P429 - Operations Processes
http://jacobs.indiana.edu/p429/Section No: 14072, 11:15-12:30 Tuesday and Thursday, BU406
Section No: 14073, 9:30-10:45 Tuesday and Thursday, BU406
Professor F. Robert Jacobs http://jacobs.indiana.edu, jacobs@indiana.edu
Office hours: Wed 9-12, 1-3 and by appointment. BU670F
Required Books:
Business Process Modeling, Simulation, and Design, by Manuel Laguna and
Johan Marklund. Prentice Hall, 2005.
P429 Case Packet, Available at TIS.
Course overview and grading criteria.
Click here to provide anonymous feedback on the course.
Tuesday 8/30/2005 Course Introduction
Reading: “The Super Efficient Company”
Discussion Questions:
What is a process?
Give some examples of processes that impact your life every day?
Can you think of ways to improve these processes?
Student Info Form
Slides
Thursday 9/1/2005 Process Analysis – Introduction
Read: Laguna and Marklund – Chapter 1 & 2
Discussion Questions (select one of the following two questions):
Document the process that you follow when you get up in the morning on a full
class day. How can your process be streamlined?
Morning routine form
Slides
Tuesday 9/6/2005 Process Analysis – Basic Tools.
Read: Laguna and Marklund – Chapter 4 (Basic Tools for Process Design)
Discussion Questions:
Develop a process flow diagram for your morning routine. Bring this to
class.
Assignment: Turn in (OnCourse Drop Box) page 134 - problem 6, and page 135 - problem 9. Due by
Friday, Sept 9 at 5:00 pm.
Slides
OM/IE Tools
(Spreadsheet Add-ins)
Thursday 9/8/2005 Process Analysis - Static Process Analysis.
Read: Kristen’s Cookie Company (A)
Discussion Questions:
See questions at the end of the case. Prepare answers to these questions
an be prepared to turn these in at the beginning of class.
Please complete
this form prior to class: Kristen Cookie
form Slides
Tuesday 9/13/2005 - Process Improvement
In-class exercise:
"The Japanese Simulation Experiments"
Tech Career Fair
Announcement
Please bring a calculator to class.
Thursday 9/15/2005 - Process Bottlenecks
Read: Laguna and Marklund – Chapter 5 (Managing Process Flows)
Calculate the following based on results from the experiments performed last
class:
cycle time, flow time, idle time, lot delay, utilization, and labor
productivity.
Slides
Tuesday 9/20/2005 - Flow Processes
Case: National Cranberry Cooperative
Discussion Questions:
1. Draw a diagram of the product flow through the system?
2. What is the capacity of this system? Assume that you are not constrained by
the workforce. Is this a good assumption?
3. What should they do to reduce the waiting time for the trucks?
Turn in a copy of your process diagram at the beginning of class.
National Cranberry form
Slides
Thursday 9/22/2005 - Facility Layout and Process Design – Assembly Lines
Case: Samsung International, Inc.
Discussion Questions:
1. What is the current capacity of Line A compared to the goal? How long does it
take a TV to pass through the line? How much time is spent in the burn-in line?
What is the efficiency of the line (worker perspective)?
2. What is the impact of the unpaced line?
3. To get 1,000 units out a day – What must we do? Are the 220 positions enough?
4. What would you recommend that Harvey and Kim do with the suggestion of Swain?
What should they pursue in general?
Samsung International form
Tuesday 9/27/2005 - No class today - Take home midterm - due Wednesday 9/28/2005 at 5:00pm
Turn in to BU670. Here
is the exam (right click to download).
Here are
the answers to the exam questions.
Thursday 9/29/2005 - Queuing and Simulation
Read:
Laguna and Marklund – Chapter 6 (Introduction to Queuing and Simulation)
Exercise: The Great Manufacturing Crapshoot
In class exercise and spreadsheet simulation.
Spreadsheet.
Tuesday 10/4/2005 Queuing problems – using and understanding the tools
Slides
Thursday 10/6/2005 Intro to Extend
Laguna and Marklund – Chapter 7 (Introduction to Extend)
For those of who own a notebook computer, please load Extend on your
computer and bring it to class.
Due - The "automated pizza vending machine" problem from last class.
