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Modern Production Operations Management 8th Edition Buffa, Elwood S., Sarin, Rakesh K. - Solutions
What is the difference in decision variables for scheduling in a job shop and in a batch shop?
Why does the SPT rule perform so well for a job shop where jobs are arriving randomly over time? Is there any negative aspect in using the SPT rule?
If a machine is idle and a job is waiting to be processed on it, is it always preferable to schedule that job on the machine in a general job shop? Give a reason for your answer.
Is there any criterion for which we can use a simple procedure that will provide an optimal solution for the general job shop problem?
What is a flow shop? For a two machine flow shop, which procedure will mini¬mize maximum flow time?
State the assumptions made in the scheduling models for a single processor.
For single processor scheduling, which procedure will minimize the following?a. Mean flow timeb. Maximum tardinessc. Number of jobs lated. Weighted flow time
What is the distinction between a scheduling rule and a scheduling criterion?
Note: This situation requires the use of a cellular simulation program such as the FMS or EXCELL, which are distributed by the Scientific Press.A new plant for the fabrication and assembly of a camera for use in nuclear medicine is to be designed. Two options for assembling the cameras are being
Note: This situation requires the use of a cellular simulation program such as the FMS or EXCELL, which are distributed by the Scientific Press.A medical clinic is in the process of deciding how many modules to include in its automated multitest laboratory. A larger number of modules will increase
An evaluation of the attractiveness of an investment project requires an estima¬tion ofthe net contribution from the new product line. The net contribution, it, is determined as follows:
A bank is considering whether to install an automated teller service for its busy downtown branch. At present, the waiting time for the customers fluctuates greatly. The bank has collected data on the arrival pattern of its customers. The time to process a customer is also variable because of the
A manufacturer of electrical circuit boards faces the problem of whether to accept a mix of large order sizes. The manufacturer has specialized in small custom orders that require precision work and innovative designs. The present mix of order sizes in a typical month is given in Table 9-7. The
A company maintains a bank of machines that are exposed to severe service, causing bearing failure to be a common maintenance problem. There are three bearings in the machines that cause trouble. The general practice had been to replace the bearings when they failed. However, excessive downtime
The manager of a drive-in restaurant is attempting to determine how many carhops he needs during his peak load period. As a policy, he wishes to offer service such that average customer waiting time does not exceed two minutes.a. How many carhops does he need if the arrival and service
A sample of 100 arrivals of customers at a check-out station of a small store yields the following distribution:Time between Arrival, Minutes Frequency 0.5 2 1.0 6 1.5 10 2.0 25 2.5 20 3.0 14 3.5 10 4.0 7 4.5 4 5.0 2 100
What are the reasons for using simulation for the analysis and evaluation of policies?
What is cellular simulation? What are its advantages and its limitations?
Why are the results of a simulation only estimates and not actual performance characteristics?
What is an experimental design?
What is the distinction between verification and validation as these terms are defined in the chapter?
What types of data are collected in a simulation?
Why don’t we simulate the system directly?
What is the distinction between a model and a system?
An organization has forecasted maximum production requirements for the coming year as follows:January 400 July 580 February 510 August 600 March 400 September 300 April 405 October 280 May 460 November 440 June 675 December 500
Approximately 300 members of the staff are classified as direct technical employees, and the bal¬ance are indirect administrative support for the operations of the laboratory.
Taubert (1968) developed an aggregate planning cost model for the Search Laboratory, a fictional name for a real company. The laboratory is housed in a 100,000 square foot facility and employs a staff of
The hospital admissions system is used as an overall mechanism for planning and scheduling the use of hospital facilities. The basic unit of capacity is the hospital bed, and bed occupancy level is the variable under management con¬trol. Bed occupancy level, in turn, opens up revenue flow from the
Schwarz and Johnson (1978) have reevaluated the empirical performance of the paint company application of the LDR. The results of the paint company appli¬cations of the LDR compared with actual company performance are sum¬marized in Table 8-9- The inventory-related costs (inventory plus
A manufacturer of containers employed a Linear Decision Rule model to derive two decision rules for setting quarterly production rates and work force levels.These rules area. Determine the production rate and work force level for quarter 1.b. Suppose the actual shipment in quarter 1 was 500 units.
