production & operarions management compre review
TRANSCRIPT
POM Review forComprehensive
Examination
PRODUCTION & OPERATIONS MANAGEMENT
1. Introduction2. Forecasting3. Design of Goods & Services, Processes &
Systems4. Facilities & Capacity Planning5. Inventory Planning and Supply Chain
Management6. Materials, Manufacturing & Enterprise
Resource Planning (MRP, ERP)8. Quality Management, TQM, ISO9. Quality Improvement, JIT, Lean, Six Sigma10. Project Management11. Service Operations Management12. Operations Strategy, Sustainability, Social
& Ethics13. Plant Tour/Group Project * 7. Midterm Exam and 14 Final Exam
REVIEW OUTLINE
POMSyllabus
INTRODUCTION
ORGANIZATION
ORGANIZATION
Figure 1.1
ORGANIZATION
POM DEFINITION
WHAT IS OPERATIONS MANAGEMENT?
Production is the creation of goods and services
Operations management (OM) is the set of activities that create value in the form of goods and services by transforming inputs into outputs
Design of Goods & Services, Processes &
Systems
IPO Model
SIPOC Model
PRODUCTIVITY CHALLENGE
Productivity is the ratio of outputs (goods and services) divided by the inputs (resources such
as labor and capital)
The objective is to improve productivity!
Important Note!Production is a measure of output only
and not a measure of efficiency
▶ Measure of process improvement
▶ Represents output relative to input
▶ Only through productivity increases can our standard of living improve
PRODUCTIVITY
Productivity =Units produced
Input used
PRODUCTIVITY CALCULATIONS
Productivity =Units produced
Labor-hours used
= = 4 units/labor-hour1,000
250
Labor Productivity
One resource input single-factor productivity
MULTI-FACTOR PRODUCTIVITY
OutputLabor + Material + Factory OHProductivity =
► Also known as total factor productivity► Output and inputs are often expressed in
dollars
Multiple resource inputs multi-factor productivity
COLLINS TITLE PRODUCTIVITY
Staff of 4 workers 8 hrs/day 8 titles/dayPayroll cost = $640/day Overhead = $400/day
Old System:
14 titles/day Overhead = $800/day
New System:
8 titles/day
$640 + 400
14 titles/day
$640 + 800
=Old multifactor
productivity
=New multifactor
productivity
= .0077 titles/dollar
= .0097 titles/dollar
IMPROVING PRODUCTIVITY AT STARBUCKS
A team of 10 analysts continually look for ways to shave time. Some improvements:
Stop requiring signatures on credit card purchases under $25
Saved 8 seconds per transaction
Change the size of the ice scoop
Saved 14 seconds per drink
New espresso machines Saved 12 seconds per shot
Operations improvements have helped Starbucks increase yearly revenue per outlet by $250,000 to $1,000,000 in seven years.
Productivity has improved by 27%, or about 4.5% per year.
Forecasting
Copyright ©2013 Pearson Education
FORECASTING METHODS
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Naïve Method
The forecast for the next period is the demand for the current period
Moving Average Method
Weighted Moving Average Method
Exponential Smoothing Method
Linear Regression Method
MOVING AVERAGE METHOD
Compute a three-week moving average forecast for the arrival of medical clinic patients in week 4. The numbers of arrivals for the past 3 weeks were:
Week Patient Arrivals1 4002 3803 411
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WEIGHTED AVERAGE METHOD
Compute the forecast for the arrival of medical patients in week 4 using the weighted average method. The numbers of arrivals were as follows:
Week
Patient Arrivals Weight
1 400 20%2 380 30%3 411 50%
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EXPONENTIAL SMOOTHING METHOD
Compute the forecast for the arrival of patients in week 4 using the exponential smoothing method. The smoothing constant is α = 0.10:
Week
Patient Arrivals
Previous Forecast
1 400
2 3803 411 415
FNew = FPrevious + α (Actual – FPrevious)
LINEAR REGRESSION METHOD
Compute forecast for week 7 using the linear regression method.
Week Patient Arrivals1 4002 3803 4114 4155 4216 427
Y = A(X) + BWhere A = slope, B = Y-intercept
LINEAR REGRESSION METHOD
Formula
Result
ΣX 21
ΣY 2,454
n 6
ΣX2 91
ΣY2 1,005,116
ΣXY 8,720
LINEAR REGRESSION METHOD
nΣXY – ΣXΣY 6(8720)-(21)(2,454) 786A = ------------- = ---------------------- = ----- = 7.485714 nΣX2 – (ΣX)2 6(91) – (21)2 105
ΣY – AΣX 2,454 – (7.485714)(21) 2296.8B = ---------- = --------------------------- = -------- = 382.8 n 6 6
Y7 = A(X7) + B = 7.485714 (7) + 382.8 = 435.2
LINEAR REGRESSION METHOD
nΣXY – ΣXΣY R = -------------------------------------- = 0.828103
REGRESSION COEFFICIENT
0 < /r/ < 0.3 = Weak Correlation
.3 < /r/ < 0.7 = Moderate Correlation
/r/ > 0.7 = Strong Correlation
Facilities PlanningCopyright ©2013 Pearson Education
11- 030
Proximity to the MarketLocation of the Plant, Warehouse and Offi ceSize of the Plant, Warehouse and Offi ceConstruction and Renovation CostsEquipment, Furniture and Fixtures RequiredOrganization and Manpower RequirementsPurchasing of Equipment, Furniture & FixturesSupply Chain for Raw Materials and
ConsumablesEnvironmental ConditionsCommunity and Social Responsibility
KEY DECISIONS IN FACILITIES PLANNING
Site Selection
Site Selection in Physical Distribution
Inventory Planning
Economic Order Quantity
A local company expects to sell 9000 tires of a certain tire next year, Annual carrying cost is P640 per tire and ordering cost is P3,000. The distributor operates 288 days a year.
