Task 1: Describe the orga
nisation and its operations
Se
lect an organisation of your choice and describe the its operations (approx. 1-2 pages).
This may including e.g.:
nature of its operations (manufacturing, non-manufacturing, or combination, et
c.),
type
of customers, market segments, method
of sales, after-sales service, et
c.,
o
rganisational size, locations, single or multi-site operati
ons,
type
of products and services
,
m
ethod of product/service creation
,
p
roduction, distribution, etc.
Task 2: Design the Operations
a)
For
the organisation you have chosen under Task 1, describe how to design a new product (or
service using) De Bono’s Six Hats Thinking model. Each hat should have at least 4 items on
it
(a
pprox. 1-2 page
s).
b)
Deve
lop a Design Review checklist consisting of
minimum 25 questions distributed evenly over
the
vari
ous aspects (minimum six different aspects)
of your new product (approx. 1-2 page
s).
Complete DR che
cklist by providing answers to the review questions and additional commen
ts.
Wr
ite a brief summary on the DR outcome (approx. half page)
.
c)
Con
struct a value stream map (VSM
) for the new product developed under section a) and b) usin
g a
MS Office
program. It should have a supplier at the one end and a customer at the other end, an
information flow with minimum one core activity, a mate
rial flow with at least five core activities, at
least three inventory locations. You should also enter the value added and non-value a
dded times
for al
l core activities and inventories, and determine the ratio of value added and non-value adde
d
times. (approx. 1-2
pag
es).
d)
As pa
rt of the VSM that you created earlier, pick at least four different waste forms and identify at
least two examples for each of the four waste forms (all together eight examples
).
De
termine at least one root cause for each waste example and recommend at least improvement
action for each of the root cause (all together eight root causes and eight improvement action
s).
(a
pprox. 1-2 pages).
Task 3: Manage the Operations
a)
De
velop a Supply Chain consisting of at least five elements/modules/functions for your product or
service. Describe specifically how these elements/modules work together to ensure a seamle
ss
sup
ply chain operation for your product or
service.
Gene
ric descriptions will not be accepted; they should be specifically related and relevant to yo
ur
pr
oduct or service (approx. 1-2 pa
ges).
b)
Determine
the Inventory Reorder Point (ROP), Safety Stock and Economic Order Quantity (E
OQ) for
you
r product or service based on the following parameters (approx. 1-2 page
s).
Demand
(D) per week = (pick a number t
hat is relevant to your assignment
)
Le
ad Time during replenishment (L/T) = a number between 1 and 4
weeks
Sta
ndard Deviation of demand during replenishment (SD) = 10
%.
Carryin
g cost (H) per week = a number between $0.50 and $3.00
Fixed cost of order (S) = a number between $5.00 and $20.00
Service Level = a number between 80% and 95
%
c)
For the process that you picked earlier for value stream mapping, construct a production (layou
t)
floo
r plan (with at least five core activities) usi
ng a MS Office program. Determine the location
of
eq
uipment, personnel, inventory, etc. as well as the
flow of materials/goods with their proper name
s.
(a
pprox 1-2 page
s).
d)
For your pro
duct, construct a JIT production flow
based on a Kanban Pull system. Label all th
e
ele
ments and activities within the layout, and
describe how the pull system works (approx 1 page)
.
e)
For o
ne of the production equipment, determine
its reliability based on a fictiti
ous MTBF and
calculate the proba
bility of a failure to occur afte
r a certain time of its intended operation ti
me
(a
pprox. 1-2 pages)
.
f)
For the
same equipment, calculate the OEE (which should be less than 85%) and de
termine at
lea
st five actions to improve its OEE (approx. 1-2 pages)
.
Task 4: Improve the Operations
a)
Pick a 2-step process that is relevant to your operations. Then assume a certain output for the step
1, and that you have produced a small number of defective items, say between 3-5% at step 1, an
d
b
etween 5-7% at step 2. For defects, assume a number that must be larger than the de
fective items
o
bserved at each step
.
No
w, determine the performance metrics Yield (defec
tive), RTY (defective), Yield (defect), and RTY
(defect) for this process, and provide a brief interpretation of the results (approx 1-2 pages).
b)
In one of the operational processes of your choice pick a particular problem. Identify its ro
ot
cau
se(s) by using the 5-Why methodology (apply at least 5 x Why). Determine a suitable action
to
e
liminate/reduce the root cause(s) (approx. 1 page
).
c)
Assume a fictitious constraint (bottleneck) in your operations. Describe what specific actions you
could take to overcome that constraint using the TOC’s Five Focusing Steps. You ca
n use the
he
adings of the Five Focusing Steps, but the actions (details under the headings) should be specif
ic
an
d relevant to your constraint (approx. 1 pag
e).