repharse the two given assignments,

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Assignment Five Assignment Five – Flowchart, Takt time and SCM These six questions are related to creating flowchart value stream mapping, calculating Takt time, explaining Kaizen, and supply chain management. You will answer the following questions and show the details of your calculation with analysis. Classroom delivery: Submit your assignment (paper copy) in the classroom. See the due date in the Course Schedule. Online delivery: post your assignment under Discussion Board, forum “Assignment Five” See the due date in the Course Schedule. Question 1 WP uniforms provides a selection of lab coats, shirts, trousers, uniforms, and outfits for area businesses. For a fee, WP uniforms will collect soiled garments once a week, wash and repair these garments, and return them the following week while picking up a new batch of soiled garments. At WP uniforms, shirts are laundered in large batches. From the laundry, these shirts are inspected, repaired, and sorted. To determine whether the process can be done more effectively, the employees stormed the following steps and placed them in order. Create a flowchart with their information. Remember to use symbols appropriately. Shirts arrive from laundry. Pull shirt from racks Remove shirts from hangers. Inspect. Ask: does shirt have holes or other damage? Make note of repair needs. Ask: is shirt beyond cost-effective repair? Discard shirt if badly damaged. Sort according to size. Fold shirt, place in proper storage area. Make hourly count. Question 2 Calculate the takt time for a company that works two 8-hour shifts per day. Each shift receives 30 minutes for a mid-shift meal and two 15-minute breaks. The customer would like to receive 25 generators per day. Question3 Calculate the takt time for the one hour of provided system data? A. B. C. D. 5 minutes 1.8 minutes 3 minutes 2 minutes A. B. C. D. Question 4 If a customer needs 280 items per day and a company operates 7 hours a day, what must be the operational takt time? 0.25 minutes/item 3.334 items/minute 40 items/hour 1.5 minutes/item Question 5 Describe the Kaizen concept and list the steps for a Kaizen project. Question 6 Why does logistics play a key role in supply chain management? From a firm you have visited or worked with or from your research, describe the logistics activities and supply chain activities there, including who is involved and what they provide. ********************************** Assignment 4 - Performance Measures Answer the following questions and show the details of your calculation. 1.There are four specific types of quality costs. Clearly define and give an example of each quality cost category. 2.A lamp manufacturing company has incurred the following quality costs. Analyze how this company is doing on the basis of these costs. Creating a graph of the values may help you see trends. Values given are in percentage of total cost of lamp. Costs Year Prevention Appraisal Internal External Failure Failure 1 1.2 3.6 4.7 5.7 2 1.6 3.5 4.3 4.6 3 2.2 3.8 4.0 3.8 4 2.5 2.7 3.5 2.2 5 3.0 2.0 2.8 0.9 3. Create a set of measures based on the Balanced Scorecard and the Lean Six Sigma Tools at Work feature Indicators or Measures of Performance for a fast-food restaurant. 4. What are the components of an effective project proposal? 5. What differentiates a Gantt chart from a PERT chart from a CPM? 6. A local bank is keeping track of the different reasons people phone the bank. Those answering the phones place a mark on their check sheet in the rows most representative of the customers’ questions. Given the following check sheet, make a Pareto diagram: Credit card payment questions 245 Transfer call to another department 145 Balance questions 377 Payment receipt questions 57 Finance charge questions 30 Other 341 7. Create cause-and-effect diagram for (a) a long line at the fast food restaurant, and (b) a car that won’t start. Online Delivery: Post your assignment under Discussion Board, forum “Assignment ThreePerformance Measures” as a file attachement, see due date in the Course Schedule. If you used your hand writing and drawing, you can drop your paper copy at my mailbox, office TRG 318D. Running header : PERFORMANCE MEASURES Assignment 3 : PERFORMANCE MEASURES Tanvi Bidwai 700673545 Lean and Quality management IndM 4230 Instructor : Mr.Willian Ford University of Central Missouri 1 PROCESS IMPROVEMENT 2 1.There are four specific types of quality costs. Clearly define and give an example of each quality cost category. Answer : Types of Quality costs  Prevention costs : Prevention costs are those costs that occur when a company is performing activities designed to prevent poor quality in products or services (Summers,2011,p.49). Example of this could be Quality circles which consist of small groups of employees who meet on a regular basis to discuss ways to improve quality.  