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business
production and operations management

Questions and Answers of Production And Operations Management

10 Re-read the ‘Operations in practice’ example on ‘Bionic duckweed’. Under what circumstances would the criticism of ‘always waiting for the next breakthrough stopping you from taking
1 Using technology for staff surveillance is clearly a controversial issue. Re-read the ‘Operations in practice’ example that discusses using technology for surveillance.(a) Draw up a list of
2 Operations managers can have a profound influence on how organisations implement their human resource strategy (the overall long-term approach to ensuring that an organisation’s human resources
3 (It is recommended that you look at the supplement to this chapter before answering this question.)A hotel has two wings, an east wing and a west wing. Each wing has four ‘room-service
4 In the example above, one of the housekeepers in the west wing wants to job share with their partner, each working 3 hours per day. Their colleagues have agreed to support them and will guarantee
5 (This question is based on an original case study by Dr Ran Bhamra, Loughborough University.)Service Adhesives Ltd produces specialist adhesives. It has always been profitable, but there had been a
6 At W.L. Gore (that makes the high-performance Gore-Tex fabrics) few in the company have any formal job titles or job descriptions. There are no managers, only leaders and associates, people are
7 Among the first large organisation to take flexible working seriously in Europe was Lloyds TSB Banking Group (now called TSB Bank). It adopted flexible working because it was sensitive to the
8 Re-read the ‘Operations in practice’ example on Torchbox selling itself to its employees. What advantages does such a move have (a) for the employees, (b) for the original owners?
9 Many staff in retail operations spend most of their time interacting with customers, not all of whom are always polite. In fact, some can be abusive. How should such operations balance their
10 Some high customer contact jobs (such as police forces) have started requiring staff to wear ‘body cameras’ that record interactions with the public. What do you see as the advantages and
1 Mark Key is an events coordinator for a small company. Returning from his annual holiday in France, he is given six events to plan. He gives them the codes A–F. He needs to decide upon the
2 It is week 35 of a busy year at Ashby Architects and Jo Ashby is facing a big problem. Both her two junior partners have been diagnosed with a serious illness contracted on a trip to scope out a
3 It takes 6 hours for a contract laundry to wash, dry and press (in that order) a batch of overalls. It takes 3 hours to wash the batch, 2 hours to dry it and 1 hour to press it. Usually, each
4 Read the following descriptions of two cinemas:Kinepolis in Brussels is one the largest cinema complexes in the world, with 28 screens, a total of 8,000 seats, and four showings of each film every
5 Think through the following three brief examples. What type of control (according to Figure¦10.16)do you think they warrant?The Games Delivery Authority (GDA) was a public body responsible for
6 Re-read the ‘Operations in practice’ example ‘Operations control at Air France’. How do the planning and control tasks compare to those in a motor servicing garage?
7 Re-read the ‘Operations in practice’ example ‘Can airline passengers be sequenced?’. What problems could airlines face if they attempt to implement the Steffen method?
8 What might a Gantt chart for the mass production of chicken salad sandwiches look like?
9 If you had to make a case against the use of triage in sequencing the treatment of patients at an accident and emergency department in a hospital, what points would you make?
10 How does scheduling staff shift patterns differ from scheduling truck maintenance?
1 In March, a law firm predicted April demand for 360 client consultations. Actual April demand was 410. Using a smoothing constant chosen by management of a = 0.20, what is the forecast for May
2 The degree of effort (and cost) to devote to forecasting is often a source of heated debate within organisations. This often comes down to two opposing arguments. One goes something like
3 A German car manufacturer defines ‘utilisation’ as the ratio of actual output for a process to its design capacity, where design capacity is the capacity of a process as it is designed to
4 In a typical 7-day period, the planning department of the pizza company programs its ‘Pizzamatic’machine for 148 hours. It knows that changeovers and set-ups take 8 hours and breakdowns average
5 Seasonal demand is particularly important to the greetings card industry. Mother’s Day, Father’s Day, Halloween, Valentine’s Day and other occasions have all been promoted as times to send
6 A pizza company has a demand forecast for the next 12 months that is shown in the table below.The current workforce of 100 staff can produce 1,500 cases of pizzas per month.(a) P repare a
7 Revisit the ‘Operations in practice’ example, ‘3M’s COVID-19 surge capacity’. With reference to this and other operations that you are familiar with:(a) What are the main challenges in
8 Why do airlines often ‘overbook’ (sell more tickets than they have seats available) and what are the risks of doing so?
