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supply chain management 2nd
Operations And Supply Chain Management 14th Edition Chase, Richard B.;Jacobs, F. Robert - Solutions
3. List at least four of the seven prominent types of waste that should be eliminated from the supply chain.
2. What term refers to the optimization of value-adding activities and elimination of non–value-adding activities that are part of a value stream?
1. What phrase refers to the idea that all steps in supply chain processes that deliver goods and services to the customer should create value?
17. Discuss ways to use lean to improve one of the following: a pizza restaurant, a hospital, or an auto dealership.
16. Will lean work in service environments? Why or why not?
15. What is the purpose of value stream mapping? How can it be achieved?
14. What is value stream mapping?
13. How would you show a pull system in VSM symbols between the blanking and CNC stages of the bolt manufacturing Solved Problem 2?
12. Stopping waste is a vital part of lean. Using value stream mapping, identify some sources of waste in your home or dorm and discuss how they may be eliminated.
11. Explain the relationship between quality and productivity under the lean philosophy.
10. Why is lean hard to implement in practice?
9. In which ways, if any, are the following systems analogous to kanban: returning empty bottles to the supermarket and picking up i lled ones; running a hot dog stand at lunchtime;withdrawing money from a checking account; raking leaves into bags?
8. Explain how cards are used in a kanban system.
7. What are the roles of suppliers and customers in a lean system?
6. What are the implications for cost accounting of lean production?
5. What objections might a marketing manager have to uniform plant loading?
4. Why must lean have a stable schedule?
3. Can a supply chain become too lean? Explain your answer—using examples if possible.
2. One way to help achieve lean production systems is to employ l exible automated manufacturing equipment and automated material handling systems. A natural result of such a move is that fewer people are required in the process, an issue addressed regularly in negotiations with labor unions. Do
1. Is it possible to achieve zero inventories? Why or why not?
8 If the process could be improved so that the standard deviation were only about .10 millimeter, what would be the best that could be expected with the processes relative to fraction defective.
7 Plot the data on your control charts. Does the current process appear to be in control?
6 Set up __ X - and range control charts for the current process. Assume the operators will take samples of 10 washers at a time.
5 What percentage of output would be expected to be out of tolerance if the process were centered?
4 What would be the Cpk for the process if it were centered between the specification limits(assume the process standard deviation is the same)?
3 What is the Cpk for the process?
2 If there are an upper and lower specii cation, where the upper thickness limit is 2.4 and the lower thickness limit is 1.4, what fraction of the output is expected to be out of tolerance?
1 If the specii cation is such that no washer should be greater than 2.4 millimeters, assuming that the thicknesses are distributed normally, what fraction of the output is expected to be greater than this thickness?
3 Twelve additional samples of curetime data from the molding process were collected from an actual production run.The data from these new samples are shown below. Update your control charts and compare the results with the previous data. The __ X - and R-charts are drawn with the new data using
2 Analyze the charts and comment on whether the process appears to be in control and stable.
1 Prepare __ X - and R-charts using these data with the method described in the chapter.
15. Large-scale integrated (LSI) circuit chips are made in one department of an electronics i rm. These chips are incorporated into analog devices that are then encased in epoxy. The yield is not particularly good for LSI manufacture, so the AQL specii ed by that department is 0.15 while the LTPD
14. In the past, Alpha Corporation has not performed incoming quality control inspections but has taken the word of its vendors. However, Alpha has been having some unsatisfactory experience recently with the quality of purchased items and wants to set up sampling plans for the receiving department
13. The following table contains the measurements of the key length dimension from a fuel injector. These samples of size i ve were taken at one-hour intervals.Construct a three-sigma __ X -chart and R-chart (use Exhibit 13.7) for the length of the fuel injector. What can you say about this
12. Some citizens complained to city council members that there should be equal protection under the law against the occurrence of crimes. The citizens argued that this equal protection should be interpreted as indicating that high-crime areas should have more police protection than low-crime
11. The state and local police departments are trying to analyze crime rates so they can shift their patrols from decreasing-rate areas to areas where rates are increasing. The city and county have been geographically segmented into areas containing 5,000 residences. The police recognize that not
10. You are the newly appointed assistant administrator at a local hospital, and your i rst project is to investigate the quality of the patient meals put out by the food-service department.You conducted a 10-day survey by submitting a simple questionnaire to the 400 patients with each meal, asking
9. Resistors for electronic circuits are manufactured on a high-speed automated machine.The machine is set up to produce a large run of resistors of 1,000 ohms each.To set up the machine and to create a control chart to be used throughout the run, 15 samples were taken with four resistors in each
8. A shirt manufacturer buys cloth by the 100-yard roll from a supplier. For setting up a control chart to manage the irregularities (e.g., loose threads and tears), the following data were collected from a sample provided by the supplier.a. Using these data, set up a c-chart with z 5 2.b. Suppose
7. Ten samples of 15 parts each were taken from an ongoing process to establish a p-chart for control. The samples and the number of defectives in each are shown in the following table:a. Develop a p-chart for 95 percent coni dence (1.96 standard deviation).b. Based on the plotted data points, what
6. C-Spec, Inc., is attempting to determine whether an existing machine is capable of milling an engine part that has a key specii cation of 4 6 .003 inches. After a trial run on this machine, C-Spec has determined that the machine has a sample mean of 4.001 inches with a standard deviation of .002
5. Design specii cations require that a key dimension on a product measure 100 6 10 units. A process being considered for producing this product has a standard deviation of four units.a. What can you say (quantitatively) regarding the process capability?b. Suppose the process average shifts to 92.
