EBK OPERATIONS MANAGEMENT
EBK OPERATIONS MANAGEMENT
12th Edition
ISBN: 8220100283963
Author: Stevenson
Publisher: YUZU
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Chapter 2, Problem 2.3CQ
Summary Introduction

Introduction:

A baking company situated in New York employs fewer than 200 blue collar employees which has informal atmosphere. The company produces soft cookies over 50 varieties. The company has niche segment of customers promising high quality biscuits. Most of the patrons are over the age of 45 and prefer soft and non-sugary cookies.

The production process begins as soon as the management gets the order from its distributors. The production follows batch processing system. The list of cookies to be made is fed into the system by the personnel in charge and the system evaluates the quantity of ingredients to be mixed. The process is followed by a giant machine where additional products are mixed, baked, cooled and tested to check the quality. Finally the cookies are boxed and labeled automatically.

The manufactured cookies are shipped instantaneously due to the perishable nature. The cookies are tested for its quality by a testing inspector. X-ray test is also done to detect the existence of any foreign materials inside the cookies.

The company takes extra care to reduce the scrap formation and gets inputs from its customer for further potential developments.

To determine: The rightness behind the decision of not implementing automation in packing the cookies and reason behind it. Does Company have any obligations towards its employees and to its community and the size is taken as a factor for consideration? Whether there is a difference when the company is situated in a large city and the size of the company matters? The change in decision if the company size is much larger?

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The S&OP team at Kansas Furniture, led by David Angelow, has received estimates of demand requirements as shown in the table. Assuming one-time stockout costs for lost sales of $125 per unit, inventory carrying costs of $30 per unit per month, and zero beginning and ending inventory, evaluate the following plan on an incremental cost basis: Plan B: Vary the workforce to produce the prior month's demand. Demand was 1,300 units in June. The cost of hiring additional workers is $35 per unit produced. The cost of layoffs is $60 per unit cut back. (Enter all responses as whole numbers.) Note: Both hiring and layoff costs are incurred in the month of the change (i.e., going from production of 1,300 in July to 1300 in August requires a layoff (and related costs) of 0 units in August). Hire Month 1 July Demand 1300 Production (Units) Layoff (Units) Ending Inventory Stockouts (Units) 2 August 1150 3 September 1100 4 October 1600 5 November 1900 6 December 1900
The S&OP team at Kansas Furniture, led by David Angelow, has received estimates of demand requirements as shown in the table. Assuming one-time stockout costs for lost sales of $100 per unit, inventory carrying costs of $20 per unit per month, and zero beginning and ending inventory, evaluate the following plan on an incremental cost basis: Plan A: Produce at a steady rate (equal to minimum requirements) of 1,100 units per month and subcontract additional units at a $65 per unit premium cost. Subcontracting capacity is limited to 800 units per month. (Enter all responses as whole numbers). Ending Month Demand Production Inventory Subcontract (Units) 1 July 1300 1,100 0 2 August 1150 1,100 0 3 September 1100 1,100 0 4 October 1600 1,100 0 5 November 1900 1,100 0 6 December 1200 1,100 0
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