OMGT 4613—(Lean) Production & Inventory Control –Term 2
Rev. 02/28/2012
Gary Sample
Office/Cell: 501-490-7376 / 501-658-1110 (8am-10pm CST; 7 days/week)
University email: gsample@uark.edu
Course Description:
Defines analytical methods used to support inventory replenishment for the
production of goods and services. Operational problems of production systems are
examined, including objective/subjective forecasting methods; aggregate planning
of work force and production under seasonal demand; and inventory models of
EOQ for known and unknown demand. Supply chain management and lean
manufacturing concepts are also discussed.
Prerequisites: OMGT 4333 and OMGT 5003.
Required Textbook and Reference Books:
Production Operations Analysis, Nahmias, 6th ed., 2009, McGraw, MHID
0073377856, ISBN-13 978 0073377858
Lean Thinking, Womack and Jones, 1996 & 2003, Free Press, New York, NY, ISBN13: 978-0-7432-4927-0
Course Goals/Objectives:
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Understand in broad terms operations strategies as they relate to
competing in the global marketplace. Examples of such strategies include
conventional purchasing versus Just-In-Time, time-based competition,
competing on quality, matching the product and process life cycles,
learning and experience curves, and make or buy decisions
Learn objective and subjective forecasting methods. Understand the
importance of evaluating forecasts and the methods of evaluation used.
Define aggregate planning and be able to evaluate chase strategy versus
constant workforce planning.
Become familiar with methods of controlling inventory when product
demand follows a known pattern. Analyze the EOQ model. Be able to
discern among the various quantity discount models within the area of
purchasing.
Become familiar with methods of controlling inventory when demand is
uncertain and random. Analyze the Newsboy model.
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Understand in broad terms the importance of supply chain management
and the phenomena of the bullwhip effect and postponement on inventory
up and down the supply chain.
Be able to compare and contrast Push/Pull control systems of MRP and
JIT.
Analyze practical examples of lean manufacturing and learn the tools of
the Toyota Production System. Determine the difference between value
added and non-value added processes. Be able to describe the benefits
of Jidoka, Pok-e-yoke, Kaizen, cellular manufacturing, 5S, and TPM.
Course Requirements:
Course Grading:
Exam 1
Exam 2
Exam 3
Quizzes
Discussions:
250 pts
250 pts
250 pts
5 x 10 pts = 50 pts
5 x 10 pts = 50 Total
Case Study:
1 x 100pts 100 Total
Book Synopses
1 x 100pts = 100 Total
Course Total
1,050 pts
Exams & Quizzes: Exams will be administered online thru Blackboard Learning System under the
Assessments menu. The exam dates below correspond to the due date for the exam to be completed.
You must arrange for the exams to be completed within the date range given. The Quizzes and the
first Exam are not Proctored. Exam #2 and Exam #3 WILL BE PROCTORED BY
PROCTOR U. You must contact Proctor U to schedule your exam at least 72 hrs prior to the
exam.
Case Study: Please refer to the Critique Guidelines for this assignment. The due date is listed
below.
Book Synopses : For the course, you are required to read and summarize key points and your
“take-aways” from various lean manufacturing books. A minimum of 2 pages and a maximum of 3
pages are required for these assignments. I do not need a summarization report of the book, as I
have read the authors’ works. I am looking for what you learned from the author and the subject
leader and how you would apply the lessons learned to the course and to your career.
Late Penalty: Late assignments for the case study assignment, quizzes
and exams will be assessed a 30% penalty deduction.
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Evaluation Procedures:
Total Course Point = 1,150 points
Grades will follow the “90/80/70/60” rule.
1,150 – 1,035 points = “A”
1,034 – 920 points = “B”
919 – 805 points = “C”
804 – 690points = “D”
689 or less = “F”
Academic Honesty Policy:
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The University of Arkansas strives to be a center of academic excellence.
As part of our Statement of Ethics, the University strives to preserve
academic honor and integrity by repudiating all forms of academic and
intellectual dishonesty, including cheating, plagiarism and all other forms of
academic dishonesty. Academic dishonesty is unacceptable and is subject to
a disciplinary response.