Given the data in Table 8-5:a. What value of inventory carrying cost would make Plans 1 and 2 equally desirable?b. What hiring—layoff cost makes Plans 1 and 2 equally desirable?c. What subcontracting cost makes Plans 2 and 3 equal?
Using the data of Table 8-8, compare the total incremental costs involved in a level production plan, in a plan that follows maximum requirements quite closely, and in some intermediate plan. Normal plant capacity is 400 units per working day. An additional 20 percent capacity can be obtained
Table 8-8 gives data that show the projected requirements for the production of a medium-priced camera, together with buffer stock requirements and available production days in each month. Develop a chart of cumulative requirements and cumulative maximum requirements for the year, plotting
What values are gained by expanding aggregate planning decision systems to produce joint decisions among operations, marketing, and finance? Are there any disadvantages?
Account for the differences in performance of the several aggregate planning decision systems in the study summarized in Table 8-10.
Cost comparisons between the results of actual managerial decisions and those produced by solving decision rule models are typically made by running both sets of decisions through the cost model and then comparing the results. Does this methodology seem valid? If not, what other approach might be
What is the meaning of the term capacity in aggregate planning models? How does a decision to hire, layoff, or subcontract affect capacity? How does physical or limiting capacity affect these decisions?
Criticize the usefulness and validity of the strict aggregate planning concept;that is, making decisions solely in the aggregate terms of work force size and production rate.
Referring to Figure 8-6:a. Rationalize why the cost of overtime should increase at an increasing rate as production rates increase.b. If the inventory varies from the optimal level (minimum cost level), why would the incremental costs increase at an increasing rate as indicated in Figure 8-6?
As a decision system, contrast the SDR with the LDR. What are the advantages and disadvantages of each?
Compare the Hanssmann-Hess linear programming model of aggregate plan¬ning with the multistage decision process discussed and summarized by Figure 8-3. What compromises with reality, if any, have been made in the linear pro¬gramming model?
Compare the Linear Decision Rule with the multistage aggregate planning deci¬sion system discussed and summarized by Figure 8-3. What compromises with reality, if any, have been made by the LDR model?
Appraise graphic methods of aggregate planning.
In what ways does a multistage aggregate planning system take account of realities that would in fact affect decisions for production rates and work force size?
Under what conditions would a single-stage aggregate planning decision system be appropriate?
Place aggregate planning in context with the term planning horizon. What is the appropriate planning horizon for aggregate planning?3- Discuss the relevant cost components involved in aggregate planning decisions.
What is the meaning of the term aggregate plan? What are the objectives of aggregate plans? What are the inputs and the nature of the outputs?
The Smash Sports Company manufactures a complete line of tennis rackets in three plants. All three types ofrackets manufactured (heavy, medium, light) can be produced in any of the three plants, which have total capacities of 550, 650, and 300 units per day, respectively. The contribution of each
A flexible manufacturing plant can produce several types of gearboxes and other parts, such as axles, with the same equipment and facilities. Demand considerations require that two types ofgearboxes need to be produced for the next two quarters. The demand for the two gearboxes for the upcoming
A newly founded pharmaceutical company mixes a long life elixir called Eter¬nity from four ingredients. These four ingredients in combination form three compounds that are critical for the effectiveness of Eternity. There must be at least 5 grams of compound A, 100 grams of compound B, and 30
A precision component. Perfect, can be manufactured using any one of three machines available. The production rate, reject rate, and the operating cost for each machine is different. A machine cannot be operated for more than four hours because it loses the tolerance required to manufacture
A company produces three products Brite, Glo, and Chumpy. The labor avail¬ability in the three departments involved in manufacturing the three products is limited. The following information provides the relevant data for planning the level of production for each product for the upcoming period:
Consider the following linear optimization model:Maximize Z = 3xi + 6x2 + 2x3 Subject to 3xi + 4x2 + x3 ^ 2 (resource A)xi + 3x2 + 2x3 < 1 (resource B)xj, x2, x3 > 0 Solve this problem for the optimal solution using the simplex method.
