Status and WIP of processes: Vendor Orders C - 3000 G - 1000

Kappa

Mu D - 1200

Pi E - 3000

Rho

Sigma

Financial Performance: Inventory Over Holding Time Cost Cost This week 0 Total 0
View Bill of Materials

0 0

View Decisions

Forecast Alpha

Forecast Beta

Initialise Game

Make / Alter Decisions

Inventory Position
9000 8000 7000 6000 5000 4000 3000 2000 1000 0

Current Week 21 Inventory Position: Product Alpha Beta Comma Delta Epsilon Fi Gamma

Current Inventory Work in progress Customer Orders

Late Delivery Penalty 0 0

View Decisions

Profit from Sales 0 0

Net Profit 0 0 << Your net result Slow

View Routing

Forecast Beta

MRP / CRP

Make / Alter Decisions

Simulate! Simulate!

Fast Animation Speed

Information

Day 1

View Model Details

Inventory Position: Current Work in Customer Inventory progress Orders 700 0 0 800 0 0 1200 3000 0 2500 1200 0 2500 3000 0 8500 0 0 900 1000 0

49

Demand Forecasting for Alpha

Main Screen
MRP

Forecast Beta

Clear Forecast

Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Demand 535 488 514 417 600 615 427 588 641 641 595 588 693 709 750 640 639 658 784 791

Forecast

Demand & Forecast

900 800 700 600 500 400 300 200 100 0 Weeks

Demand / Forecast

51 52 53 54 55 56 57 58 59 60 61 62

Clear Forecast

Demand & Forecast

Demand Forecast

Weeks

Demand Forecasting for Beta

Main Screen
MRP

Forecast Alpha

Clear Forecast

Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Demand 1005 930 978 1033 908 665 949 879 970 930 833 835 894 757 884 825 843 867 718 818

Forecast

Demand and Forecast

1200
Demand / Forecast

1000 800 600

400 200 0

Week

51 52 53 54 55 56 57 58 59 60 61 62

Demand and Forecast

Demand Forecast

Week

Master Production Schedule for Alpha and Beta Alpha Week Forecast Scheduled Receipts Projected on hand MPS for Alpha Planned Order Release
Past due

Current Week 21 22 500 23 24 25 26 27 28 29 30 31 32

Past

Safety stock = 21

Action Bucket

Beta Week Forecast Scheduled Receipts Projected on hand MPS for Beta Planned Order Release MRP for components

Past

Safety stock = 21

22

500 23

24

25

26

27

28

29

30

31

32

Forecast Alpha

Forecast Beta

Capacity Requirement Planning

Main Screen

Comma Week Gross requirements Scheduled receipts Projected on hand Planned Receipts Planned Order Release Delta Week Gross requirements Scheduled receipts Projected on hand Planned Receipts Planned Order Release Epsilon Week Gross requirements Scheduled receipts Projected on hand Planned Receipts Planned Order Release Fi Week Gross requirements Scheduled receipts Projected on hand Planned Receipts Planned Order Release Gamma Week Gross requirements Scheduled receipts Projected on hand Planned Receipts Planned Order Release

Past

Safety stock = 21

22

500 23

24

25

26

27

28

29

30

31

32

Past

Safety stock = 21

22

500 23

24

25

26

27

28

29

30

31

32

Past

Safety stock = 21

22

500 23

24

25

26

27

28

29

30

31

32

Past

Safety stock = 21

22

500 23

24

25

26

27

28

29

30

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32

Past

Safety stock = 21

22

500 23

24

25

26

27

28

29

30

31

32

Capacity Requirements Planning Average capacity needed, in hours Week Kappa Mu Pi Rho Sigma Past due 21

Back to MRP

Main Screen

22

23

24

25

26

27

28

29

30

31

32

Summary of order releases:

Alpha Beta Comma Delta Epsilon Fi Gamma Overtime: Kappa Mu Pi Rho Sigma

BILL OF MATERIALS

Alpha

Main Screen

View Routing

Comma

Delta

Epsilon

Fi

Fi

This is a "GOZINTO" diagram, showing what goes into what. It shows, for example, that to build one unit of Alpha you need two units of Comma, 1 unit of Delta, and 1 unit of Epsilon. By convention, the number of Fi 's for Epsilon shows how many Fi's (2) go into one unit of Epsilon, not how many Fi's are required to assemble Alpha or Beta.

ROUTINGS These drawings show the processes (shown in rectangular blocks) needed to build a finished product. The blocks show the machines, and the process time per product, including set up time. In the case of the purchased parts, it shows the lead time required by the vendor. It is important to remember that these are average times, and a variation up or down occurs in processing

Kappa 1.2 min

Rho 0.6 min

Alpha

Kappa 1.8 min

Rho 0.48 min

Beta

Purchased Material

Purchased Material Vendor lead time = 1220 min

Comma

Mu 0.6 min

Pi 0.3 min

Sigma 0.5 min

Sigma 0.8 min

Mu 0.5 min

Pi 0.6 min

Purchased Material Vendor lead time = 1440 min

Fi

Purchased Material Vendor lead time = 2000 min

Gamma

Main Screen

Beta

View Routing

Gamma

Delta

Epsilon

Fi

Fi

of Delta, and 1 unit of Epsilon.