a. What is the EOQ?b. How many times does the store have
to re-order per year?c. What is the total annual cost, if the
EOQ is ordered?
EOQ
a. Economic Order Quantity
b. Optimal No. of Orders Per YearN = D = 9,000
EOQ 290N = 31 Orders/Year
Given:K = Ordering Cost 3,000.00 PesosH = Carrying Cost 640.00 Pesos/YrD = Demand 9,000 Units/YrWorking Days 288 DaysDaily Demand = Consumption 31.25 Units/Day
EOQ = 2 D K = 2(9,000)(3,000)H 640
= 54,000,000 = 84,375640
EOQ = 290 Units
ξ ξξ ξ
EOQGiven:K = Ordering Cost 3,000.00 PesosH = Carrying Cost 640.00 Pesos/YrD = Demand 9,000 Units/YrWorking Days 288 DaysDaily Demand = Consumption 31.25 Units/Day
c. Minimum Total Annual Inventory CostTotal Cost = Ordering + Holding
Tc = To + Th
+ H Q/2+ (640)(290)
2+ 92,952
Pesos Per Year92,952
D K/Q (3000)(9000)
290
185,903.20
Quality Management
Quality Management
A time study in an assembly line yielded the following observation times and the performance rating is 1.13 seconds.
a. Using an allowance of 20% on job time, determine the appropriate standard time for the operation.
b. Develop a quality control chart for the process, using six sigma limits.
Observation Time (secs.)
1 1.122 1.153 1.164 1.125 1.156 1.187 1.148 1.149 1.19
Given allowance 20%
Assembly Line
Quality Management
a. Using an allowance of 20% on job time, determine the appropriate standard time for the operation.
Observation Time (secs.)1 1.122 1.153 1.164 1.125 1.156 1.187 1.148 1.149 1.19
Mean 1.15Allowance (20%) 0.23Standard Time Lower limit = 0.92 Upper limit = 1.38
Six Sigma Limits
6 Sigma Limits
4 Sigma Limits
2 Sigma Limits
99.73%
95.45%
68.27%
Six Sigma Control Chart
Observation Time (secs.)1 1.122 1.153 1.164 1.125 1.156 1.187 1.148 1.149 1.19
Mean 1.15Standard Deviation 0.0240Six-Sigma Limits Lower limit = 1.08 Upper limit = 1.22
1.221.08 1.15
b. Develop a quality control chart for the process, using six sigma limits.
Project Management
Garage
BedRoom1
Master’s Bedroom
Living Room
Kitchen
BedRoom2
3 – Bedroom Bungalow (One Storey) House
BUILDING A HOUSE
Watch Video
BUILDING A HOUSE RECORD
4 Hours, 18 Minutes700 PeopleCement Mixer and CranesSkilled Workers w/ Power ToolsPre-Fabricated Wood FramingSan Diego California Team A vs Team B
will attempt to break the world record.
FinishStart
A
B
C
D
E
F
G
H
I
J
KA
—B
—C
AD
BE
BF
AG
CH
DI
AJ
E,G,HK
F,I,J
Immediate Predecessor
02 - 47
CRITICAL PATH METHOD
Duration (Days)
GANTT CHART
FinishStart
A
B
C
D
E
F
G
H
I
J
KPath Time (days)
A-I-K 33A-F-K 28A-C-G-J-K 67B-D-H-J-K 69B-E-J-K 43
Paths are the sequence of activities between a
project’s start and finish.
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CRITICAL PATH METHOD
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Latest finish time
Latest start time
Activity
Duration
Earliest start time
Earliest finish time
0
2
12
14
A
12
CRITICAL PATH METHOD
K
6
C
10
G
35
J
4
H
40
B
9
D
10
E
24
I
15
FinishStart
A
12
F
10
0 9
9 33
9 19 19 59
22 5712 22
59 63
12 27
12 22 63 690 12
48 63
53 63
59 63
24 59
19 59
35 59
14 24
9 19
2 14
0 9
63 69
PERT/CPM
S = 0
S = 2
S = 26
S = 0
S = 36
S = 2
S = 2
S = 41 S = 0
S = 0 S = 0
The critical path is B–D –H
–J - K with a project
duration of 69 days.