Module 4 PDF
Module 4 PDF
Module 4
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Unit 9
Unit 9
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C4: Operations Management
Activity 4.1
Now that we have introduced the subject, reflect on what
inventory does for an organisation. Think of an organisation with
which you are familiar and try answering these questions:
1. How much inventory should the organisation have?
Activity
2. When should you pay for it?
3. How much should you pay for it?
4. What happens if you have too much inventory?
5. What happens if you have too little inventory?
6. Where is inventory stored?
7. How much storage space is required?
8. How is inventory transported?
9. How much inventory is transported at one time?
10. How is inventory stored?
11. What happens if the inventory is a hazardous substance (or
dangerous to handle)?
12. How do you keep track of what inventory you have?
13. What is the value of the inventory you have?
14. What can you do with the inventory you do have?
15. We could consider many more questions at this stage but the
above give some idea of where we are heading.
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Activity 4.2
Now that we have introduced the subject of material requirements
planning, try answering this question:
What data is required to develop a very basic MRP?
Activity
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Unit 9
Activity 4.3
Work through the following questions. You may need to go back
and re-read the unit to help you.
1. Explain why the economic order quantity model is not
appropriate for modern business.
Activity
2. Explain the difference between MRP and MRP II.
3. Explain the sales and operations planning process.
4. Explain why sales and operations planning is performed at the
aggregate level.
5. Explain the theory of constraints.
6. Explain how the drum-buffer-rope works.
7. Explain the difference between a capacity-constrained resource
and a bottleneck.
8. Explain why an organisation might carry safety stock.
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Unit 10
Activity 4.4
Work through the following questions. You may need to go back
and reread the unit to help you.
1. Explain the bullwhip effect. In particular, explain how it
happens and what can be done to minimise adverse effects.
Activity
2. Describe the Triple-A supply chain approach.
3. Explain vertical integration as a means to secure more linkages
in the supply chain.
4. Evaluate the criteria for selecting a supplier.
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Unit 11
Unit 11
Project management
Upon completion of this unit students will be able to:
Define a project.
Describe the nature of project management.
Discuss the strategic nature of projects.
Describe project organisation structures.
Discuss the role of the project manager.
Outcomes
Discuss project management processes.
Define a critical path.
Discuss project risk and uncertainty.
Discuss the critical chain method.
Outline what makes a project successful.
Activity 4.5
Work through the following questions. You may need to go back
and reread the unit to help you.
1. What is a project?
2. What makes a project different from other business activities?
Activity
3. What is project “creep” and what should be done to prevent it?
4. Explain the critical chain method.
5. What makes a project successful?
6. As a project manager, how would you ensure that your project
is successful?
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Unit 12
Performance measurement
Upon completion of this unit students will be able to:
Describe measurements for business excellence.
Describe the Hoshin process for setting goals and using
measurement systems.
Describe the balanced scorecard approach to performance
Outcomes measurement.
Describe how the closed-loop management system links
strategy and operations.
Describe benchmarking.
Activity 4.6
Work through the following questions. You may need to go back
and reread the unit to help you.
1. Describe the balanced scorecard approach.
2. Evaluate Hoshin planning as a strategic planning system.
Activity
3. Evaluate Hoshin planning as a performance measuring system.
4. What are some financial measurements for an organisation?
5. What are some operational measurements for an organisation?
6. How can innovation and learning be measured?
7. What is an appropriate measurement for internal processes?
8. What performance measurements are suitable for a call centre?
9. How does benchmarking benefit an organisation?
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Guidelines
The allocated exam time is three hours.
The student should answer six questions from a choice of eight.
Each question should take about 30 minutes to answer.
Lecturer to choose eight questions from the 15 provided below.
Choose only one from each heading.
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Inventory waste is the storage of items that are not needed. This
requires storage in a warehouse and that requires additional cost
which would not occur if the inventory did not exist.
Producing defects, scrap and rework is waste. Scrap is an output
that is dumped at the end of processing because it does not meet
customer specification. Why is that product made in the first place?
