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Part 1 Introduction
1
Introduction to Operations Management..........................................................................1
2
Competitiveness, Strategy, and Productivity....................................................................7
Part II Forecasting
3
Forecasting......................................................................................................................14
Part III System Design
4
Product and Service Design............................................................................................47
4S Reliability................................................................................................................53
5
Capacity Planning...........................................................................................................59
5S Decision Theory......................................................................................................66
6
Process Selection and Facility Layout............................................................................77
6S Linear Programming..............................................................................................102
7
Design of Work Systems..............................................................................................121
7S Learning Curves....................................................................................................127
8
Location Planning and Analysis...................................................................................143
8S The Transportation Model.....................................................................................162
Part IV Quality
9
Introduction to Quality.................................................................................................170
10
Quality Control.............................................................................................................175
10S Acceptance Sampling..........................................................................................190
11
TQM and Quality Tools................................................................................................195
Part V Supply Chain Management
12
Supply Chain Management..........................................................................................206
12S Purchasing and Supplier Management................................................................211
13
Inventory Management.................................................................................................215
14
Aggregate Planning......................................................................................................239
15
MRP and ERP...............................................................................................................259
16
Just-In-Time Systems...................................................................................................291
16S Maintenance........................................................................................................295
17
Scheduling....................................................................................................................298
Part VI Project Management
18
Project Management.....................................................................................................313
Part VII Waiting Lines and Simulation
19
Waiting Lines................................................................................................................332
19S Simulation...........................................................................................................343
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PREFACE
This Instructor's Manual accompanies Operations Management, 2nd Canadian edition, by William J.
Stevenson and Mehran Hojati. The Instructor's Manual has two main partsReferences, and Teaching
Notes and Solutions.
References
Excel Templates.
This part provides a brief description of how to use the Excel templates and contains chapter-by-chapter
listings of Excel templates.
Video Guide.
This section includes brief summaries of the McGraw-Hill/Irwin OM video series. These videotape
segments consist of plant tours and "real world" operations management problems or issues and
recommended solutions. These videos provide an effective way of demonstrating how companies use the
techniques and methods covered in the textbook to tackle real problems.
Using PageOut
PageOut is a McGraw-Hill custom course Web site development tool that allows you to create and post
your own personal Web site, complete with URL, to give to your students. It can be used free with the
adoption of any McGraw-Hill textbook. Your McGraw-Hill rep can set you up with a User ID and
Password. The PageOut Web site provides additional information and a demo. This section of the
Instructors Manual explains how to download this Instructors Manual from the text Web site for use
with PageOut.
Solutions
This is the main section of the instructor's manual. For each chapter and supplement in the textbook, this
section provides the instructor with teaching notes, answers to discussion and review questions, suggested
answers for memo writing exercises, solutions to problems, answers to questions in readings and
solutions to cases. In addition, selected chapters will contain enrichment modules designed to enhance the
coverage of material. Heres a brief overview.
Teaching Notes: This section will provide a short description of the purpose of the chapter, highlight the
important concepts of the chapter and/or indicate how to use the chapter.
Answers to Discussion and Review Questions: This section contains answers to each of the discussion
and review questions given at the end of each chapter. The answers are designed to be correct and
thorough. The questions cover the key points contained in the chapter and can be assigned either as
homework or as examination questions.
Answers to Memo Writing Exercises: The content of these exercises is similar to the content of the
discussion and review questions. Due to the limitation of space, the answers are not given in the form of
memorandums. However, the content of the answer, though concise, is accurate.
Solutions to Problems: All of the quantitative chapters include numerical end-of-chapter problems. The
textbook contains a rich variety of problems of different lengths and difficulty levels. There is at least one
problem and often multiple problems for each quantitative method or technique covered. Many of the
solutions include graphical output to clarify the results. These problems are appropriate for both
homework and examination purposes.
Solutions/Answers to Case Problems: The length and difficulty of the cases as well as the length of the
solutions/answers varies. Some of the cases require quantitative solutions, others only require a
qualitative answer and some have both quantitative and qualitative components. However, the solutions
and answers are designed to be thorough.
Answers to Questions for Readings: There are many current "readings" that are used to place the topic in
the context of an actual business setting. These "readings" should assist you in demonstrating the
relevance of a topical area to students as well as the application of the methods covered in the textbook.
Complete answers are given to all questions provided at the end of some of the readings.
Enrichment Modules: Due to the space limitations or other considerations, certain topics are not covered
in the textbook. However, an explanation of these selected topics, related exercises, problems and their
complete solutions are provided in several of the enrichment modules to give you additional topical
flexibility and to provide depth or breath to the coverage of the material in various chapters. Some of
these enrichment modules are included as part of the CD-ROM while others are included only as part of
the Instructor's Manual.
