ISQA 459_559

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ISQA 459_559

    ISQA 459/559

    Production Planning and Control

    Winter 2013

INSTRUCTOR: Mellie Pullman, Ph.D. OFFICE: 230 B


    or by appointment

    E-MAIL: TELEPHONE: 503-725-4768


    1. The Fundamentals of Production Planning and Control, by Stephen N.

    Chapman, published by Pearson Prentice Hall. ISBN-0-13-017615-X.

    (Henceforth referred to as “Text”) Price ranges from $20 (used) to $71 (new)

    on or bookstore.

    2. Cases Packet (Required) available at Clean Copy Center

Course Description

    The objective of this course is to familiarize students with the major tools used for manufacturing planning and control. To this end, we will perform an in-depth analysis of integrated operations management systems with emphasis on operations planning and control, material requirements planning, master scheduling, forecasting, capacity planning, just-in-time and related topics. These tools will be covered with more detail than previous SCM courses and we will examine how the various components fit together to form a complete system.

    1. Understanding the role of production planning in the operations strategy

    of the firm,

    2. Understanding the mechanics of developing production plans,

    3. Developing advanced computer skills (spreadsheets) for production


    4. Learning how to communicate goals and schedules across an organization.


    1. Classes are not professor versus student. They are professor and student

    trying to achieve the same goal preparing the student for the working


    2. I will expect that you are putting time into this class outside of our meeting

    times. For instance, I will expect that you have read the assigned readings

    and done the homework before class.

    3. If you ever are wondering why I have structured the class a particular way

    or given a particular assignment, ask me. Often, the answer may help you

    better understand the material and the goals of this class.

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    EVALUATION: Your course grade will be determined according to the following breakdown:

    Individual Activities Problem Sets 50%

     Cases 10%

     Class Participation 10%

     Exams 15%

     Group Activities In Class Games write-up & 15% performance

    Total 100%


    General Class Administration Guidelines

    The following are the two guiding principles that will direct all elements of class administration. This is especially so for those issues that may come up but are not explicitly covered on the syllabus.

    1. It will be easier to ask for permission ahead of time rather than beg for forgiveness after the fact.

    2. Translate your situation to a real business situation. What would a superior do in the situation? What would he/she find acceptable? That is probably how I will react.

Classroom Format & Meetings

    This class is taught through a variety of methods. Each class period will combine several of the following methods: interactive activities such as demonstrations of concepts through exercises or games, case discussion, lectures, guest speakers, and field trips. In addition, you will do homework problems, a technical case and two quizzes.

    I will expect that when you are in class, your attention is on the class. Doing crossword puzzles, surfing the web and sleeping are no more acceptable in class than they will be a few years from now in business meetings. If you intend to engage in these types of activities, I would prefer if you would not show up at all.

    ; Please use your laptop in class when we are working on computer

    exercises not for non-class related activities,

    ; Calculators will be very helpful for in-class exercises,

    ; Cell phones/Blackberries/etc. should be turned off for class periods,

    ; Please be respectful of your classmates and professor by listening when

    they are talking and not creating side conversations.

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    Homework problem sets and analytical cases will be assigned. These problems provide excellent practice of the technique-oriented material that will be needed at work (and on the quizzes). While you can work on the problems with others, you should hand in your own unique work and interpretation of the results. It is unlikely that you can do well in this field without working on the techniques.

All homework assignments are due at the beginning of class on the date

    indicated in the schedule. Any homework assignment handed in late will be penalized 50%.


    There are 2 quizzes with scheduled deadlines for each part. While you can hand in the quiz earlier than the deadlines, you may not hand them in late. You must do this work alone without help from other students. Please come to the professor or email her with any questions or clarifications.

Participation & Attendance

    Being proactive is a good thing. It will help this class run smoother, makes it more fun and lively for everyone, and is a good habit to develop before you head out into the business world. An important part of the course is your individual participation in daily class discussions, exercises, and case discussions. While a minimum level of participation is expected of every class member, primary emphasis is placed on the quality of classroom contributions. In grading class participation, little emphasis will be placed on redundant or extraneous contributions. Rather emphasis will be placed on contributions which add new insights to the discussion or which build on the comments of others.

    Interesting current articles brought in for class discussion on relevant topics will contribute extra credit to your participation points (up to 5 addition percentage points).

    Class attendance is expected since much of the learning occurs through in-class cases and simulations. Lack of attendance will be reflected in your participation grade. If you anticipate missing a class I would appreciate if you would let me know about the situation in advance. Generally one missed class will not affect your participation grade if you regularly participate in other classes.


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Several cases are provided in the course packet. With the exception of Greaves

    Brewery and Salmones Puyuhaupi, all game write-ups are done as a group.