Consider the following linear optimization model:Maximize Z = 3xj + x2 + 4x3
A manufacturer has two products, both of which are made in two steps by machines A and B. The process times for the two products on the two machines are as follows:
Once upon a time, Lucretia Borgia invited 50 enemies to dinner. The piece de resistance was to be poison. In those crude days only two poisons were on the market, poison X and poison Y. Before preparing the menu, however, the remarkably talented young lady considered some of the restrictions on her
What is a feasible solution? A basic solution? Identify both kinds ofsolutions in Figure 7-1. Can a feasible solution be basic? Must a feasible solution be basic?
What is the physical meaning of slack variables for the following types of con¬straints?a. Constraint on the capacity of a machineb. Constraint on the size of the marketc. Constraint on the total expenditure on advertising in various media
What is the function of slack variables in the simplex method of solution?
What is the practical value of knowing whether the bounds on one or more prices are “tight”?
What is the interpretation of the upper and lower bounds on the “prices” given in Figure 7-4? Of what value is this information to the manager?
What is the interpretation of the upper and lower bounds on the shadow prices indicated in Figure 7-4? Of what value is this information to a manager?
Explain the concept of dual or shadow prices. How can a manager use a knowl¬edge of dual prices in decision making?
Suppose that in the chemical production problems, the availability of time on machine A is drastically reduced to only 40 hours because of a breakdown.How does this change the solution space shown in Figure 7-2? Is it likely to change the optimum number of units of each chemical to produce?
Outline the model-building process used for developing linear optimization models.
Which of the following mathematical expressions are linear? Why?a. x + y — 1b. x2 + y2 = 10c. llx + 2x = 10d. x + xy + y = 1e. x\ + x2 + x3 + X4 = 1
Cookware, Inc. (Cl) produces a line of pots and pans in various types and sizes.For example, saucepans are produced in three sizes: 1, 2, and 3 quarts. The saucepans and covers are made of stainless steel with plastic handles. The stainless steel parts are fabricated in plant, and all other parts
The Wheel Pump Company was originally the Pump Company, but many years ago the owner had an opportunity to bid on a contract to produce steel wheels for one ofthe smaller automobile companies. The Pump Company was success¬ful in its venture into this new field, and it became a supplier of wheels
A company has three components that go into its final assembly process as indicated by the diagram below.B
A toy company manufactures a boxed game for children. There are four depart¬ments in the company. The cardboard production department makes cardboard for the game boards. The finished cardboard is shipped to the board fabrication department, which prints the game boards. Dice manufacturing makes
The requirements for the motor drive unit described in problem 10 have been stabilized considerably by compensatory promotion of the dictating machine and by designing a line of portable tape recorders that have a general use and a counterseasonal cycle. The tape recorder uses the same motor drive
The requirements for a motor drive unit to be assembled into a dictating ma¬chine follow the assembly schedule for the completed unit. The assembly schedule requires motor drive units with the timing shown in Table 6-9- Other data for the motor drive unit are as follows: Average requirements are R
Still using the dinette table as an example, suppose that they are produced in lots of 400 in weeks 3, 6, 9, and so on. Legs are produced in lots of 3200 every six weeks. How should the leg production be phased with respect to the table assemblies? Why?
Using the dinette table shown in Figure 6-1 as an example for requirements planning, why not produce enough components every two weeks to key in with a schedule of 100 completed tables per two weeks? What are the disadvantages of doing this?
Figure 6-13 is a cross-classification chart showing the subassemblies, parts, and raw materials that are used in each of nine primary products. For example, reading horizontally, product 1 requires subassembly 11 and part 28; subassem¬bly 11 requires parts 20 and 28; and parts 20 and 28 require
Under what situations are EOQ/ROP methods suitable for the inventory control of a component or a subassembly for which demand can be derived from the requirement for end items?
What is the rationale for using (a) safety lead time and (b) safety stock in a requirements planning system?
Describe the following methods for lot size decisions in requirements planning.a. Lot-for-lotb. EOQc. POQd. Part-period cost balancing
If demand is lumpy, why may EOQ/ROP methods not be appropriate for scheduling production or controlling inventories?