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Students who are caught cheating or committing plagiarism may be given a
failing grade in the course by the professor and may be subject to dismissal
or further discipline.
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Plagiarism is often misunderstood as referring only to passing off another’s
writing as one’s own. The definition also extends to ideas and arguments
taken from others’ work without proper citing of the original source. It is
also not permissible to construct papers or reports by merely “cutting and
pasting” and then just citing another’s work. In writing for homework or
projects, you should read and learn, process information through your mind,
relate ideas, and then express your take on the material you’ve read in your
own words. Cite the references where you found your information. If you
do use someone else’s words, do so sparingly, use quotation marks, and cite.
A complete statement of the U of A’s Academic Honesty Policy is available in the UA Student
Handbook and the UA Graduate Catalog.
Inclement Weather Policy:
If the base or campus closes for inclement weather or other reasons, your site
coordinator will be the first to know. She will call the professors and send the
students e-mail advising of class cancellations. If your professor cancels a class
he/she will contact the site coordinator, and she will send an e-mail to the students
in that class advising of class cancellation.
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Course Units/Calendar:
Week #1 3/14 – 3/20:
Introduction, Syllabus, Textbook, Ch. 1: Strategy and Competition
Discussion Topic #1, Due March 20 by 5 pm - Introduction
Week #2 3/21 – 3/27:
Ch. 1: Strategy and Competition; Learning & Experience Curves, Make vs. Buy, Capacity
Growth Planning
Discussion Topic #2, Due March 27 by 5 pm - The Product/Process Matrix: Where does
your company operate or where does your chosen company operate?
Week #3 3/28 – 4/3:
Ch. 2: Forecasting; Trend Based Methods, Regression, and Seasonality
Ch. 3: Aggregate Planning, Workforce Planning,
Quizzes #1 & #2 available March 28 – April 3 Due April 3 by 5 pm.
Discussion Topic #3, Due April 3 by 5 pm – New Product Launch
Week #4 4/4 – 4/10:
Exam #1 available April 4 – April 10, Due April 10 by 5 pm Over material covered n
weeks 1 – 3.
Ch. 4: Inventory Control Subject to Known Demand, The EOQ Model; All Units &
Incremental Discounts, EOQ Models for Production Planning
Week #5 4/11 – 4/17:
Ch. 5: Inventory Control Subject to Uncertain Demand, Randomness, The Newsboy Model;
Multiple Planning Periods, and Lot-Size Reorder Point Systems
Ch. 6: No lecture Video; Study the chapter on Supply Chain Management.
Quizzes #3 & #4 available April 11 – April 17. Due April 17 by 5 pm
Discussion Topic #4, Due April 17 by 5pm – The GM pinch – Bailout or Bankruptcy
Exam #2 available April 11 - April 17, Due April 17 by 5pm. Over material covered n
weeks 4 – 5.
Week #6 4/18 – 4/24:
Ch. 7: Push vs. Pull Production Control Systems – MRP & JIT.
Lean Manufacturing Systems – Overview, Batch Production Exercise, Kaizen and
Continuous Improvement Events, Jidoka, Pok-A-Yoke, and Error-Proofing
Discussion Topic #5, Due April 24, by 5 pm– Lean Manufacturing Pros & Cons
Book Synopses Assignment Due April 24 by 5pm Lean Thinking, Womack, Jones, and
Roos
Week #7 4/25 – 5/1:
Guest Speaker – David Mann, Corp. Engineering Mgr, Central States Mfg, Inc.
Lean Manufacturing Principles, 5S, Set-up Reduction, and TPM.
Quiz #5 Available April 25 – May 1, Due May 1 by 5pm.
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Week #8 5/2 – 5/10:
Case Study Due May 10 by 5pm – “Creating Lean Suppliers: Diffusing Lean Production
Throughout the Supply Chain” by MacDuffle and Helper
Exam #3 available May 2 – May 10, Due May 10 by 5pm. Over material covered n
weeks 6 & 7.
Caveat re: changes to syllabus
“The above schedule and procedures in this course are subject to change in the event of
extenuating circumstances.”
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