Operations Management Key Concepts & Principles
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Operations Management Key Concepts
Inventory Management & Production Planning
Final Inventories Analysis
Final inventories for the last 4 months: FI = S(100) O(120) N(-130) D(430). Response: O(2750) N(1400) D(3750).
Production Strategy Aggregation
Which production strategy aggregates production? Response: Strategy to adjust demand.
Production Planning Metrics
Number of Products (N.Prod) = 10,000 units | Production Days = 20 | Workforce = 43. Response: 459 units.
Actuation Possibilities
Actuation possibilities: Demand/Capacity. Response: Actuation/Aggressive.
Lot-for-Lot (LFL) Parameters
LFL parameters: Ts2 Av25 Ss10 Level0 RefP3.
Gross Requirements Calculation
Gross Requirements: (0.50, 0.100, 0.75, 0.80, 0.90, 0.100). Response: (0.100, 0.70, 0.70, 0.100).
Production Strategy Details
Production Strategy. Response: Article E: Sum of Total Direct Elements.
Lot Sizing & Net Requirements
Silver-Meal Heuristic Application
Cost of Setup (Ce) = 3200, Cost per Unit (Cp) = 2, Period = 1 week, Silver-Meal. Response: 1 (2100).
Silver-Meal Parameters
Silver-Meal parameters: Level 3, Ts1, Av2, Ss0.
Gross Requirements for Lot Sizing
Gross Requirements: (0.234, 0.694, 0.410, 0.170, 0.55, 0.5, 0). Response: Five.
Net Requirements Calculation
Net Requirements: 4 x 200. Response: 2y6 = 400.
Period Order Quantity (POQ)
Net Requirements = 6,000, Cost of Setup (Ce) = 1500, Cost per Unit (Cp) = 1, Period Order Quantity (POQ). Response: Each 2 periods.
Scheduling & Sequencing
Johnson's Rule for Machine Scheduling
Johnson's Rule for Machines: M1 (5, 3, 9, 3, 6), M2 (8, 6, 7, 7, 4), M3 (3, 1, 4, 8, 10). Response: All.
Jackson's Machine Scheduling
Jackson's Machine 2. Response: (2-1) + 2 + (1-2).
Johnson's Rule Sequencing
Johnson's Rule. Response: Smallest to largest, alternate sequence.
Scheduling Rule Application
TRUE (Johnson/Jackson). Response: None.
Order Sequencing Example
10 orders. Response: ABIJGHDEFC.
Facility Layout & Surface Area
Surface Area Calculation
Surface area (Sm) (2, 2, 4). Response: Sg = 24 m2.
Total Surface K Factor
Total Surface (TSurf) K = 2.
Static Surface Measurement
Static Surface (1.8, 2.4, 2.3, 2.1, 1.8, 1.9, 2.2, 3.0, 2.4). Response: 321.9 m2.
Workstation Surface Reservation
Surface reserved between workstations. Response: Surface Evolution.
Fictitious Range for Workstations
Fictitious range for 10 workstations. Response: ABE’DCEFGHIG’J.
Workstation Capacity Example
Previous: 8 hours, 5 days = 19 workstations.
Fictitious Range for Products & Workstations
Fictitious range for 3 products, 8 workstations. Response: ABCA’DEF’EGH.
Minimum Required Surface
K = 2, minimum required surface for 10 elements.
Static Surface Calculation (Second Example)
Static Surface (1.4, 1.8, 2.2, 2.6, 1.8, 2.6, 1.9, 1.6, 3.6, 4). Response: 355.5 m2.
Line Balancing & Cycle Time
Production Chain Requirements
Chain to satisfy 45,000 units, 1,800 hours, minimum cycle time 10 minutes. Response: TC10min-Stat7-6u/h.
Work Elements & Line Balancing
Work Elements (/-1-1-3-3-4.5-2-7.6-8-9) if T = 12 minutes... Response: (1.3.4-2-5.7-6). Line Balancing previous example. Response: 94%. Previous Quantity = All.
Annual Demand & Cycle Time
Annual Demand = 27,960 units, 233 days, 8 hours/day. Response: 12 minutes cycle time.
Workstation Assignment for Chain Elements
Chain of 12 elements. Timing (5, 5, 3, 4, 5, 4, 4, 2, 5, 3, 5, 12). Response: Workstations (1: 1,2,3,8), (2: 4,6,7,10), (3: 5,9,11), (4: 12).
Lean Manufacturing & Theory of Constraints
Standard Operations & Just-In-Time (JIT)
Standard Operations, Just-In-Time (JIT). Response: All.
Exploiting Maximum Profit (TOC)
Exploiting Maximum Profit (TOC). Response: All.
JIT Principles: Autonomous Control
JIT principles include: Response: Autonomous control of defects.
PULL System Definition
PULL system. Response: Fabrication from client orders.
Goldratt's Influence on JIT
NOT Just-In-Time. Response: Result of Goldratt.
Theory of Limitations & Subsystem Optimization
Theory of Limitations applied to subsystem optimization. Response: Basic equation of fluctuation.
TOC Performance Parameters
According to TOC, three parameters explain performance: Response: Net Income (NI), Inventory (Inv), Operating Costs (OpCosts).
JIT & Poka-Yoke
JIT autonomous control of defects refers to: Response: Poka-Yoke.
TOC Principles: Non-Bottleneck Resources
TOC principles include: Response: Every non-bottleneck resource must work at full capacity.
Kanban System Type
NOT advanced Kanban. Response: Push system.
Quality Control & Metrics
Defect Rate Calculation
Number of defects (55, 9, 86, 4, 97, 13, 8...). Response: 80.13%.
Sampling Plan Example
10,000 units, Sample P1 (c6-n82). Response: 82 units.
Probability of LTPD
FALSE. Response: Probability of Lot Tolerance Percent Defective (LTPD).
Quality Control Tools
Quality control. Response: Control graphs.
Costs of No Quality
FALSE. Response: Costs of no quality = inspection prevention.
Process Control Indicators
Process is under control if graph shows: Response: All.
Defects Before Market Production
If defects occur before market production: Response: All.
Acceptance Sampling Plans
According to sample plans acceptance, affirm: Response: Curve-sample.
Shewhart/Deming Principles
Shewhart/Deming: Response: Design to improve processes, 4 stages.