    Everyone must read the case and contribute otherwise your group will not do well in the in-class simulations, reflected in your grade. Greaves Brewery and

    Salmones Puyuhaupi should be done as a formal write-up shown below while the other cases require a brief written answer.

    The case write-ups are due at the start of class. Case assignments may not be handed in late and you will receive 0 points for any cases not turned in at the beginning of class.

Case Write-up Guidelines

    (Use for Greaves Brewery and Salmones Puyuhaupi)

    1. Format and Logistics

    The case write-up should not exceed 2 (two) pages in length, plus additional pages allowed for exhibits (showing all technical analysis). The Text should be written double-spaced, in Times 12 font.

    2. Case Write-up Grading Criteria


    ; Does the paper contain analyses of relevant questions?

    ; Does the analysis incorporate concepts from the text, readings or class? ; Are assumptions made in the analysis stated explicitly?

    ; Does the analysis isolate the fundamental causes of problems? Exhibits (Tables, graphics, etc.)

    ; Do the key exhibits support and add to the text on key points? ; Is the text referring to all the exhibits?

    Overall Criteria

    ; Is the paper logically consistent and effectively structured so it sells its recommendations?

    ; Has the case been proofread for spelling, grammar, and typos? Participation will be evaluated accordingly to the following guidelines:

Grade Attendance Punctuality Willingness to Participate Value of Participation

    A Perfect or close Never late Participates a lot, works to Able to demonstrate a

    to keep discussions going, possibly keen understanding of

    even brings in other materials concepts and explicate

    to discuss in class. key points of cases.

    B A few absences Late a few Participates regularly, asks Brings up decent points

    times questions occasionally. and keeps discussion

    going in useful direction.

    C Somewhat Often late Participates minimally by Demonstrates a limited

    regular absences speaking up maybe once or understanding of cases

    twice per quarter. and concepts.

    D/F Absent more Almost Shows up for class, but does Does not appear to have

    than present always late not participate in any read the cases or

    noticeable way. understand the concepts

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    Note: Participation that falls in between these criteria will be given the appropriate evaluation (i.e., +/- grades will be used in evaluating participation)

Groups Activity:

    Please form a group of 3 people to work on the cases and a classroom breakout discussion/game team. In most instances, the case work involves short cases with game strategy formulation. You team should come prepared to class (having read the case assignment and written responses to the case questions).

Group Game Preparation

    Each group communicate prior to class and develop a strategy for playing that day’s game. Your team will turn in the answers to the requested questions prior to the game. After completing the game, you will submit your team’s

    results via email. There are 4 Games: Lamson Corporation, Again Agame, B’s

    Wax Candle Company, and Shell Job Shop.

Miscellaneous class administration

    1. Class attendance is expected. Students generally will not perform well

    in class without attending class.

    2. Students must have completed the required prerequisite course or

    received instructor permission before taking this class.

    3. Assigned readings and cases should be read before class.

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    ISQA 449/559 Production Planning and Control

    Tentative Schedule as of January, 2013

    # Date Topic Reading Material Hand in 1 Jan 8 Introduction

     Demand Management Review

    2 Jan 15 Demand Management Advanced TEXT CHAPTER 1 & 2 Problem Set 1 (# 1 only)

     Case: Sport Obermeyer Read: Sport Obermeyer & be prepared to answer questions

    3 Jan 22 Intro to Linear Programming Read: Lamson Corporation & answer Q1-3(group activity) Lamson Q1, 2 & 3 (1 per group)

     Individual Case: Greaves Brewery Read and write-up Greaves Brewery Case Greaves Brewery Case Write-up

    Group Game: Lamson Corporation

    4 Jan 29 Linear Programming & TEXT CHAPTER 3 Problem Set 1 (# 2 & #3)

     Aggregate Production Planning Read: Aggregate Production Management 2002

    5 Feb 5 Inventory & MPS TEXT CHAPTER 4 & 5 Again Agame Q1-2 (1 per group)

     Game: Again Agame Read: Again Agame & Answer Q1-2 (group activity). Problem Set 2 (#1-4)

    6 Feb 12 Midterm: Take Home/ No class Midterm: Salmones Puyuhaupi Case (spreadsheet & Quiz due on Monday Feb. 18 by

    Due Feb. 18 questions) 5 PM (turn in to Faculty thPlease use case format (note: this will require Solver) Services on 5 floor of SBA) 7 Feb 19 MPS Continued & MRP TEXT CHAPTER 6 Problem Set 3 (#1)

     Game: B’s Wax Candle Company Read: Note on Material Requirements Planning and B’s Wax Recalculate B’s plan for first

    Candle period (1 per group)

    Familiarize yourself with B’s Wax spreadsheet

    8 Feb 26 JIT Planning TEXT CHAPTER 9 Problem Set 3 (#2, A-Cat Case)

     Salmones Puyuhaupi Midterm Wrap-up Read: Decoding the DNA and Tamago-Ya of Japan:

    Guest Speakers Delivering Lunch Boxes to Your Work

    9 Mar 5 Production Activity Control TEXT CHAPTER 8 Shell Game Q1-3 (1 per group)

     Game: Shell Game(Job Shop) Due: Homework Set 2 Problem Set 3 (#3 & #4)

    Read: Shell Game Q1-3 (group activity).