9 Re-examine the chocolate manufacturer’s demand shown in Figure¦11.14. Use this data to explore two alternative plans:Plan 1 – Produce at 8.7 tonnes per day for the first 124 days of the year,
10 If you were managing a small farm park that attracted visitors to observe farming exhibits, watch cows being milked, visit a farm shop and café, etc., how would you go about determining the
1 The COO of Super Cycles was considering her sourcing strategy. ‘I have two key questions, for each of our outsourced parts: what is the risk in the supply market, and what is the criticality of
2 A chain of women’s apparel retailers had all their products made by Lopez Industries, a small but high-quality garment manufacturer. They worked based on two seasons: Spring/Summer season and
3 The example of the bullwhip effect shown in Table¦12.4 shows how a simple 5 per cent reduction in demand at the end of supply chain causes fluctuations that increase in severity the further back
4 If you were the owner of a small local retail shop, what criteria would you use to select suppliers for the goods that you wish to stock in your shop? Visit two or three shops that are local to you
5 Many companies devise a policy on ethical sourcing, covering such things as workplace standards and business practices, health and safety conditions, human rights, legal systems, child labour,
6 Airline catering is a tough business. Meals must be of a quality that is appropriate for the class and type of flight, yet the airlines that are their customers are always looking to keep costs as
1 A supplier makes monthly shipments to ‘House & Garden Stores’, in average lot sizes of 200 coffee tables. The average demand for these items is 50 tables per week, and the lead time from the
2 A local shop has a relatively stable demand for tins of sweetcorn throughout the year, with an annual total of 1,400 tins. The cost of placing an order is estimated at £15 and the annual cost of
3 A fruit canning plant has a single line for three different fruit types. Demand for each type of tin is reasonably constant at 50,000 per month (a month has 160 production hours). The canning
4 ‘Our suppliers often offer better prices if we are willing to buy in larger quantities. This creates a pressure on us to hold higher levels of stock. Therefore, to find the best quantity to order
5 Most countries have blood collection and distribution services that collect from donors, process the blood by either breaking the blood down into its constituent parts or keeping it whole, and
6 Re-read the ‘Operations in practice’ example, ‘An inventory of energy’. It mentions the potential of battery storage of energy, but stresses the cost of this method. What do you think would
7 Re-read the ‘Operations in practice’ example, ‘Safety stocks for coffee and COVID’. List and comment on the differences between the two examples (coffee and COVID) described.
8 Inventory management systems should not only get order quantities and timing right, they also need to make sure that stocks are in the right place. One airline found this out when a shortage of
9 In the colder parts of the world (such as northern Europe and North America) where winter snow and ice can cause huge disruption to everyday life, local governments ‘grit’ the roads (actually
10 Two retail managers who had been at university together, Rosanne and Abeke, were having dinner together. ‘It’s such a coincidence that we both went into garment retailing’, said Rosanne,
1 Rolls-Royce is one of the world’s largest manufacturers of gas turbines. Their complex products typically have around 25,000 parts and hundreds of sub-assemblies, and their production is equally
2 SAP is a large European software company selling ERP systems. It is well known for developing a network of ‘business partners’ to develop new products, sell its ‘solutions’, implement them
3 Re-read the ‘Operations in practice’ example, ‘The ERP for a chicken salad sandwich’.The company on which this example is based found it difficult to implement its ERP system. ‘It was a
4 Re-read the ‘Operations in practice’ example, ‘It’s not that easy’. Why did things go wrong, specifically with the relationship between SAP and Waste Management?
5 (It is advised that you read the supplement to this chapter before attempting this question.) Your company has developed a simple, but amazingly effective mango peeler. It is constructed from a
6 A lunch kiosk serves two meals every day: veggie fritters and mushroom stroganoff, the recipes for which are as follows:Veggie fritters (serves 10) – Prepare the ‘veggie mix’ by grating 500 g
7 The nature of the product structure is closely related to the design of the product. This is reflected in the product structure shape. The shape is partly determined by the number of components and
9 Based on web searches, identify two examples of ‘successful’ ERP implementation, one from manufacturing and the other from a service or government organisation. Summarise the claimed benefits
1 Sophie was sick of her daily commute. ‘Why’, she thought, ‘should I have to spend so much time in the morning stuck in traffic listening to some babbling halfwit on the radio? We can work
2 ‘Everything we do can be broken down into a process’, said Lucile, COO of an outsourcing business for the ‘back-office’ functions of a range of companies. ‘It maybe more straightforward
3 Develop cause–effect diagrams for the following types of problems: Staff waiting too long for their calls to be answered by their IT helpdesk. Poor food in the company restaurant. Poor
4 For over 10 years, a hotel group had been developing self-managed improvement groups within its hotels. At one hotel reception desk, staff were concerned about the amount of time the reception desk
5 A transport services company provided a whole range of services to railway operators. Its reputation for quality was a valuable asset in its increasingly competitive market. ‘We are continually
6 Step 1 – As a group, identify a ‘high-visibility’ operation that you all are familiar with. This could be a type of quick-service restaurant, record stores, public transport systems,
7 There is an old saying that goes, ‘How do you learn to charm a snake? Answer – start with a slow, non-venomous snake. Then a slow, venomous snake. Then try a fast, non-venomous snake. Then a
8 The idea of ‘organisational ambidexterity’, described earlier sounds attractive. What do you think are the barriers to achieving it, and what could be done to overcome them?
9 ‘This coffee is terrible’, said Anita, the catering manager. ‘We have to look into it before we get even more complaints’. How might a cause–effect diagram be used to investigate the
10 Benchmarking can be used to learn from other types of operation. What could, for example, a supermarket learn, by studying an airport?
