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Operations Management Managing Global Supply Chains 1st edition Ray R. Venkataraman, Jeffrey K. Pinto - Solutions
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 assembled daily at the rate of 200 per day. The company operates 300 days a year. The setup cost for a
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. The annual usage rate of this subcomponents is 30,000 units. The holding cost is US$3 per unit per
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 brewing and bottling a batch of beer is US$1,800 per setup. The holding cost of storing a bottle 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 overseas. The company has narrowed its choice to two suppliers€” one in India and the other in
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 order, and the holding cost is 40% of the unit price per year. The jewelry store is open 300 days a
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 supplies the paper to the printing company has just announced a quantity discount schedule given in
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 the security wand. Ordering costs are US$30 per order. If the company orders in quantities of 500 or
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 demand for this is normally distributed with a mean of 35 quarts per day and a daily standard deviation
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 manager of a college bookstore, purchases polo shirts from a local vendor with the college name and
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 US$20 per shirt. The bookstore incurs an ordering cost of US$80 per order, and the annual holding
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 for milk is normally distributed with a mean of 30 one-gallon bottles per day and a daily standard
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 deviation of 1 cake. The cost to prepare each graduation cake is $35 and can be sold for $63 (in
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 season is normally distributed with a mean of 40 pounds per day and a daily standard deviation of
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 review system. The manager must place replenishment orders for SKU-11 from the continuous review
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 days and places an order. The lead time is 5 days. The daily demand for the cold medicine is
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 60 units per month, and subcontracting is used if additional units are needed to meet the
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 cost of holding inventory. Discuss the impact of this change on the company’s sales and operations
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 use various “supply influencing options” for improving capacity and sales planning at the
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 examples of how you would employ different options (e.g., price, advertising and promotions, etc.) for
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 your S&OP? What would likely be some of the advantages and disadvantages of each approach?
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 their demand planning differ for the launch of an updated version of an existing product?
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 customer relations a critical issue to integrate into the S&OP process?In autumn 2013, Sony
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 development. Using the example of a local restaurant, how would S&OP help with their overall
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 compressor and backlog costs are $80 per compressor per month.Data from problem 9The manager of a
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. The company had the options of using subcontracting and backorders to meet demand. A maximum of
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 conditioners in November and December. Use a level strategy of maximum regular time production each month,
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 has the option of using overtime to meet any excess demand. Overtime cost is $300/unit. Hiring and
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 inventory levels for its annual planning horizon. Among the variety of items the company produces, one of
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 Planning DataHiring cost: $400 per worker hired.Firing cost: $200 per worker fired.Regular time cost:
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 for the 12 months of the planning horizon, given in the following table. Demand is seasonal and is
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: $80 per printer.Overtime cost: $120 per printer.Subcontracting cost: $140 per printer.Inventory
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; 4,600; 5,800; 7,600; 6,700; and 4,700, as well as the following cost data (in U.S. dollars):Regular
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 are manufactured in the same factory and require the same amount of equipment and labor resources.
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 first 6 months of 2016. Due to seasonal factors, the cost of regular time production is not constant.
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 production work standards are also given as follows:1. What is the capacity utilization for each resource
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 processes these systems could influence positively?2. How can enterprise systems be used to track safety
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 machines and operators at this work center are 95% and 90%, respectively. The following table presents the
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 and two wheel assemblies. Each wheel assembly requires two wheels, one spindle, one wheel mount
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 the loads. Discuss the implications of shifting the work to other periods. R (2) Q (3) T (2) S (4) P.
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 components are as follows: skateboard (1 week), fiberglass board (2 weeks), wheel assembly (2 weeks),
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 the loads. Discuss the implications of shifting the work to other periods. J (2) L (2) K (1) N (2) M
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 arrive at the beginning of week 3. The lead time for assembling Q from S and T is 1 week, and the lead
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 components. Assume no inventories are on hand and a lot-for-lot lot-sizing rule.Data from problem
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 assembly requires a bent blade and a bent blade grip. There is demand for 800 pair of scissors on
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 Projected On-Hand Inventory = 50 Planned Order Receipts Plannad Order RaleaRAR
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 On-Hand Inventory = 200 Planned Order Receipts Planned Order Releases. 60 60 90 130 65 75 100 40 85 55
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 this component, which of the following lot-sizing techniques will yield the lowest total cost?1.
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 this component, which of the following lot-sizing techniques will yield the lowest total cost?1.
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 on the projected on-hand inventory and the available-to-promise record for that week?3. Complete
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 units of Z.1. Construct a product structure tree for R.2. Assuming zero inventories on hand, how many
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 MRP can be used to promote sustainable operations and give three specific actions that you would
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 beginning inventory.Data from problem 19A finished product R is assembled from two units of S and two units
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 hand at the beginning of week 1.There is a scheduled receipt of 70 units of Q in week 2. Week 9
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) D (1) B (1) н 2) K (2) G (1) Н 2) F (1) Н(2 K (1) ш Week 10 11 12 13 14 15 Gross Requirements
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 structure tree and the following data: C (1) E (1) D (1) B (1) н 2) K (2) G (1) Н 2) F (1) Н(2 K (1)
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 work. Determine the cumulative deviation and the backlog for each period:
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 member of his county sheriff department€™s softball team. Every summer, the team plays
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 beginning backlog is 10 standard hours of work:
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 each period. The beginning backlog is 15 standard hours of work: 2 3 Week 4 in 70 Planned input Actual
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 various truck-route combinations are given in the following table. Develop an assignment that will
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 patient to the next based on the type of care, experience, and skill level of the nurses. Given the
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 asked the patients to evaluate the quality of care they received and their preferences for nurses on a
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 productive ratings of these machines vary depending on the component they are assigned for processing. 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 will minimize the total time it takes to conclude the cases. Data on past performance of each
Explain when Johnson’s rule can be used as a scheduling technique.
What is finite capacity scheduling (FCS), and what are its features?
Ross Barber is a senior at Pennsylvania State University pursuing a dual degree in marketing and supply chain management. Ross is overwhelmed because he has several assignments to be completed in the upcoming weeks. The estimated time required to complete these assignments and their due dates are
Explain how applying the principles of the theory of constraints can minimize the complexity of scheduling.
A local tool and die shop has the following jobs to be processed. Today is day 120:Using the critical ratio rule, determine the sequence in which the jobs should be processed. Date Job Arrived Processing Days Required 25 30 Job Due Date Job 100 130 140 90 40 170 95 120 50 170 110 20 180
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