1. Identify and describe the five focused steps of the Theory of Constraints (TOC) approach. Briefly compare it to Lean ManufacturingorSix Sigma and provide any reasons why you might prefer one approach over the other. Use a Google search for a general understanding of Lean and Six Sigma, if you are unfamiliar with either of those approaches.

2. A wholesale grocery distribution system uses a two-step process to fill orders. Tomorrow's work willconsist of filling the seven orders shown below.

Time (hours)

Order Step 1 Step 2

A 1.20 1.40

B 0.90 1.30

C 2.00 0.80

D 1.70 1.50

E 1.60 1.80

F 2.20 1.75

G 1.30 1.40

(i) Using Johnson's rule, what is the job sequence that will minimize the time required to fill ALL the orders?

(ii) Based on your job sequence in (i) above, determine the total throughput time across all 7 orders, assuming that products that are completed in Step-1 must wait till Step-2 is available.

Note: Building a simple 2-Step Gantt chart may help visualize the process flow.

5. The following table contains information on four jobs waiting for processing at a work center (Note - The jobs are listed in the order of their arrival):

Job Job Time (days) Due Date (days)

A 14 20

B 10 16

C 7 15

D 6 17

(i) Determine job sequence for using each of the following rules: (1) FCFS, (2) SPT, (3) EDD, (4) LCFS, (5) STR

FCFS:

SPT:

EDD:

LCFS:

STR:

(ii) For each of the methods above, find the (1) average flow time and (2) average tardiness, and (iii) determine which approach is superior to others.

Note:

Job flow time = Time it takes from when job arrives (day 0 in this problem) until it is complete. Tardiness = Flow time - Due date (0 if negative).