ed product.

s in processing

View BOM

Main Screen

View BOM

Main Screen

Delta

Epsilon

Model

PRODUCTS Number of Products =

Main Screen

Products Initial inventory Alpha List of all parts 700 This inventory will be available at time = 0 Beta 800 Comma 1200 Delta 2500 Epsilon 2500 Fi 8500 Gamma 900

PROCESSES Number of work centers = Number of units 1 1 1 1 1 Time Between Failures

Name Kappa Mu Pi Rho Sigma

0 0 0 0 0

Repair Time Time in minutes 30 A TBF of zero signifies no breakdowns 15 20 25 100

Bill of Materials (Got to list all parts) If any item does not have components, it is a purchased part A purchased part has no need of processing for it to be finished Number of components Components Number off 3 Comma Delta Epsilon 0 3 Gamma Delta Epsilon 1 Fi 1 Fi 0 0

Product Alpha

2 1 1 1 1 2 2 1

Comma Beta

Epsilon Delta Fi Gamma

ROUTINGS Number of processes 2 2 3

Routing Alpha Beta Delta

Work Center 1 4 1 4 2 3 5

Process time

Units are minutes

1.2 All parts must be shown here, but order does not matter 0.6 Unit processing times for manufactured parts 1.8 0.48 0.6 0.3 0.5

Page 28

Model

Epsilon

5 2 3

Gamma Comma Fi

0 0 0

0.8 0.5 0.6 2000 1220 Number of processes = 0 for purchased parts 1440 Purchased part, shows lead time in minutes For purchased parts, process times show vendor lead times, not unit processing time

Customer Ordering process Number of products to be ordered = Pending Customer Orders Product Batch Size Date 2 Number of orders = 0

Work in Process Number of orders = Product Batch size Process Step Priority Delta 1200 1 2 Epsilon 3000 3 5

Pending Vendor Orders Product Gamma Comma Batch size 1000 3000 Remaining Time 500 600

Number of orders = Priority 2 5

Costs and Profits Over Time Penalty Inventory cost Profit

150 20 0.25 65

$/hour of overtime on any process $/unit/day when an order is late from the date of order $/unit/day for any product or work in process held at the factory, but not at the vendor $/unit for each product sold

Page 29

Model

here, but order does not matter

Page 30

Model

0 for purchased parts

ocess times show vendor lead times,

Main Screen

actory, but not at the vendor

Page 31

Order Releases (Got to list all parts) Current Item Inventory Order Release Priority Alpha 700 0 Beta 800 0 Comma 1200 0 Delta 2500 0 Epsilon 2500 0 Fi 8500 0 Gamma 900 0 Overtime hours Work Center Normal Hours Overtime Hrs Kappa 40 Mu 40 Pi 40 Rho 40 Sigma 40 Total 0 0 0 0 0

1 1 1 1 1 1 1

Items here must be in the same order as in the worksheet "Model" The higher the number the higher the priority If there is no order, enter 0

40 40 40 40 40

Overtime in hours All the machines must be listed in 1 to n order

Current work being processed at the factory Work in Process Product Batch size Process Step Priority Delta 1200 1 Epsilon 3000 3 Delta 1000 3

Pending orders from your customers Pending Customer Orders Product Batch Date, in days 2 Alpha 137 109 5 1

Main Screen

Your orders to vendors, still to be received Pending Vendor Orders Product Batch Comma 3000 Gamma 1000

INFORMATION In this game you play the role of the production planner of the Greek Manufacturing Company. Your job is to release orders to the factory workers and to your vendors. You do this once a week, at the beginning of a week. Once the orders are released, the factory swings into action (simulates a week). At the end of the week, a tally of costs and profits are calculated. The current inventory position, costs and profit/loss are then reported. You then release another order for the next week, and the cycle repeats. View the model to acquaint yourself with the particulars of the factory. You incur three kinds of costs: inventory holding costs for every item in the factory each day, over time costs per hour for each machine that you order to work over time, penalty costs for each product in the customer order for each day it is late. For every item sold, you receive a profit. Before you begin the game, you need to initialise the game. Then the game sequence is: Make decisions, Simulate, Make decisions, Simulate, and so on until the game is over. Then you may reinitialise and play again. You can visit the other worksheets to help you make decisions in between. You have two finished products (Alpha and Beta) to offer to your customers. These are made out of components, some of which are ordered from a vendor, the others are manufactured at your plant. See the bill of materials, and the routings. When the order from your customer (customer order) arrives, the orders are filled from available inventory. Unfilled orders are kept on file, and filled when the product is available. Orders may be filled partially. A penalty is charged for each day an ordered item is late. Once you have decided what to order for next week, press the Make / Alter Decisions button to enter your decisions. Please be aware that if you do not have the required comopnents for an order, the shop order will not be released until the components are available. For purchased components, there is no need of components. To help you decide the quantities of order releases, you may look at the past history of orders for the products.

You may create material requirements planning and capacity requirements planning worksheets to help you in your planning. At the end of the game, the net profit made by you is shown.

Main Screen

View the Model Details

View Bill of Materials

View Routing

Forecast Alpha

MRP / CRP