Appraisal costs : Appraisal costs are the costs associated with measuring, evaluating, or auditing products or services to make sure that they conform to specifications or requirements (Summers,2011,p.50). For example,there are food tasters in many food industries who get paid to just taste the food.This is done so the final product meets the customer satisfaction.This is where the appraisal costs arise.This cost can be avoided once the company reaches to a higher level.  Failure costs : Failure costs occur when the completed product or service does not conform to customer requirements (Summers,2011,p.50). This include two types1.Internal failure costs : These are those costs associated with product nonconformities or service failures found before the product is shipped or the service is provided to the customers (Summers,2011,p.50). PROCESS IMPROVEMENT 3 Examples are if any product gets damaged while manufacturing, that thing goes in scrap and we have to rework on that which costs money. 2.External failure costs : These costs are the costs that occur when a nonconforming product or service reaches the customer (Summers,2011,p.50). One example would be of a product or service which gets damaged while shipping and customer returns it back it causes shipping charges.  Intangible costs : Intangible costs,the hidden costs associated with providing a nonconforming product or service to a customer, involve the company’s image (Summers,2011,p.50). Examples - Company image, Customer dissatisfaction, Lost sales, Customer time loss. 2.A lamp manufacturing company has incurred the following quality costs. Analyze how this company is doing on the basis of these costs. Creating a graph of the values may help you see trends. Values given are in percentage of total cost of lamp. Costs Answer : Year Prevention Appraisal 1 2 3 4 5 1.2 1.6 2.2 2.5 3.0 3.6 3.5 3.8 2.7 2.0 Internal Failure 4.7 4.3 4.0 3.5 2.8 External Failure 5.7 4.6 3.8 2.2 0.9 PROCESS IMPROVEMENT 4 6 5 4 3 2 1 0 1 2 Prevention 3 Appraisal 4 Internal failure 5 External failure We can see from the graph,that the overall performance of the lamp manufacturing company is good.Except for the prevention cost all other three costs (Appraisal, External failure, Internal failure) have decreased over years,whereas prevention cost has been increasing (ASQ, n.d.). 3. Create a set of measures based on the Balanced Scorecard and the Lean Six Sigma Tools at Work feature Indicators or Measures of Performance for a fast-food restaurant. Answer : (Summers,2011,p.63) Customer measures: Results measures: Overall customer satisfaction (KPOV) Market share (KPOV) -number of customers PROCESS IMPROVEMENT 5 -number of repeat customers -number of new customers Process measures: Changes in customer requirements versus Changes in processes to serve customers (KPIV) Improvements to processes critical to serving customers Financial measures: Results measures: Cost per food item (KPOV) Profitability (KPOV) Return on Investment (KPOV) Process measures: Cost avoidance (safety, hygiene) (KPIV) Internal measures: Results measures: Improvements in hours paid versus Amount of food served (KPIV) Process measures: Improvements in order turn-around time (KPIV) (Cycle time reduction/removal of non-value-added activities) Improvements in first time through quality (KPIV) (Reduction in rework/scrap) Learning and Growth measures: Results measures: Improvements in employee retention (KPIV) Process measures: Progress toward cross-training goals for critical processes as identified by customers (KPIV) PROCESS IMPROVEMENT 6 4. What are the components of an effective project proposal? Answer : An effective project proposal provides readers with insight into what needs to be accomplished and how it will get accomplished. Through the use of clearly stated mission, deliverables, goals and objectives associated with the project, proposals sell the project. As an introduction, proposals provide background information about the need for the project. They contain a description or overview of the expectations of the project, including details about