What is the information contained ina. Product structures?b. Bills of materials?c. Master schedules?
What are “dependent” and “independent” demand items? What kind of fore¬casting methods are appropriate for each as a basis for production and inventory control?
Mr. Dale Patterson, Chairman of the Topanga Gas and Electric (TG&E), is reexamining the billing policy of the company. The present policy is to bill all customers once a month. Mr. Patterson feels that a better billing policy would result in faster collection so that more money would be available
The Mixing and Bagging Company produces a line of commercial animal feeds in 10 mixes. The production process itself is rather simple, as the company name implies. A variety of basic grain and filler ingredients is mixed in batches.The mixture is then fed to an intermediate storage hopper, from
Cindy Williams operates a consulting business that caters to small business enterprises. One of her clients, a large independent supermarket called Ron¬nies, has asked Cindy to investigate its order policy for bread, particularly its order policy for Pepperidge Farm Cracked Wheat Bread. Ronnies
The Delicate Bakery orders ingredient A for bread from an out of town sup¬plier. The lead time as well as the requirements for ingredient A during the lead time are uncertain. The Delicate Bakery has collected the following information using past history:
Seers Company orders vacuum cleaners at $50 each. The annual demand for the past two years has been relatively constant at 500 units/year. The other perti¬nent information is provided in the following table.
As a manager of the Constrained Warehouse, you are faced with the order quantity decision for two products, A and B. The following table provides the relevant information on these two products:
A nursery is in the process of deciding how many Christmas trees should be stocked. The trees are sold for $20 and cost $5. The trees can be purchased only once and unsold trees are a complete loss. The probability distribution for demand is as follows:
Consider the following data for a product:Demand = 1000 units/year Order cost = $4/order Holding cost = 10% of unit cost/unit-year Unit cost = $50/unit
Consider a product with an average annual demand of approximately 9000 units/year. Order costs are $250 per order and holding costs are $2/unit/year.Lead time demand is distributed as follows:
A firm with a uniform demand for its product currently places an order for 100 units once a month, and there is no backlogging. The company has some difficulty in determining cH. However, an analyst may be able to infer an appar¬ent cH based on the firm’s inventory policy. We have the following
Consider the inventory graph in Figure 5-10.a. What ordering policy is being followed?b. What is the lead time between when an order is placed and when it is received?c. If average demand is 150 units/week, how many units of safety stock are being held by the firm?d. If the lead time calculated in
A manufacturer is attempting to set the production lot size for a particular item that is manufactured only periodically. The incremental cost of setting up ma¬chines for production is $40. The inventory holding cost is $1 per unit per year.The annual requirements for the item are 52,000 and the
Weekly demand for a product, exclusive of seasonal and trend variations, is represented by the empirical distribution shown in Figure 5-9. What safety or buffer stock would be required for the item to ensure that one would not run out of stock more than 15 percent of the time? More than 5 percent
A price discount schedule for an item that we purchase is offered as follows: $1 per unit in quantities below 800, $0.98 per unit in quantities of 800 to 1599, and $0.97 per unit in quantities of 1600 or more. Other data are R = 1600 units per year; cP = $5 per order; and inventory holding costs
Suppose that the estimate of cH in problem 20 was in error and should actually be $15 per unit per year. What is the value of EOQ ? What is the percentage change in EOQ for the 50 percent increase in cH?
Suppose that the estimate of cP in problem 20 was in error and should be only$20 per order. What is the value ofEOQ ? What is the percentage change in EOQ for the 20 percent decrease in cP?
We have the following data for an item that we purchase regularly: annual requirement, R — 10,000 units; order preparation cost, cP = $25 per order;inventory holding cost, cH = $10 per unit per year.a. Compute the economic order quantity, EOQ.b. Compute the number of orders that must be placed
In arid and semiarid climates, permanently installed lawn sprinkler systems are used. Automating the control of such systems has been a common procedure for parks and golf courses. More recently, systems have been designed that are
What are the criteria a general manager will use in evaluating the over-all performance of inventory system?
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