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production and operations management

Operations Management: Sustainability And Supply Chain Management 13th Edition Jay Heizer; Barry Render; Chuck Munson - Solutions

Sara James Bakery has a plant for processing Deluxe breakfast rolls and wants to better understand its capability. Last week the facility produced 148,000 rolls. The effective capacity is 175,000 rolls. The production line operates 7 days per week, with three 8-hour shifts per day. The line was
Define capacity
LO 7.5 Computer-integrated manufacturing (CIM) includes manufacturing systems that have:a) computer-aided design, direct numerical control machines, and material-handling equipment controlled by automation.b) transaction processing, a management information system, and decision support systems.c)
LO 7.4 Customer feedback in process design is lower as:a) the degree of customization is increased.b) the degree of labor is increased.c) the degree of customization is lowered.d) both a and b.e) both b and c.
LO 7.3 Tools for process analysis include all of the following except:a) flowchart.b) vision systems.c) service blueprinting.d) time-function mapping.e) value-stream mapping.
LO 7.2 A crossover chart for process selection focuses on:a) labor costs.b) material cost.c) both labor and material costs.d) fixed and variable costs.e) fixed costs.
LO 7.1 Low-volume, high-variety processes are also known as:a) continuous processes.b) process focused.c) repetitive processes.d) product focused.
4. Describe in detail a process that the hospital could analyze, besides the ones mentioned in this case The Arnold Palmer Hospital (APH) in Orlando, Florida, is one of the busiest and most respected hospitals for the medical treatment of children and women in the U.S. Since its opening on golfing
3. If all mothers were electronically (or manually) preregistered, how would the flowchart change? Redraw the chart to show your changes.The Arnold Palmer Hospital (APH) in Orlando, Florida, is one of the busiest and most respected hospitals for the medical treatment of children and women in the
2. If a mother is scheduled for a Caesarean-section birth (i.e., the baby is removed from the womb surgically), how would this flowchart change?The Arnold Palmer Hospital (APH) in Orlando, Florida, is one of the busiest and most respected hospitals for the medical treatment of children and women in
1. As Diane’s new assistant, you need to flowchart this process.Explain how the process might be improved once you have completed the chart.The Arnold Palmer Hospital (APH) in Orlando, Florida, is one of the busiest and most respected hospitals for the medical treatment of children and women in
5. What is the role of bar code scanners in the baggage process? Alaska Airlines is unique among the nine major U.S. carriers not only for its extensive flight coverage of remote towns throughout Alaska (it also covers the U.S., Hawaii, and Mexico from its primary hub in Seattle). It is also one of
4. What metrics (quantifiable measures) are needed to track baggage? Alaska Airlines is unique among the nine major U.S. carriers not only for its extensive flight coverage of remote towns throughout Alaska (it also covers the U.S., Hawaii, and Mexico from its primary hub in Seattle). It is also
3. How does the kiosk alter the check-in process? Alaska Airlines is unique among the nine major U.S. carriers not only for its extensive flight coverage of remote towns throughout Alaska (it also covers the U.S., Hawaii, and Mexico from its primary hub in Seattle). It is also one of the smallest
2. What other processes can an airline examine? Why is each important? Alaska Airlines is unique among the nine major U.S. carriers not only for its extensive flight coverage of remote towns throughout Alaska (it also covers the U.S., Hawaii, and Mexico from its primary hub in Seattle). It is also
1. Prepare a flowchart of the process a passenger’s bag follows from kiosk to destination carousel. (See Example 2 in Chapter 6 for a sample flowchart.) Include the exception process for the TSA opening of selected bags. Alaska Airlines is unique among the nine major U.S. carriers not only for
4. How does Wheeled Coach manage the tasks to be performed at each work station?Wheeled Coach, based in Winter Park, Florida, is the world’s largest manufacturer of ambulances. Working four 10-hour days each week, 350 employees make only custom-made ambulances;virtually every vehicle is unique.