the technical aspects of the project. Essential tasks are outlined and delineated. A thorough project proposal will contain information concerning financial requirements, time constraints, and administrative and logistical support for the project. In the proposal there is usually information about the key individuals associated with the project, including the identify of the project manager. Basic areas of performance responsibility are assigned. Tentative schedules and budgets are established. The project proposal creates a general understanding of: -what is needed, -what is going to be done, -why it is going to be done, -who is going to do it, -when it will be done, -where it will be done, -how it will be done? (Summers,2011,p.70) PROCESS IMPROVEMENT 7 5.What differentiates a Gantt chart from a PERT chart from a CPM? Answer : A PERT chart improves upon a Gantt chart by showing the relationships between tasks.Unlike the Gantt chart, which is a list of tasks, the PERT chart enables the project to be viewed as an integrated whole.CPM builds on PERT by adding the concept of cost per unit time.CPM gets its name from the ability to determine the longest series of interrelated events that must be completed in a project, a critical path (M, E., 2011). 6. A local bank is keeping track of the different reason people phone the bank. Those answering the phones place a mark on their check sheet in the rows most representative of the customers’ questions. Given the following check sheet, make a Pareto diagram: Credit card payment questions Transfer call to another department Balance questions Payment receipt questions Finance charge questions Other Answer : (ASQ, n.d.) 245 145 377 57 30 341 PROCESS IMPROVEMENT 8 no. of times 400 350 300 250 200 150 100 50 0 A B A : Balance questions C B : Other D : Transfer call to another department D E F C : Credit card payment questions E : Payment receipt questions F : Finance charge questions 7. Create cause-and-effect diagram for (a) a long line at the fast food restaurant, (b) a car that won’t start (a) A long line at restaurant (ASQ, n.d.) PROCESS IMPROVEMENT (b) Car won’t start (ASQ, n.d.) 9 PROCESS IMPROVEMENT 10 References ASQ (n.d.) Cause-Analysis-tools. Retrieved from http://asq.org/learn-aboutquality/cause-analysis-tools/overview/overview.html M, E. (October 27, 2011). Difference between CPM and PERT. Retrieved from http://www. differencebetween.net/business/management-business/difference-between-cpm-andpert/ Summers, D.C.S. (2011). Lean six sigma: Process improvement tools and techniques. Upper Saddle River, NJ: Pearson Education, Inc. INDM 4230 – LEAN QUALITY MANAGEMENT BABALOLA DOLAPO ABIMBO ASSIGNMENT 5 1 START Question 1 SHIRT ARRIVE FROM LAUNDRY PULL SHIRTS FROM RACKS REMOVE SHIRT FROM HANGERS INSPECT HOLES OR OTHER DAMAGE YES REPAIR NEEDS YES NO SORT ACCORDING TO SIZE FOLD SHIRTS STOR AGE MAKE HOURLY COUNT COST EFFECTI VE YES NO DISCARD SHIRT INDM 4230 – LEAN QUALITY MANAGEMENT BABALOLA DOLAPO ABIMBO ASSIGNMENT 5 2 Question2 Calculate the takt time for a company that works two 8-hour shifts per day. Each shift receives 30 minutes for a mid-shift meal and two 15-minute breaks. The customer would like to receive 25 generators per day. Takt time = Available working time per day Customer demand rate per day Working time per shift in minutes = 480 minutes Available working time for a shift= 420 minutes Customer demand per day = 25 generators per day Takt time = 420 minutes per day = 16.8 minutes 25 per day A generator must be produced every 16. 8 minutes I assumed that since both shift are evenly shared, i.e has the same duration of available working hours and break time, the takt time in shift A will also the takt time in shift B. Since, there won’t be a need to adjust the available working time except if demand in shift B changes or shift time increases or decreases, which in this case is constant for both shifts. Question 3 Calculate the takt time for the one hour of provided system data? Demand rate = 30 units/per hr Available working time = 1hr = 60min Takt time = Available working time per day Customer demand rate per day Takt time/ Customer demand rate = 60 min per hour 30 units per hour = 2minutes/ units (D) a) 5 minutes b) 1.8 minutes c) 3 minutes d) 2 minutes INDM 4230 – LEAN QUALITY MANAGEMENT BABALOLA DOLAPO ABIMBO ASSIGNMENT 5 3 Question4 If a customer needs 280 items per day and a company operates 7 hours a day, what must be the operational takt time? A. B. C. D. 0.25 minutes/item 3.334 items/minute 