It may be quicker to just throw money away or flush it down the
toilet. Rework occurs when a product is made and it is determined
that a defect can be corrected if it passes through the processing
step again. Painting and repainting is an example. When this waste
occurs the item is made twice but the customer only pays once.
That is waste.
Guide to markers: Students should have clearly described each of
the seven categories of waste and included the key points noted
above.
Question 7
“A big breakthrough in the development of lean thinking systems
was to realise the difference between process and operations;
process is the total flow of production from the customer’s order to
the finished product while operations is a set of machines.” Discuss
how a focus on the process teaches us to smooth out our operations
and make us more effective. (Note: Lean thinking systems are
synonymous with lean production systems and just-in-time
production systems.)
Guide to markers: Students should focus discussion on
elimination of waste to make production flow. They should
highlight inefficiencies in particular areas and how these can be
improved. If companies just concentrate on individual machines it
becomes too disjointed and unconnected. They need connection
and flow.
Product design
Question 8
What is quality function deployment?
Answer
Quality function deployment is a methodology that identifies
customer needs (the voice of the customer) and ensures these needs
are met or exceeded with the technical (design) requirements
throughout the product development and production process.
Quality function deployment can be viewed as a set of
communication and translation tools. It tries to eliminate the gap
between what the customer wants in a new product and what the
product is capable of delivering.
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Answer
Six sigma quality is a business improvement approach that seeks to
find and eliminate causes of defects and errors in manufacturing
and service processes by focusing on outputs that are critical to
customers and a clear financial return for the organisation. It is a
business process that allows organisations to improve bottom-line
performance, creating and monitoring business activities to reduce
waste and resource requirements while increasing customer
satisfaction.
Six sigma quality is a proven methodology for driving and
achieving transformational change within an organisation. It is a
business improvement process that focuses on customer
requirements, process alignment, analytical rigour and timely
execution.
In its original form it concentrated on manufacturing variables,
both controlled and uncontrolled, such as temperature, pressure,
flow rate and time. It also improved the process output variables
such as yield, waste, capacity, downtime and production rate.
This has now been extended to include non-manufacturing
variables, both controlled and uncontrolled, such as communication
methods, completeness, accuracy, training, inventory levels,
shipping methods, promise dates, days of the week, seasons of the
year and customer required date. It improves output variables such
as order correctness, delivery time and package quality.
Six sigma quality aims to align executives to the right objectives
and targets, to mobilise improvement teams, to accelerate results
and to govern sustained improvement.
It has been practised by Motorola for more than 30 years and other
large organisations have since unravelled the mysteries and applied
the gains to their operations. It has been rather slow to be
implemented within smaller companies. However, now the basic
concepts are more widespread within small to medium enterprises
despite the start-up costs and commitment required. In fact, some
of the real benefits are being achieved with service companies.
It has its foundations in statistics — well, that is where the name
comes from. Originally it was termed ± six sigma capability and it
measured the variation of each process. The process had to be
designed such that it was capable of producing ± six standard
deviations (sigma) of the process within the customer-defined
process limits.
Six sigma quality allows organisations to identify customer
requirements and to design, and subsequently modify, business
processes to consistently achieve nothing less than the minimum of
customer requirements. Keep the customer happy, supply them
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with exactly what they want, when they want it and they will come
back for more.
A concentration on increased reliability by making processes more
repeatable helps improve production, yield and efficiency.
Resources are focused on the right products and the right projects.
Guide to markers: Look for at least five of the paragraphs above.
If a student described any five paragraphs then that would
constitute an excellent answer.
Inventory planning and management
Question 10
Discuss the theory of constraints and how it can be applied to
operations.
Answer
Goldratt explains that the goal of the firm is to make money by:
Increasing throughput, which is the rate at which money is
generated by sales.
Reducing inventory, which is the money spent on buying
items for subsequent sale.
Reducing operating expense, which is the money spent to
convert inventory into throughput.
Traditionally, management emphasises reducing operating expense
and reducing inventory. Organisations take pride in proclaiming
that they are on a “cost-cutting drive”. They target opportunities to
cut expenses and reduce inventory. Expenses are easy to cut when
the organisation stops spending money. Likewise inventory is easy
to reduce when the organisation stops replenishing supplies.