3. Why is it more efficient for the work cells to prepare“ modules” and deliver them to the assembly line than it would be to produce the component (e.g., interior upholstery)on the line?Wheeled Coach, based in Winter Park, Florida, is the world’s largest manufacturer of ambulances. Working
2. What is an alternative process strategy to the assembly line that Wheeled Coach currently uses?Wheeled Coach, based in Winter Park, Florida, is the world’s largest manufacturer of ambulances. Working four 10-hour days each week, 350 employees make only custom-made ambulances;virtually every
1. Why do you think major auto manufacturers do not build ambulances?Wheeled Coach, based in Winter Park, Florida, is the world’s largest manufacturer of ambulances. Working four 10-hour days each week, 350 employees make only custom-made ambulances;virtually every vehicle is unique. Wheeled
3. Prepare the case for an optimistic sales manager that you should move ahead with the FMS now.Rochester Manufacturing Corporation (RMC) is considering moving some of its production from traditional numerically controlled machines to a flexible manufacturing system (FMS). Its computer numerical
2. Prepare a case by a conservative plant manager for maintaining the status quo until the returns are more obvious.Rochester Manufacturing Corporation (RMC) is considering moving some of its production from traditional numerically controlled machines to a flexible manufacturing system (FMS). Its
1. As a production manager for RMC, what do you recommend?Why?Rochester Manufacturing Corporation (RMC) is considering moving some of its production from traditional numerically controlled machines to a flexible manufacturing system (FMS). Its computer numerical control machines have been operating
• • 7.17 Using Figure 7.6 in the discussion of value-stream mapping as a starting point, analyze an opportunity for improvement in a process with which you are familiar and develop an improved process
• • 7.16 Prepare a service blueprint for one of the activities in Problem 7.13.
• • 7.15 Prepare a time-function map for one of the activities in Problem 7.13.
• 7.14 Prepare a process chart for one of the activities in Problem 7.13.
• 7.13 Prepare a flowchart for one of the following:a) the registration process at a schoolb) the process at the local car washc) a shoe shined) some other process with the approval of the instructor
• • 7.12 Stapleton Manufacturing intends to increase capacity through the addition of new equipment. Two vendors have presented proposals. The fixed cost for proposal A is $65,000, and for proposal B, $34,000. The variable cost for A is $10, and for B,$14. The revenue generated by each unit is
• • 7.11 Nagle Electric, Inc., of Lincoln, Nebraska, must replace a robotic MIG welder and is evaluating two alternatives. Machine A has a fixed cost for the first year of $75,000 and a variable cost of$16, with a capacity of 18,000 units per year. Machine B is slower, with a speed of one-half
• • 7.10 California Gardens, Inc., prewashes, shreds, and distributes a variety of salad mixes in 2-pound bags. Doug Voss, Operations VP, is considering a new Hi-Speed shredder to replace the old machine, referred to in the shop as “Clunker.” Hi-Speed will have a fixed cost of $85,000 per
• • 7.8 Matthew Bailey, as manager of Designs by Bailey, is upgrading his CAD software. The high-performance (HP)software rents for $3,000 per month per workstation. The standard-performance (SP) software rents for $2,000 per month per workstation. The productivity figures that he has available
• • 7.7 Tim Urban, owner/manager of Urban’s Motor Court in Key West, is considering outsourcing the daily room cleanup for his motel to Duffy’s Maid Service. Tim rents an average of 50 rooms for each of 365 nights (365 3 50 equals the total rooms rented for the year). Tim’s cost to clean
• • 7.5 Stan Fawcett’s company is considering producing a gear assembly that it now purchases from Salt Lake Supply, Inc.Salt Lake Supply charges $4 per unit, with a minimum order of 3,000 units. Stan estimates that it will cost $15,000 to set up the process and then $1.82 per unit for labor
• 7.4 Refer to Problem 7.1. If a contract for the second and third years is pending, what are the implications for process selection?
• 7.3 Using the data in Problem 7.1, determine the best process for each of the following volumes: (1) 75,000, (2) 275,000, and (3) 375,000.
• 7.2 Using the data in Problem 7.1, determine the most economical volume for each process.
Bagot Copy Shop has a volume of 125,000 black-and-white copies per month. Two salespeople have made presentations to Gordon Bagot for machines of equal quality and reliability.The Print Shop 5 has a cost of $2,000 per month and a variable cost of $.03. The other machine (a Speed Copy 100) will cost
19. Discuss the advantages and disadvantages of 3D printing.
18. What is additive manufacturing?
17. In what ways do CAD and FMS connect?
16. Explain what a flexible manufacturing system (FMS) is.
15. Name some of the advances being made in technology that enhance production and productivity.
14. Describe briefly what an automatic identification system(AIS) is and how service organizations could use AIS to increase productivity and at the same time increase the variety of services offered.