40 items/hour 1.5 minutes/item Operational takt time = Available working time per day Customer demand rate per day Available working time = 420 minutes Customer items per day = 280 items per day = 420 minutes per day 280 items per day = 1.5 minutes/ Item (D) Question 5 Describe the Kaizen concept and list the steps for a Kaizen project. As explained by Summers (2011), Kaizen is the combination of two words. Kai, which means little, ongoing and good and Zen, which means better and good in Japanese. The Kaizen concept seeks to standardize process while eliminating waste. It is based on improving the work activities in a work area, while it seeks to improve processes, improve quality, reduce costs, increase productivity, safety and customer service. Kaizen like continuous improvement, refers to small incremental improvements that can be completed rapid often in one week or less. The kaizen team usually consists of people closest to the problem, who have been pulled from their regular work to focus immensely on solving a problem related to standardize problem and elimination of waste. The steps for a kaizen project are: • • • • Begin by identifying that a problem such as defects, waste, or a process that is not working effectively Generate improvement ideas for the problem identified Review this improvement ideas with Management Select and implement the effective improvement solution – e.g use of 5S activities INDM 4230 – LEAN QUALITY MANAGEMENT BABALOLA DOLAPO ABIMBO ASSIGNMENT 5 4 Question 6 Why does logistics play a key role in supply chain management? From a firm you have visited or worked with or from your research, describe the logistics activities and supply chain activities there, including who is involved and what they provide. Logistics play an important role in supply chain management because its influences customer’s overall satisfaction, because the aim of every business is make sure customer demands are met on time and when needed. An inefficient logistic network can terribly influence the rate at which customers demand is met. According to Summers (2011), Logistics is the process of determining the best methods of procuring, maintaining, packaging, transporting, and sorting materials and personnel to satisfy customers demand. I will be describing the logistic activities of United Parcel Service (UPS), a service company. United Parcel Service or UPS was founded in 1907, Seattle, Washington, USA as a parcel delivery company setting Louisville, Kentucky as its strategic main hub while setting the hubs around the world and operating center around those hubs. More locations and next-day ground delivery occurred routinely among all operating center area. UPS drivers collect the package from the customer; sort at the local center and deliver to a nearby airport. UPS aircraft served as ‘feeder’ vehicles contains packages together with documents to hundreds of locations, with specific truckload arrives in the airplane destination service area. (Kah Ling, 2009, p. 26) UPS operates using a hub-and-spoke model for its network. First, a package gets picked up by the truck and get delivered to a local UPS center, where it’s sorted into ground or air services. If it’s ground, the parcel is sent to the closest hub, shipped to the destination hub (often via rail), and then out to a local center. If it’s air, the package is sent to a “gateway” facility at the airport, shipped to a national hub—like the World Hub in Louisville, Kentucky—then sent from there to another airport and out to the local center. At that point, regardless of whether it was ground or air, the parcel is loaded onto a truck and delivered to the final destination. (Jennings, 2016) Below is a picture representation of UPS network, INDM 4230 – LEAN QUALITY MANAGEMENT BABALOLA DOLAPO ABIMBO ASSIGNMENT 5 Image Source: http://idrivelogistics.com/fedex-vs-ups-part-3-differences-between-networks/ 5 INDM 4230 – LEAN QUALITY MANAGEMENT BABALOLA DOLAPO ABIMBO ASSIGNMENT 5 References Jennings, A. (2016). FedEx vs. UPS: part 3 -Diffrences between networks. Retrieved from http://idrivelogistics.com/fedex-vs-ups-part-3-differences-between-networks/ Kah Ling, T. &. (2009). The analysis and case studies of successful express logistics companies. International Journal of Value Chain Management, Vol 3, pp 26. Summers, D.C.S (2011). Lean six sigma: Process tools and techniques (2nd ed.). Upper Saddle River, NJ: Pearson Education, Inc. 6
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Explanation & Answer