Looking at both operating expenses and inventory, what happens
when the organisation reaches zero? Managers argue that they will
not actually reach zero and they will stop before they reach that
limit. But they do not tell anyone where to stop, when to stop or
how to stop. They just say, “Reduce operating expenses and
inventory!” The finite limit is zero.
What kind of organisation have you built when operating expense
is zero and inventory is zero?
There is no finite limit to increasing throughput, which is defined
as the rate at which money is generated by sales. Having raw
materials sitting in the yard waiting to be processed does not make
the manufacturer successful. Having products sitting in a
warehouse does not make an organisation profitable. Having
products sitting on the shelf in a retail store does not make the
retailer wealthy.
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them, or they can access it themselves from the retailers’ web sites.
Thus, all suppliers know the true demand and they can initiate
replenishment before the actual request filters through the supply
chain. This allows all suppliers, not just the first tier suppliers,
throughout the entire supply chain to prepare goods for despatch,
confident that replenishment is required.
The delivery process speeds up and suppliers have a better
understanding of true consumer demand.
Information about product movement (as recorded at the point of
sale), outside factors that affect demand (such as seasonal changes),
actual inventory levels, product receipts, and an acceptable agreed
safety stock level are integrated electronically.
Guide to markers: Students should discuss the two distinct parts
— the supply side and demand side and provide at least three
strategies that could overcome the problem.
Project management
Question 13
Discuss how a project manager should manage a project to meet
the various time, cost and quality constraints.
Answer
The role played by the project manager is critical to the success of
every project and it is not easy to find really good project managers
for every project. It certainly helps when the project manager has
an understanding and an appreciation of the technical aspects
associated with the project but the project manager does not have to
be an expert in the field. A project manager for a project assembled
to set up new information and communications technology, for
example, should have an appreciation of the strategic role
computers play in a business environment, but the manager does
not have to be a computer technician. The technical knowledge,
though, must be sufficient to be able to ask the right questions and
make the right decisions.
The project manager should be able to ask penetrating questions,
have credibility, sensitivity and the ability to handle stress.
Leadership and expertise in strategy are essential attributes for the
project manager. The leadership is necessary to provide direction,
motivation and help to all project team members and the strategy
expertise is required to gain the overall perspective of the business
need for the project.
A defining characteristic of the project manager is communication
and people skills displayed at all times. The project manager may
be dealing, at times, with a personal issue with one individual and,
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Performance measurement
Question 15
Discuss the four perspectives of the balanced scorecard approach
and outline how the balanced scorecard approach could be used for
performance measurement.
Answer
The balanced scorecard measures business performance from four
perspectives:
1. Customer
2. Internal
3. Innovation and learning
4. Financial.
1. Customer perspective
The customer perspective asks, “How do customers see us?”.
Organisations may have a strategic objective to add value to
customers, to satisfy customer needs, to listen to customer wants, to
allow customers to participate in process and product design and to
act and think from a customer’s viewpoint. This needs measuring.
This needs measuring from a customer perspective by asking
customers for their views.
2. Internal perspective
The customer perspective looks at the organisation from the outside
while the internal perspective looks at the organisation from the
inside and asks, “At what aspects of business should we excel?”.
Process design and improvement all occur internally and the results
affect customers.
Processes measured as part of the balanced scorecard have the most
impact on customer satisfaction. Clearly these affect lead time,
throughput time, employee skills and attitudes, flexibility,
availability, responsiveness and information systems.
3. Innovation and learning perspective
Innovation and learning perspective asks, “Can we continue to
improve and create value?”. Competitive activities constantly
challenge every organisation’s position. All other organisations
challenge the organisation at the top of the league. Even
organisations positioned somewhere in the middle have to face
constant challenges for their position. Customer expectations
constantly change and force organisations to be totally aware of the
range and scope of those changes.
4. Financial perspective
The financial perspective asks, “How do shareholders see us?”. In
the end it is the bottom line that counts. Firms can have any amount
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References
References
Gardiner, D. (2010). Operations Management for Business
Excellence (2nd ed.). North Shore, New Zealand: Pearson
Education.
Reading
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