13. What are numerically controlled machines?
12. Identify the competitive advantage of each of the four firms identified in Discussion Question 11.
11. Identify service firms that compete on each of the four processes shown in Figure 7.1.
10. Identify the competitive advantage of each of the four firms identified in Discussion Question 9.
9. Identify manufacturing firms that compete on each of the four processes shown in Figure 7.1.
8. What do we mean by a process-control system, and what are the typical elements in such systems?
7. What is CIM?
6. Name the four quadrants of the service process matrix.Discuss how the matrix is used to classify services into categories.
5. What are the techniques for improving service productivity?
4. What is process redesign?
3. What is service blueprinting?
2. What type of process is used for making each of the following products?(a) beer(b) wedding invitations(c) automobiles(d) paper(e) Big Macs(f ) custom homes(g) motorcycles
1. What is process strategy?
LO 7.5 Identify recent advances in production technology
LO 7.4 Describe customer interaction in service processes
Describe four process strategies
Explain when to use each of the four qualitative models
Donna’s Garden Supply wants a 3-month moving-average forecast, including a forecast for next January, for shed sales.APPROACH c Storage shed sales are shown in the middle column of the following table. A 3-month moving average appears on the right MONTH January February ACTUAL SHED SALES 10
Donna’s Garden Supply (see Example 1) wants to forecast storage shed sales by weighting the past 3 months, with more weight given to recent data to make them more significant.APPROACH c Assign more weight to recent data, as follows: WEIGHTS APPLIED 3216 Forecast for this month = PERIOD Last month
In January, a car dealer predicted February demand for 142 Ford Mustangs. Actual February demand was 153 autos. Using a smoothing constant chosen by management of a = .20, the dealer wants to forecast March demand using the exponential smoothing model.APPROACH c The exponential smoothing model in
During the past 8 quarters, the Port of Baltimore has unloaded large quantities of grain from ships. The port’s operations manager wants to test the use of exponential smoothing to see how well the technique works in predicting tonnage unloaded. He guesses that the forecast of grain unloaded in
The operations manager for the Port of Baltimore now wants to compute MSE for a = .10.APPROACH c Using the same forecast data for a = .10 from Example 4, compute the MSE with Equation (4-6).
DETERMINING THE MEAN ABSOLUTE PERCENT ERROR (MAPE)The Port of Baltimore wants to now calculate the MAPE when a = .10.APPROACH c Equation (4-7) is applied to the forecast data computed in Example 4.
A large Portland manufacturer wants to forecast demand for a piece of pollution-control equipment. A review of past sales, as shown below, indicates that an increasing trend is present:Smoothing constants are assigned the values of a = .2 and b = .4. The firm assumes the initial forecast average
The demand for electric power at N.Y. Edison over the past 7 years is shown in the following table, in megawatts. The firm wants to forecast next year’s demand by fitting a straight-line trend to these dataAPPROACH Equations (4-12) and (4-13) can be used to create the trend projection model.
A Des Moines distributor of Lenova laptop computers wants to develop monthly indices for sales. Data from the past 3 years, by month, are available.APPROACH c Follow the five steps listed above.
San Diego Hospital wants to improve its forecasting by applying both trend and seasonal indices to 66 months of data it has collected. It will then forecast “patient days” over the coming year.APPROACH c A trend line is created; then monthly seasonal indices are computed. Finally, a
Management at Jagoda Wholesalers, in Calgary, Canada, has used time-series regression based on point-of-sale data to forecast sales for the next 4 quarters. Sales estimates are $100,000, $120,000,$140,000, and $160,000 for the respective quarters. Seasonal indices for the 4 quarters have been found
Nodel’s VP of operations now wants to know the error associated with the regression line computed in Example 12.APPROACH c Compute the standard error of the estimate, Sy,x, using Equation (4-15).
In Example 12, we looked at the relationship between Nodel Construction Company’s renovation sales and payroll in its hometown of West Bloomfield. The VP now wants to know the strength of the association between area payroll and sales.APPROACH c We compute the r value using Equation (4-16). We
Nodel Construction wants to see the impact of a second independent variable, interest rates, on its sales.APPROACH c The new multiple regression line for Nodel Construction, calculated by computer software, is:We also find that the new coefficient of correlation is .96, implying the inclusion of
Carlson’s Bakery wants to evaluate performance of its croissant forecast.APPROACH c Develop a tracking signal for the forecast, and see if it stays within acceptable limits, which we define as {4 MADs
