2. Read the case: Katz Carpeting, available in the Operations Management textboo
ID: 3880173 • Letter: 2
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2. Read the case: Katz Carpeting, available in the Operations Management textbook, Chapter 7. If production of standards and specials is separated, how different will JIT implementation be for production of the different products? Explain what would be needed in JIT implantation for both products. Use at least two unique references. Length: 4-5 paragraphs. 3. Describe the two aspects to implementing the six-sigma concept. Use at least two unique references. Length: 4-5 paragraphs 4. Describe the ten guidelines for selecting forecasting software. Use at least two unique references. Length: 4-5 paragraphs.Explanation / Answer
2) If production of standards and specials is separated, how different will JIT implementation be for production of the different products? Explain what would be needed in JIT implementation for both products.
Ans) JIT(Just- in-time systems ) beliefs in the elimination of waste, the ability of the employees to see , simple solutions, continuous improvement, visibility and flexibility. The three major elements of JIT are just-in-time manufacturing, total qualitymanagement (TQM) and respect for people. JIT implementation process consists of make quality improvements, reorganize the workplace, reduce setup times, reduce lot sizes and lead times, implement layout changes, switch to pull production and develop relationships with suppliers.
JIT implementation will not differ much for these two types of products. The main difference is the critical need of reducing setup times for the production of specials. To implement JIT for both products,first we have to make quality improvements -to produce the right number of products at the right time, without waste, we need to improve quality.Second, Reorganize the workplace- Improve the layout, cleanliness and organization of the environment.
Third,Set up time reduction-setup time does not generate income,so reduce set up time to allow flexibility in production, and reduce waste. we need short setup times in order to be able to justify production in small batches to be flexible. It is much more important to reduce the setup times for special products since these times are quit high.Fourth,Reduction of lot size and lead time-setup time reduction helps to reducelot size and lead time. Reducing the setup times and batch sizes cause the lead times to significantly decrease.
Fifth,Layout changes implementation-to improve the process, We should form line flows and create cells of these lines which leads implementation of laypout changes.Sixth, Switch to pull production- The customer orders pull the products through the production process.Last,develop relationships with suppliers- to develop relationships with suppliers in order to improve quality and receive frequent deliveries of raw materials.
Better knowledge of the size and timing of orders would allow them to plan operations more efficiently. As they are responsiblefor much of the ordering, they can better coordinate their operations with the order cycles. Order timing becomes the responsibility of the vendor. Quality should improve and deliveries should become more reliable. Through better coordination, the supplier’s costs should improve, which may eventually be reflected in their price.So, JIT uses frozen schedules for manufacturing for some period of time before allowing changes to improve efficiency.
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3) Desribe two aspects to implementing the Six Sigma concept.
Ans) Six Sigma is a measure of quality that strives for near perfection. Six Sigma is a disciplined, data-driven approach and methodology for eliminating defects in any process – from manufacturing to transactional and from product to service. Six Sigma describes quantitatively how a process is performing. To achieve Six Sigma, a process must not produce more than 3.4 defects per million opportunities. A Six Sigma defect is defined as anything outside of customer specifications. A Six Sigma opportunity is then the total quantity of chances for a defect.
There are two aspects to implementing the Six Sigma concept:-First aspect is, Use of technical tools to identify and eliminate causes of quality problems. In fact, Six Sigma relies heavily on quantitative and data-driven technical tools. These technical tools include the statistical quality control tools and also the problem- solving tools.Second aspect is, people involvement in Six Sigma, all employees have the training to use technical tools and are responsible for rooting out quality problems. Employees are given martial arts titles that reflect their skills in the Six Sigma process.
The fundamental objective of the Six Sigma methodology is the implementation of a measurement-based strategy that focuses on process improvement and variation reduction through the application of six sigma improvement projects. This is accomplished through the use of two Six Sigma sub-methodologies: DMAIC and DMADV. The Six Sigma DMAIC process is an improvement system for existing processes falling below specification and looking for incremental improvement. The Six Sigma DMADV process is an improvement system used to develop new processes or products at Six Sigma quality levels. It can also be employed if a current process requires more than just incremental improvement. Both Six Sigma processes are executed by Six Sigma Green Belts and Six Sigma Black Belts, and are overseen by Six Sigma Master Black Belts.
Instead of focusing on the individual tools, it is best when Six Sigma training provides a process-oriented approach that teaches practitioners a methodology to select the right tool, at the right time, for a predefined project. Some of the statistical and graphical tools commonly used in improvement projects are :- Defining a problem, improvement opportunity, or requirements(Project charter,value stream map…), Measuring process performance(process map,pareto chart..), Analyzing processes to determine root causes of variation, defects, or poor performance(root cause analysis,multi vari chart…etc), Improving process performance by addressing root causes(kaizen event…) and for Controlling the improved process and future performance(control plan,mistake proofing…).
Six Sigma has proven itself as an effective strategy for business success in both private and public sectors. The methodology has helped enterprise leaders recognize business processes as engines that drive performance excellence and help to deliver value. Lean Six Sigma offers a comprehensible road map, tools, and techniques for achieving superior performance. Six Sigma’s effectiveness is a measurement-based approach to managing and continually improving the contribution of another powerful driver of process performance: people. Have strong and unwavering support from top leadership,develop a quality-focused culture and effectively manage their people’s contribution to performance is one of the basic aspects in six sigma.
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4) gudelines for selecting forecasting software
Ans)
Forecasting is a decision-making tool used by many businesses to help in budgeting, planning, and estimating future growth. In the simplest terms, forecasting is the attempt to predict future outcomes based on past events and management insight.
Guidelines for Selecting Software are :-
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