    10 Mar 12 Production Planning in Action Problem Set 3 (#5)

     Final Field Trip: Widmer Brewing Co.

    5:30 PM

    11 Mar 19 Final Exam: Take Home Exam will be posted on-line (website) Due on Tuesday March 19 by 9

    AM (email to Dr. Pullman) MEP Page 6 3/20/2014

    Game & Case Questions

    Sports Obermeyer

    Prior to Class, read the case and address the following questions:

    1. What issues should Wally Obermeyer consider as he decides how much to

    order of each style in November?

    2. Using the sample data given in Exhibit 10, you will be asked in class to make

    a recommendation for how many units of each style Wally Obermeyer

    should order during the initial phase of production. Assume that all ten

    styles in the sample problem are made in Hong Kong, and that Obermeyer’s

    initial production commitment must be at least 10,000 units. (Ignore price

    differences among styles in your initial analysis.)

    3. What operational changes would you recommend to Wally to improve


    4. How should Obermeyer management think (both short-term and long-term)

    about sourcing in Hong Kong versus China?

    Greaves Brewery: Bottle Replenishment (Individual Assignment) Prior to Class, read the case and address the following questions in a write-up:

    1. How many thousand cases will Greaves Brewery sell in the next year? Come up

    with a forecasting method using the available data and justify why you chose

    that method with the available data. Explain your assumptions in detail.

    a. Plot all available historic data

    b. Attempt at least 3 different forecasting approaches

    c. Using the MAD calculation from each method, pick the best one.

    2. Map the flow of reusable bottles in the supply chain.

    3. Using your map, your forecast, and other case facts, please predict how many

    new bottles are required for the coming year.

    4. Detail the significant challenges with these two forecasting exercises and

    indicate what other industries might also face this type of planning challenge.

    Lamson Corporation Game (Group Assignment)

    Prior to Class, read the case and address the following questions:

    1. How many 18-inch tiles do you have in inventory before you start?

    2. How many 36-inch tiles do you have in inventory before you start?

    3. What is your cumulative cost total before you start the game?

    Again Agame Game (Group Assignment)

    Prior to Class, read the case and address the following questions:

    1. How much would you order and what would the frequency of the orders be?

    You can use the past history as representative of the demand and the extra

    simulation sheets can be “practice”.

    2. Come to class with some form of inventory policy or rule for managing the

    inventory in this problem.

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    B’s Wax Candle Company Game (Group Assignment)

    Prior to Class, read the case and address the following:

    1. Using Exhibit 3 as a guide, make Master Schedule Plan for period 1 (follows

    period 0) using the production decision form (exhibit 4). Hand this in at the

    beginning of class.

    Shell Game Questions (Group Assignment)

    Prior to Class, read the case and the book chapter and address the following:

    1. What formal job scheduling rules are available for dispatchers to use for

    scheduling jobs in this game (please use chapter 8 as a reference)?

    2. How many finished parts will be made in the facility during this game?

    3. How is this production facility different from one that produces jobs that are

    exactly the same?

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    Team Peer Evaluation

    Team Number: ____________________________________

Evaluating Team Member: ____________________________________

    Throughout the quarter you have worked together in teams to produce the project required for the course. This is your opportunity to reward team members for excellent work or to indicate those members that did not fully participate in the group learning opportunities. Team peer grades are taken seriously and will be used to adjust grades.

    You have two options. Option A takes to heart the principles of socialism and should be chosen if you believe that all members of your team are equally deserving of the team grade. Option B, on the other hand, recognizes that some team members are more ‘equal’ than others. By selecting Option B, you have

    the choice of divvying up 100 points among your team members (including yourself). The fraction of total points awarded to each team member will then represent your assessment of their relative contribution. For example, if you are in a four member team, the baseline from Option A would indicate that you award each member 25 points. Using Option B, if you give one member 30 points, however, one or more team members must then receive less than 20 points. Option A: All team members receive the same team grade this is the option

    that you will be assumed to have selected if you do not turn in a peer evaluation form.

    Option B: Some team members may contribute more than others. Please write each team member’s name below and assign each a number of points between

    0 and 100 (including your self) that you think reflects their relative contribution. Be sure that the total points assigned to all team members equals 100.

Name: ___________________________________ Points: ________

    Name: ___________________________________ Points: ________

    Name: ___________________________________ Points: ________

    Name: ___________________________________ Points: ________

    Name: ___________________________________ Points: ________

     Total Points: 100

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