4. There is a 3 percent error rate at a specii c point in a production process. If an inspector is placed at this point, all the errors can be detected and eliminated. However, the inspector is paid $8 per hour and can inspect units in the process at the rate of 30 per hour.If no inspector is used
3. Output from a process contains 0.02 defective unit. Defective units that go undetected into i nal assemblies cost $25 each to replace. An inspection process, which would detect and remove all defectives, can be established to test these units. However, the inspector, who can test 20 units per
2. A metal fabricator produces connecting rods with an outer diameter that has a 1 6 .01 inch specii cation. A machine operator takes several sample measurements over time and determines the sample mean outer diameter to be 1.002 inches with a standard deviation of .003 inch.a. Calculate the
1. A company currently using an inspection process in its material receiving department is trying to install an overall cost reduction program. One possible reduction is the elimination of one inspection position. This position tests material that has a defective content on the average of 0.04. By
7. The cost of performing inspection sampling moves inversely to the cost of quality failures.We can reduce the cost of quality failures by increased levels of inspection, but that of course would increase the cost of inspection. Can you think of any methods to reduce the cost of quality failures
6. Discuss the trade-off between achieving a zero AQL (acceptable quality level) and a positive AQL (such as an AQL of 2 percent).
5. The application of control charts is straightforward in manufacturing processes when you have tangible goods with physical characteristics you can easily measure on a numerical scale. Quality control is also important in service businesses, but you are generally not going to want to measure the
4. Discuss the purposes of and differences between p-charts and __ X - and R-charts.
3. In the situation described in question 2, what would be the effect on the cost of quality to the supplier?
2. In an agreement between a supplier and a customer, the supplier must ensure that all parts are within specii cation before shipment to the customer. What is the effect on the cost of quality to the customer?
1. The capability index allows for some drifting of the process mean. Discuss what this means in terms of product quality output.
16. What is it called when a i rm looks externally and examines other companies for examples of best practices?
15. Which industry specii c standard has been developed by the big three automakers for suppliers of parts, materials, and services to the automotive industry?
14. Which international standard has recently been developed to address socially responsible behavior of i rms?
13. A customer call center is evaluating customer satisfaction surveys to identify the most prevalent quality problems in their process. Specii c customer complaints have been analyzed and grouped into eight different categories. Every instance of a complaint adds to the count in its category.
12. What does the acronym DMAIC stand for?
11. What is the term for a l owchart that is used to separate value-added from non–value-added steps in a process?
10. A manufacturing company has been inspecting units of output from a process. Each product inspected is evaluated on i ve criteria. If the unit does not meet standards for the criteria it counts as a defect for the unit. Each unit could have as few as zero defects, and as many as i ve. After
9. A common problem that many drivers encounter is a car that will not start. Create a i shbone diagram to assist in the diagnosis of the potential causes of this problem.
8. Below is a table of data collected over a six-month period in a local grocery store. Construct a Pareto analysis of the data and determine the percentage of total complaints represented by the two most common categories.All Other 71 Checker 59 General 58 Service Level 55 Policy/Procedures 40
7. The following table lists all costs of quality incurred by Sam’s Surf Shop last year. What was Sam’s appraisal cost for quality last year?Annual inspection costs $ 155,000 Annual cost of scrap materials 286,000 Annual rework cost 34,679 Annual cost of quality training 456,000 Annual warranty
6. A manager states that her process is really working well. Out of 1,500 parts, 1,477 were produced free of a particular defect and passed inspection. Based upon Six Sigma theory, how would you rate this performance, other things being equal?
5. What term means managing the entire organization so that it excels on all dimensions of products and services that are important to customers?
4. What are the four general categories of quality costs?
3. What is the term that means making the person who does the work responsible for ensuring that specii cations are met?
2. Match the quality “guru” with the specii c aspects of their teachings. Use C for Crosby, D for Deming, and J for Juran.Dei ned quality as “i tness for use.”Dei ned quality as “conformance to requirements.”Set the performance standard as “zero defects.”Dei ned 14 points for
1. What is the name of the national quality award given by the government of the United States?
10. Do you see any relationship between the ISO standards mentioned in this chapter and the competitive strategy concepts mentioned earlier in the text?
9. Is certii cation under the ISO standards in this chapter necessary for competing in the modern market? What should companies consider when deciding whether or not to become certii ed?
8. A typical word processing package is loaded with poka-yokes. List three. Are there any others you wish the packages had?
