c$)$ Some operation managers argue that it is possible to $$manage by numbers$,$ discuss the validity of this statement.

$3$ marks

Processes are essential in the operation of any businesses. In class, we have studied that involvement of customers, workforces and equipment in design and implementation of processes depends on the nature of the business.

$($a$)$ Provide examples of three different processes that rely on the customer for approximately $100\%$ of the process; about $50\%$; and about $0\%.$ For each of your chosen examples, discuss the unique challenges faced by operations and supply chain managers and process designer.

$3$ marks

$($b$)$ Using suitable examples, comment on the need for flexibility in both the workforce and capital equipment. Using suitable examples, discuss process types and production situations that require greater flexibility.

$4$ marks

$($c$)$ In class, we have seen that seven mistakes should be avoided when implementing the introduction of new processes or improved processes. We can argue that failure to manage processes is ultimately a failure to manage the business. Discuss any two of those mistakes.

$4$ marks

The Value stream map of a production system of a toy company is reported in Figure $3.$

Use the value stream map from Figure $3$ to conduct a complete analysis of the production process.

$($d$)$ Calculate all raw material and WIP lead times and determine overall process capacity assuming the company uses a batch size of $300$ units.

$2$ marks

$($e$)$ If his order is one of an average of $2,230$ orders during an average of $5$ day working week, how long before it would reach the customer.

$2$ marks

$*$Assume that the days indicated on the lead time ladder are based on a different batch size and not applicable to the $300$ unit batch currently in use.$*$

The company uses a Kanban system to make plastic wheels that are a component of several toys. The waiting time for a container of the wheels during production is $0\mathrm{.}25$ day; average processing time is $0\mathrm{.}15$ day per container. Each container holds $200$ wheels. The company uses $2,000$ wheels a day in the production of its products.

$($f$)$ Using a policy variable of $5\%,$ calculate the number of Kanban containers needed for the wheels.

$2$ marks