IE3104: Supply Chain Modeling: Manufacturing & Warehousing Instructor: Spyros Reveliotis Office: Room 316, ISyE Bldng tel #: (404) 894-6608 e-mail: spyros@isye.gatech.edu homepage: www.isye.gatech.edu/~spyros “Course Logistics” • TA: Mr. Karin Boonertvanich • Office Hours: 1:15-2:30pm MW (ow, an open-door policy will be generally adopted, but an appointment arranged by e-mail is preferred) • Grading policy: – – – – – – Homework: 25% Midterm I: 20% (Tent. Date: June 10) Midterm II: 20% (Tent. Date: July 8) Final: 35% (Tent. Date: July 29) Exams closed-book, with 2 pages of notes per exam Make-up exams and Incompletes: Only for very serious reasons, which are officially documented. • Reading Materials: – Course Textbook: “Operations Management” by J. Heizer and B. Render, Prentice Hall, 6th ed. – Material posted at my homepage or the library electronic reserves Course Objectives (What this course is all about?) • How to design and operate manufacturing and warehousing facilities (and more…) – A conceptual description and classification of modern production and warehousing environments and their operation – An identification of the major issues to be addressed during the planning and control of the production and warehousing activity – Decomposition of the overall production planning and control problem to a number of sub-problems and the development of quantitative methodologies for addressing the arising sub-problems – Computational implementation of the presented techniques (e.g., Excel, LP solvers, etc.) primarily through the homework assignments – Emerging trends, including the implications of a globalized and internet-based economy Organizational Operations • Organization / Production System: A transformation process (physical, locational, physiological, intellectual, etc.) Inputs Outputs •Materials •Capital •Labor •Manag. Res. Organization •Goods •Services • Supply or Value Chain / Network: Stage 1 Stage 2 Stage 4 Suppliers Stage 3 Stage 5 Customers The growth of the service sector in modern economies • Figure 1.5, pg. 14 • Table 1.4, pg. 15 • Figure 1.4, pg. 13 The major functional units of a modern organization Strategic Planning: defining the organization’s mission and the required/perceived core competencies Production/ Operations: product/service creation Finance/ Accounting: monitoring of the organization cash-flows Example: Figure 1.2, pg. 9 Marketing: demand generation and order taking Operations Management (OM) Definition: The study and improvement / optimization of the set of activities that create goods and services in an organization. Typical issues addressed: • Service and product selection and design • Quality Management • Process and capacity design • Facility Location • Layout design • Human resources and job design • Supply-chain management • Inventory management • Production planning and control • Maintenance Productivity: Basic Organizational Performance Measure Productivity = Units produced / Input used = Output / (Labor + Material + Capital + Energy + Miscellaneous) Remarks: • Typically both the numerator and the denominator are measured in $$$. If the output corresponds to actual sales, then productivity measures both effectiveness (doing the right thing) and efficiency (in the right way). • Yet, an accurate measurement of the system productivity is a difficult proposition due to the large number of intangible/external factors that can affect it: e.g., a political/military crisis leading to higher energy prices. • Traditional measures of input and/or output can be very poor measures for issues like quality of product/service, customer satisfaction, etc. • From an economic standpoint, major emphasis is placed on the annual percentage change (hopefully increase) of productivity. • For the entire US economy, the current annual increase in productivity is 1.7% (38% of this increase is due to capital improvements, 10% to labor improvements and 52% to management improvements). Major Productivity Variables and their contribution to productivity increase • Labor – – – – Better basic education Better diet Better social infrastructure like transportation and sanitation Better labor utilization and motivation • Capital – Steady and well-planned investments on equipment and its timely maintenance – Research & Development – Controlling of the cost of capital • Management – Exploitation of new (information) technologies – Utilization of accumulated knowledge – Education Knowledge Society Example of Productivity Improvement through better Management Practices: Taco Bell • The challenge: Control costs through better operations design and control. • The approach: – adopt meals easy to prepare (product design) – Shift a substantial portion of food preparation to suppliers (SCM; economies of scale) – layout improvements – adoption of automation, whenever possible – increase of the span of management from 5 to 30 restaurants, through training and empowerment • The results – – – – cut the taco and burrito preparation to 8 secs (enhanced responsiveness) cut in-store labor by 15 hours per day (labor cost reduction) reduce floor space by 50% (facility cost reduction) 73% share of the Mexican fast-food market OM history, achievements, and current trends • Early concepts (1776-1880) – Labor specialization (Smith, Babbage) – Standardized parts (Whitney) • Scientific Management Era (1880-1910) – Gantt Charts for systematic scheduling (Gantt) – Motion & Time Studies (Gibreth) – Process Analysis (Taylor - employee selection, training, work methods and tools, work incentive system) – Queueing theory (Erlang) • Mass Production Era (1910-1980) – – – – – Moving Assembly Line (Ford/Sorensen) Statistical Sampling (Shewhart) Economic Order Quantity (Harris) Linear Programming (Dantzig) Material Requirements Planning (MRP) OM history, achievements, and current trends (cont.) • Lean Production Era (1980-1995) – – – – – – – Just-In-Time (JIT) Pull Production Systems Total Quality Management (TQM) Empowerment Baldrige Award Computer Aided Design (CAD) Electronic Data Interchange (EDI) • Mass Customization Era (1995-2002) – – – – – – – – Globalization Internet Enterprise Resource Planning (ERP) Supply Chain Management (SCM) E-commerce International Quality Standards Learning Organization Agile Manufacturing Reading Assignment • Chapter 1 from your textbook (including the inset examples and case-studies)