7. Shingo told a story of a poka-yoke he developed to make sure that the operators avoided the mistake of putting fewer than the required four springs in a push-button device. The existing method involved assemblers taking individual springs from a box containing several hundred and then placing
6. Develop a cause- and-effect (i shbone) diagram to address everything that impacts your grade in this course. How much is under your control?
5. Business writer Tom Peters has suggested that in making process changes, we should“Try it, test it, and get on with it.” How does this square with the DMAIC/continuous improvement philosophy?
4. “Before you build quality in, you must think it in.” How do the implications of this statement differ from those in question 3?
3. “You don’t inspect quality into a product; you have to build it in.” Discuss the implications of this statement.
2. “If line employees are required to work on quality improvement activities, their productivity will suffer.” Discuss.
1. Is the goal of Six Sigma realistic for services such as Blockbuster Video stores or Redbox DVD kiosks?
4 What would be the impact of purchasing “electronic”slot machines that do not use coins?
3 The casino is considering the purchase of a second coin-wrapping machine. What impact would this have on the hard count process? Is this the most desirable machine to purchase?
2 Draw a diagram of the hard count process. How long should this process take to complete for 300 silver dollar slot machines? Assume that each slot machine has an average of 750 silver dollars when it is emptied.
1 Draw a diagram of the drop process. How long should it take to empty 300 silver dollar slot machines?
21. Remember Mr. Rockness in Question 11? He now retrains college professors. It is a much more challenging task but still involves i ve steps. He has worked hard to balance the line; however, there is a lot of variability. Each stage in the process now handles between one and six faculty members
20. A small barber shop has a single chair and an area for waiting, where only one person can be in the chair at a time, and no one leaves without getting their hair cut. So the system is roughly:Entrance Wait Haircut Exit Assume customers arrive at the rate of 10 per hour and stay an average of
19. A quoting department for a custom publishing house can complete 4 quotes per day, and there are 20 quotes in various stages in the department. Applying Little’s law, the current lead time for a quote is how many days?
18. I-mart is a discount optical shop that can i ll most prescription orders in around 1 hour.The management is analyzing the processes at the store. There currently is one person assigned to each task below. The optometrist assigned to task B takes an hour off for lunch and the other employees
17. The National State Bank is trying to make sure that it has enough tellers to handle the Friday afternoon rush of workers wanting to cash their paychecks. It is only concerned with the last hour of the day from 4:00 to 5:00 p.m. It takes 5 minutes per customer to be processed by the tellers. The
16. Wally’s Widget Warehouse takes orders from 7 a.m. to 7 p.m. The manager wants to analyze the process and has provided the process l ow diagram shown below. There are three steps required to ship a customer order. The i rst step is to take the order from a customer. The second step is to pick
15. The following represents a process used to assemble a chair with an upholstered seat. Stations A, B, and C make the seat; stations J, K, and L assemble the chair frame; station X is where the two subassemblies are brought together; and some i nal tasks are completed in stations Y and Z. One
14. A processor makes two components, A and B, which are then packaged together as the i nal product (each product sold contains one A and one B). The processor can do only one component at a time: Either it can make As or it can make Bs. There is a setup time when switching from A to B.Current
13. A local market research i rm has just won a contract for several thousand small projects involving data gathering and statistical analysis. In the past, the i rm has assigned each project to a single member of its highly trained professional staff. This person would both gather and analyze the
12. The bathtub theory of operations management is being promoted as the next breakthrough for global competitiveness. The factory is a bathtub with 50 gallons of capacity. The drain is the outlet to the market and can output three gallons per hour when wide open. The faucet is the raw material
11. Rockness Recycling refurbishes rundown business students. The process uses a moving belt, which carries each student through the i ve steps of the process in sequence. The i ve steps are as follows:Time Required Step Description per Student 1 Unpack and place on belt 1.0 minute 2 Strip off bad
10. An enterprising student has set up an internship clearinghouse for business students. Each student who uses the service i lls out a form and lists up to 10 companies that he or she would like to have contacted. The clearinghouse has a choice of two methods to use for processing the forms. The
9. Which work measurement technique is most appropriate for tasks that are infrequent or have a long cycle time?
8. What are the four basic techniques for measuring work and setting time standards?
7. At the Children’s Hospital in Seattle there are, on average, 60 births per week. Mother and child stay, on average, two days before they leave the hospital. At the Swedish Hospital(also in Seattle), the average number of births per week is 210. Mothers and children stay in the hospital two
6. Avis Company is a car rental company that is located three miles from the Los Angeles airport (LAX). Avis is dispatching a bus from its ofi ces to the airport every 2 minutes.The average traveling time (round-trip) is 20 minutes.a. How many Avis buses are traveling to and from the airport?b. The
5. A i rm has redesigned its production process so that it now takes 10 hours for a unit to be made. Using the old process, it took 15 hours to make a unit. If the process makes one unit each hour on average and each unit is worth $1,500, what is the reduction in work-inprocess value?
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