10. What is the primary difference between a time-series model and an associative model?
12. What effect does the value of the smoothing constant have on the weight given to the recent values?
13. Explain the value of seasonal indices in forecasting. How are seasonal patterns different from cyclical patterns?
14. Which forecasting technique can place the most emphasis on recent values? How does it do this?
15. How can an exponential smoothing model be made more responsive?
16. What is the purpose of a tracking signal?
18. If the benefits of implementing CPFR are so evident, why are companies reticent to commit to this concept?
21. What happens to the ability to forecast for periods farther into the future?
Sales of Volkswagen’s popular Beetle have grown steadily at auto dealerships in Nevada during the past 5 years (see the table). The sales manager had predicted before the new model was introduced that first year sales would be 410 VWs. Using exponential smoothing with a weight of a 5 .30, develop
In Example 7, we applied trend-adjusted exponential smoothing to forecast demand for a piece of pollution-control equipment for months 2 and 3 (out of 9 months of data provided).Let us now continue this process for month 4. We want to confirm the forecast for month 4 shown in Table 4.2 (p. 155) and
Using the data in Solved Problem 4.7, find the coefficient of determination, r2, for the model
• • 4.5 The Carbondale Hospital is considering the purchase of a new ambulance. The decision will rest partly on the anticipated mileage to be driven next year. The miles driven during the past 5 years are as follows:a) Forecast the mileage for next year (6th year) using a 2-year moving
•• 4.6 The monthly sales for Yazici Batteries, Inc., were as follows:a) Plot the monthly sales data.b) Forecast January sales using each of the following:i) Naive method.ii) A 3-month moving average.iii) A 6-month weighted average using .1, .1, .1, .2, .2, and .3, with the heaviest weights
• • 4.7 The actual demand for the patients at Providence Emergency Medical Clinic for the first 6 weeks of this year follows:Clinic administrator Dara Schniederjans wants you to forecast patient demand at the clinic for week 7 by using this data. You decide to use a weighted-moving-average
• • • 4.9 Lenovo uses the ZX-81 chip in some of its laptop computers. The prices for the chip during the past 12 months were as follows:a) Use a 2-month moving average on all the data and plot the averages and the prices.b) Use a 3-month moving average and add the 3-month plot to the graph
• • • 4.13 As you can see in the following table, demand for heart transplant surgery at Washington General Hospital has increased steadily in the past few years:The director of medical services predicted 6 years ago that demand in year 1 would be 41 surgeries.a) Use exponential smoothing,
• 4.15 Refer to Solved Problem 4.1 on page 176.a) Use a 3-year moving average to forecast the sales of Volkswagen Beetles in Nevada through year 6.b) What is the MAD?c) What is the MSE?
• 4.16 Refer to Solved Problem 4.1 on page 176.a) Using the trend-projection (regression) method, develop a forecast for the sales of Volkswagen Beetles in Nevada through year 6.b) What is the MAD?c) What is the MSE?
• 4.17 Refer to Solved Problem 4.1 on page 176. Using smoothing constants of .6 and .9, develop forecasts for the sales of VW Beetles. What effect did the smoothing constant have on the forecast?Use MAD to determine which of the three smoothing constants (.3,.6, or .9) gives the most accurate
• • • • 4.18 Consider the following actual (At) and forecast (Ft)demand levels for a commercial multiline telephone at Office Max:The first forecast, F1, was derived by observing A1 and setting F1 equal to A1. Subsequent forecast averages were derived by exponential smoothing. Using the
• • • 4.19 Income at the architectural firm Spraggins and Yunes for the period February to July was as follows:Use trend-adjusted exponential smoothing to forecast the firm’s August income. Assume that the initial forecast average for February is $65,000 and the initial trend adjustment is
• • • 4.20 Resolve Problem 4.19 with a = .1 and b = .8. Using MSE, determine which smoothing constants provide a better forecast.
• 4.21 Refer to the trend-adjusted exponential smoothing illustration in Example 7 on pages 154–155. Using a = .2 and b = .4, we forecast sales for 9 months, showing the detailed calculations for months 2 and 3. In Solved Problem 4.2, we continued the process for month 4.In this problem, show
• 4.24 The following gives the number of accidents that occurred on Florida State Highway 101 during the past 4 months:Forecast the number of accidents that will occur in May, using least-squares regression to derive a trend equation. MONTH NUMBER OF ACCIDENTS January 30 February 40 March 60

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