Attached.

INDM 4230 – LEAN QUALITY MANAGEMENT
BABALOLA DOLAPO ABIMBO
ASSIGNMENT 5

1

START

Question 1
SHIRT ARRIVE
FROM LAUNDRY

PULL SHIRTS
FROM RACKS

REMOVE SHIRT
FROM HANGERS

INSPECT

HOLES
OR
OTHER
DAMAGE

REPAIR NEEDS

YES

COST
EFFECTI
VE

NO

YES

NO
SORT ACCORDING
TO SIZE

DISCARD
SHIRT

YES

FOLD SHIRTS

INDM 4230 – LEAN QUALITY MANAGEMENT
BABALOLA DOLAPO ABIMBO
ASSIGNMENT 5

2

STOR
AGE

MAKE HOURLY
COUNT

Question2
Takt time = Available working time per day
Customer demand rate per day
Working time per shift in minutes = 480 minutes
Available working time for a shift= 420 minutes
Customer demand per day = 25 generators per day
Takt time = 420 minutes per day = 16.8 minutes
25 per day
A generator must be produced every 16. 8 minutes
In this case the assumption is that both shift are shared and thus the duration they work and break
are the same. With this shift A and B. with this the calculations must be based on common
denominator.
Question 3
Demand rate = 30 units/per hr
Available working time = 1hr = 60min
Takt time = Available working time per day
Customer demand rate per day
Takt time/ Customer demand rate = 60 min per hour
30 units per hour
= 2minutes/ units (D)
Question4
Operational takt time = Available working time per day
Customer demand rate per day
Available working time = 420 minutes

INDM 4230 – LEAN QUALITY MANAGEMENT
BABALOLA DOLAPO ABIMBO
ASSIGNMENT 5

3

Customer items per day = 280 items per day
= 420 minutes per day
280 items per day
= 1.5 minutes/ Item (D)

Question 5
Kaizen concept
The concept is based on the need to standardize process will eliminating the waste from the
process. The idea is to improve the work activities in the working areas which emphasis on element
such as improving the quality and also reducing the cost among others. Kaizen team is developed
by those who are very close to the problem. The team is developed with the need to create a unit
that can be used to deal with the coming situation. By the end the team must standardize the issue
at hand and deliver the solution.
Steps
1.
2.
3.
4.

Problem identification
Generating idea of improving the defect
Reviewing the ideas suggested.
Selecting and implement the most effective improvement solution.

Question 6
Role of logistics in supply chain management.
When looking at logistics through the lens of the supply chain management they are vital in
influencing the customer’s satisfaction as it is the aim of every business to meet customers demand
on time. Logistics influence when the customers’ demands are met at the end. With this if logistics
are not well sort within the organization they can lead to its final collapse.
The united parcel service which is a company tasked with delivering the parcel is company that
works around the globe and has realized the importance of logistics with its numerous locations it
has to deliver the parcel on timely manner. The UPS work by making the drivers collect the
package from the customer they sort the package and deliver them to nearest airport for shipment.
To do this the UPS carrier vehicles are feed with documents from all locations so that each delivery
point is known.

INDM 4230 – LEAN QUALITY MANAGEMENT
BABALOLA DOLAPO ABIMBO
ASSIGNMENT 5

4

The UPS operation are based on the hub and spoke mode of networking. Where the deriver collects
the package second is delivering in UPS center where sorting takes place. The package is sent to
the nearest hub and shipped to the destination to a local center. If it is by the air the parcel is sent
to gateway at the airport for shipping in the national hub. With the model all th...


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