Slides
Tuesday 10/11/2005 Modeling Business Processes with Extend
Laguna and Marklund – Chapter 8
Prepare problems 1, 2, 3 (page 263) prior to class.
Class
Notes Team Assignments
(tentative)
Extend models, chapter 7, problems
1a,
1b,
2a,
3a,
3b, and
3c.
Concepts - Setting simulation time units, simulation length and number of runs.
Thursday 10/13/2005 Modeling concepts – attributes, priorities, routing,
costing.
Presentation expectations.
Examples: balking 8.06,
reneging 8.08, item priority
8.10, probabilistic paths
8.13, shortest line
8.14, parallel paths
8.18.
Tuesday 10/18/2005 - Modeling concepts - continued
Due - Problem 4, page 264.
Original System.
Revised
System.
Slides
Examples: variable processing time
8.20, batching
8.25, cycle (throughput) time
analysis 8.29.
Thursday 10/20/2005 -
Extend problem - consulting
Tuesday 10/25/2005 -
Student presentations – Extend problems
Thursday 10/27/2005 Student presentation - Extend problems
Tuesday 11/1/2005 Intro to Lean Manufacturing & Project Assignment
Read: “Decoding the DNA of the Toyota Production System”
HP JIT Video. Slides.
Thursday 11/3/2005 Discussion of Project Assignment Cases
Cases: “Sunwind” and “Donner”
Due for presentation on Tuesday 11/15, Thursday 11/17.
Dumore Corporation Video.
Case Deliverables.
Donner Discussion Questions (teams 1, 3, 5, 7):
1. In what market(s) does Donner compete? On what basis does Donner compete?
2. What are the current problems at Donner and what are their causes?
3. Prepare a diagram of the “normal process flow” of material through this shop.
4. What is the capacity utilization of operations such as the CNC drill, the
punch press, and the electroplate operation (assume 160 hours were available in
September)? For the drilling operation, when should the CNC drill be used versus
the manual drill?
5. What are the sources of the problems at Donner? What should be done to
alleviate these problems in both the short and long term?
Sunwind Case Questions (teams 2, 4, 6, 8):
1. What are the primary problems facing Sunwind?
2. How does product flow in Sunwind? More generally, what does the whole value
chain look like from raw material to consumer product?
3. How will Volvo’s new requirements affect Sunwind? Can they cope with the
current and expected demand? How?
4. What is required for JIT? Does Sunwind have it?
5. What would Sunwind (and Volvo) gain from JIT?
6. Should Sunwind undertake JIT now? If they decide to go to JIT, how should it
be implemented?
Tuesday 11/8/2005 Project Consulting
Thursday 11/10/2005 Project Consulting
Tuesday 11/15/2005 Project Presentations
Thursday 11/17/2005 Project Presentations
11/21/2005-11/25/2005
Thanksgiving Recess
Tuesday 11/29/2005 Project Debrief, Intro to DEA
Project Debrief Slides
Read: Laguna and Marklund – Chapter 11 (Process Benchmarking with Data
Envelopment Analysis)
Thursday 12/1/2005 DEA and Process Benchmarking
DEA Slides
Problem 6 (p. 409) Data
Tuesday 12/6/2005 DEA Problem
Due Problem 6, p. 409.
Thursday 12/8/2005 Final Exam Review - Case Discussion
Case: Benihanna of Tokyo
Discussion Questions:
1. Define the Benihana concept.
2. Benihana’s operating statistics appear to be favorable compared to the
typical service restaurant. Why are they that way? What are the key success
factors?
3. What is the function of the bar/lounge area in this service delivery system?
How is the process paced? Evaluate the capacity of the bar/lounge area. How long
do you expect customers to wait in the bar/lounge area when the restaurant is
operating at capacity? What is the capacity of the restaurant?
4. Develop an Extend model of the Benihana restaurant. Model the
restaurant after the 2nd New York restaurant (the one shown in the diagram).
Assume that the restaurant has 48 seats in the bar and 14 tables. Also, assume that the restaurant is running at full capacity
and that
customers are seated at tabled in groups of 8. Finally, it takes exactly
60 minutes to serve a group of customers at each table.
There is a drop-box available in OnCourse for this assignment. This
assignment is due on Friday, Dec. 16 at 10 am.
12/12-16/2005 Final Exam
Exam
Due Friday, Dec. 16, 10 am.