.3, and W3 = 0.1. (The most recent week is
What are the four steps to managing demand effectively?How does global demand volatility affect an organization’s upstream and downstream suppliers? Use a grocery store as an example.
Referring to problem 4, did the firm engage in a service recovery act? If so, what did they do? How did its service recovery change your opinion of the firm’s overall performance, and what is the implication of service recovery for improving your perceptions of the business?Data from problem
How has Amazon Prime demonstrated the truth of the statement that demand management and customer service are closely linked? (Remember that order fulfillment is a key determinant of how satisfied customers are and whether you can retain them for future sales.)
“If we don’t take care of our customers, someone else will.” Explain the nature of this statement. Why does customer service management matter in the modern, global environment?
1. Imagine you are a member of the demand planning staff for a hospital in a rural part of Florida. How would you begin developing a plan for the future demand for health care at your hospital? What demographic and other factors would you consider critical to developing such a plan?2. Research some
Suppose you were a senior manager at an oil refinery in Texas and you were considering partnering with a major railroad and investing money to help them upgrade their rail lines used for shipping oil from Canada south to your refinery. Prior to making this investment decision, what other long-term
Discuss the importance of demand management from the perspectives of both a manufacturing firm and a service organization. What are the five key reasons why demand management is so critical for an organization’s success?
Why is demand planning difficult in high-tech companies? What are the consequences of the lack of an effective demand-planning process in such companies?
1. In your opinion, what is the future of fast food around the world? Are consumer taste changes and concerns about healthy eating likely to diminish the demand for fast food?2. How would you evaluate McDonald’s reinvention strategy? Do the changes represent a fundamental shift in the company’s
Imagine that you were considering the potential of opening an upscale restaurant in a remote area of the Oregon coast. What demand management (economic and technological) factors should you consider as part of the decision of whether such a restaurant would be feasible?
How are ethical and sustainability considerations addressed through logistics management?
What are some critical functions played by logistics in the service sector?
What are the various critical factors to consider in global logistics?
What are the functions of a warehouse?
Explain the differences among supply warehouses, cross-docking warehouses, and distribution centers.
What four strategies can improve packaging efficiency?
What are the critical functions served by packaging?
Discuss the critical trade-offs related to transportation management: (a) Transportation vs. inventory costs and (b) Transportation costs vs. customer responsiveness. Why do these trade-offs typically occur?
How does cross-docking work?
Describe a milk-run delivery system. When would a firm use such a system?
Identify the three main goals of sustainable logistics. Using a product such as bottled water, explain how an organization can be creative in packaging and delivering bottled water to its markets worldwide.
What are backhauls, and why are they often an unnecessary drain on a company’s transportation resources?
Use the Internet to search for examples of sustainable product packaging. What are some key features that many of these packages have in common?
“If a company’s target market consists of price-conscious consumers, then the firm is more likely to use slower modes of transportation.” Discuss why this is so.
Consider the challenges of global logistics management for selling supply chain textbooks to universities in South Africa. Identify how packaging, labeling, and inventory issues can all play critical roles in successfully managing the logistics, shipping, and distribution of the textbooks.
Identify the key modes of transportation, and discuss the benefits and drawbacks of each mode.
Assume you are the logistics manager for fictional StayFresh Grocery Stores, in Cleveland, Ohio. You are responsible for 7 stores in the metropolitan area. How might you employ crossdocking at your biggest regional warehouse to improve the distribution of goods to each of the stores? Identify how
What is transportation management, and why is it a critical part of an integrated logistics management system?
Suppose you were designing packaging for organically grown tea. What are some of the features you would emphasize? Why? How would the various functions of packaging affect how you would package your product?
What are the key benefits of an integrated logistics management system?
A company involved in global distribution of its products faces many challenges. Discuss some strategies that you would implement for distribution of a company’s products in Japan.1. Suppose, in the first instance, that the products were high-technology electronics that were very fragile and
1. Why are the logistics decisions of a retailer like Wal-Mart so important for other firms to be aware of and emulate?2. Why has Wal-Mart taken a more environmentally conscious approach to logistics?3. How does sustainable logistics equal ethical logistics?Wal-Mart is the world’s largest
How do direct and indirect material purchases differ?
The following product structure tree is for a step stool:A company that assembles step stools wants to ship 110 units at the beginning of week 4, 140 units at the beginning of week 5, and 200 units at the beginning of week 7. A scheduled receipt of 100 top boards will arrive at the beginning of
What are the major assumptions of the EOQ model, and how do they restrict the model’s applicability to real-life inventory issues?
Refer to problem 1. Assuming that holding cost and order costing remain the same, if annual demand for wiper blades doubles to 32000, does the EOQ also double? Explain your answer with relevant calculations.Data Problem 1Auto Mart is a mythical seller of a variety of automobile parts and
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 holding cost is 40% of the cost of the oven per unit per year.1. What is the optimal order
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 tires for the distribution center for each order placed is $1,200 per order. The annual holding cost
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