1 Define the concept of lean as it would apply to a hospital.
2 The Zucchero mail-order clothing company in Milan receives order forms, types in the customer details, checks the information provided from the customers and that the products are in stock,
3 Consider this record of an ordinary flight. ‘Breakfast was a little rushed but left the house at 6.15.Had to return a few minutes later, forgot my passport. Managed to find it and leave (again)
4 An insurance underwriting process consists of the following separate stages.What is the value-added percentage for the process? (Hint – use Little’s law to work out how long applications have
5 Examine the marking process of an assignment you are currently working on. What is the typical elapsed time between handing the assignment in and receiving it back with comments? How much of this
6 A production process is required to produce 980 of product X, 560 of product Y and 280 of product Z in a 4-week period. If the process works 7 hours per day and 5 days per week, devise a production
7 Examine the value-added versus non-value-added times for some other services. For example, posting a letter (the elapsed time is between posting the letter in the box and it being delivered to the
8 One physician, in an attempt to emphasise the need for civility, used the slogan, ‘Assholes kill people’.What did they mean by this?
9 Re-examine the ‘Operations in practice’ example, ‘The rise of the personal kanban’. Make your own‘kanban list’, as described in the example.
10 How might a creative business such as an advertising agency or film studio adopt lean principles?
1 Human error is a significant source of quality problems. Think through the times that you have (with hindsight) made an error and answer the following questions:(a) How do you think that human
2 The owner of a small wedding photography business realises that the market is changing. ‘I used to take a few photos during the wedding ceremony and then formal group shots outside. It rarely
3 Ryanair is the best-known budget airline in Europe, focusing on a popular routes and very low operating costs. For years, the airline’s policy on customer service was clear. It aimed to give the
4 Understanding type I and type II errors is essential for surgeons’ quality planning. For example, in the case of appendicitis, removal of the appendix is necessary because of the risk of its
5 ‘Tea and Sympathy’ (not a made-up name) was a British restaurant and café in the heart of New York’s West Village. It became fashionable not only with expatriate Brits but also with native
1 Although rare, air crashes do happen. Predominantly, the reason for this is human failure such as pilot fatigue. One kind of accident, which is known as ‘controlled flight into terrain’, where
2 Wyco is a leading international retailer selling clothing and accessories, with stores throughout the world. The countries from which it sources its products include Sri Lanka, Bangladesh, India
3 An Airbus A320 would not turn left no matter what the pilot tried. Eventually they made an emergency landing. Fortunately, no one was hurt. The cause of the near-disaster was that engineers had
4 A light bulb in the men’s lavatories of a firm finally burnt out when it was over 70 years old. It had survived bombs dropped in the Second World War that had devastated buildings in neighbouring
5 An automated sandwich-making machine in a food manufacturer’s factory has six major components, with individual reliabilities as shown in Table¦18.3.(a) What is the reliability of the whole
6 Every time we enter an elevator, we are trusting our lives to the people who designed, made and maintain it. Without effective maintenance, elevators would literally be death traps. Otis, the
7 Carlsberg, the brewing company, learned of its crisis late one Friday afternoon. Something appeared to have gone wrong with the ‘widget’ (the device which gives some canned beer its creamy
8 What risks does a technology such as the ‘Internet of Things’ (IoT) pose to all elements of a supply network?
9 How might climate change affect how operations managers view risk management?
10 ‘Your feedback is very important to us’, is something that businesses often tell their customers.(a) I s this always true?(b) Why do they do it?
1 Revisit the ‘Operations in practice’ example, ‘The risk of changing project scope – sinking the Vasa’, in this chapter.(a) Who should be held responsible for this disaster?(b) What can be
2 ‘Funding comes from a variety of sources; to restore the literally irreplaceable buildings we work on.We try to reconcile historical integrity with commercial viability and rely on the support of
3 Table 19.6 shows the activities, their durations and precedences for designing, writing and installing a bespoke computer database for a commercial bank headquartered in Singapore. Draw a network
4 The table shows the planned time and budget for a legal consulting project being developed for a client in Copenhagen, Denmark. Complete an earned value analysis (EVA) for the project, based at the
5 In the oil industry, project teams are increasingly using virtual reality and visualisation models of offshore structures that allow them to check out not only the original design but any
6 The idea of the ‘critical path’ is important in project planning. What different ideas might be meant by the word ‘critical’?
7 Re-read the ‘Operations in practice’ example, ‘“For the benefit of all” – NASA’s highs and lows’. How might an organisation like NASA view the trade-offs implied by the ‘iron
2. In a paint manufacturing unit, each type of paint is to be ground to a specified degree of fineness. The manufacturer uses the same ball mill for a variety of paints and after completion of each
1. A firm has to place orders for the supply of raw materials every 3 months. The raw materials are pro- cured from a supplier at periodic intervals. The annual requirements of the raw materials
8. What are the advantages of implementing ERP in MRP-I and MRP-II?

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