It is hoped that instructors who are teaching an introductory course in operations management will find
this manual a useful supplement to the textbook.
Mehran Hojati
University of Saskatchewan
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EXCEL TEMPLATES
Student and Instructor CDs contain templates and copies of the examples and solved problems from the
textbook. The electronic version of this manual also contains embedded Excel worksheets of the solutions
to some of the problems from the end of some chapters. You may copy the worksheet to Excel or doubleclick to use the embedded version. The templates on the CD use macros (working like black boxes) and
can be used if your class has limited skill in setting up and manipulating Excel worksheets.
If you have a computer and projector in the classroom, you may want to use the templates to help
demonstrate the methods during your lectures. Excel facilitates "what if analysis (e.g. see what happens
to the Exponential smoothing forecast when you change the smoothing constant alpha). Most of the
templates have graphs to visually help the students understand the problems. The templates and graphs
are of course "live," that is they contain formulas and immediately recalculate the effect of your changes.
Once students have become accustomed to using the templates, they should be able to solve more
problems in less time, and hopefully gain a greater understanding of the problems by viewing the
templates as they solve the problems. You should encourage the students to investigate and understand the
solutions presented by the templates. In fact, most templates require active participation by the student in
reaching the solution. However, you may consider that some templates do too much of the work" and
you may want to use these templates as a key and require students to either solve the problems by hand or
with their own spreadsheet solution. Or you may want to go beyond the problem and investigate
sensitivity analysis (spreadsheets are very good at that) or other "finer points" of the problem. You may
also want to assign more difficult problems because the templates generally relieve the student from the
long and tedious calculations. The templates should help the students appreciate the power of
spreadsheets while solving the problems.
Using the Templates on the CD
The templates on the CD are contained in Excel workbooks, one workbook for each chapter or chapter
supplement (e.g. Chap8S.xlt contains the templates for the Supplement to Chapter 8). To use a specific
template, open the workbook for the appropriate chapter and select the template in the index (first
worksheet) or on the worksheet tab (at the bottom of the Excel screen).
Entering Data
Enter data only in cells which are shaded like the cell to the right.
Input Area
You may enter formulas with an equal sign (e.g. =5*.243/12 or =H3).
Deleting Data
To remove data from shaded cells, select the cell(s) and press delete, do not enter a space or zero because
many templates will distinguish between a blank cell and a cell containing the space character or zero.
Copying Data
If you copy data to put it into the input (i.e. shaded) area of a template, be sure to use the Excel edit
command Paste Special Values. Do not use the Paste command to put data into a template as it may
change the formatting including the shading.
You may copy any part (i.e. data or results) of a template to paste into another worksheet.
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Programmed buttons
Command buttons (see right) will allow you to clear the data from a template
or to solve the current problem entered in a templatejust press it.
Command
Notes:
Some of the templates have notes for using the template. The notes are at the
bottom of the template, there may be a hyperlink (e.g. see at right) at the top
of the screen to take you down to the notes.
Notes
Printing a Template
You may print a template by pressing the Print task button or using the File Print command.
Examples and Solved Problems
Data for the examples and solved problems in the text are also included in the workbook for each chapter.
You must enter the data into the appropriate template, either by typing or by Copy and Paste Special
Values (you can only paste in shaded areas - see below).
Template files
These templates are saved as Excel template (.x1t) files, so if you make changes and save the file, a
number will be added to the end of the file name (e.g. file.xlt becomes file1.xlt) to prevent you from
storing over the original.
Using Solver
Some templates (e.g. Linear Programming and Transportation) use the Excel Add In Solver. You must use
the Tools Add-Ins command to add in Solver before using these templates. You may solve (i.e. optimize)
the problem by pressing the Solve button or using the Tools Solver command.
Round off
There are several types of round off. First, the Solver Add-In has a set precision which also results in an
extremely small round off error (e.g. 1.234E-10) and these numbers may be treated as zero. Second, the
templates do not round off numbers, but the textbook does (e.g. probabilities for the normal distribution
are rounded off to 3-4 places), this will result in small but noticeable differences between results in
templates and the textbook.
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shown along with some discussion of different control methods for specific types of operations at Honda.
(Chapter 10Quality Control; Chapter 11TQM and Quality Tools)
Segment ThreeStatistical Process ControlFeaturing Honda (Approx 7 minutes) This segment
describes Honda's SPC efforts in several areas, and then focuses on one process test for door closing
speeds. An out of control situation is discovered and remedied. (Chapter 10Quality Control)
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