Chapter Correlations – Page 143 – The OM Blog by Heizer, Render, & Munson

OM in the News: The (Gentler) Chicken-Killing Assembly Line

I was 7 years old when my Dad proudly took me to the Dubuque (Iowa) Packing Co. to show me what he did as a supervisor in the cow butchering department. I won’t go into graphic detail as to how the animals were queued up to have their throats slit. They were stunned first to make the process as pain free as possible.

Maybe you can see why yesterday’s New York Times (Oct.22,2010) front page headline, “New Way to Help Chickens Cross to the Other Side”, caught my attention. It turns out that chicken producers, egged on by animal rights groups, are also switching to a system of killing their birds more humanely. The new process uses gas to render the chickens unconscious before they are hung by their feet to have their throats slit.

“When you grab a chicken, turn it upside down and put it on the line, its stress, stress, stress”, says one chicken producer. The new system is not only meant to be kinder to the animals, but to plant workers as well. Dealing with struggling, flapping chickens–like dealing with bellowing cows who sense impending doom– makes meat processing plant jobs among the worst in the country.

This topic can fit in your OM course in 3 ways: (1) students have strong opinions about the issue of how we slaughter animals (see the Ethical Dilemma box on pig production in Ch.7, Process Strategy); (2) when you discuss job satisfaction/motivation in Ch.10, it makes the point that not all jobs are easy to staff/manage; and (3) this is a classic case of an assembly line, in Ch.9’s photo, at the end of the chapter.

Discussion questions:

1. Does killing chickens this way make you more comfortable with the production process?

2. How are most chickens raised in preparation for slaughter?

3. Will it be easier to market a chicken as “killed stress-free”?

Teaching Tip: Location, Location, Louisville?

We open Chapter 8, Location Strategies, with a Global Company Profile on why FedEx selected Memphis as its US superhub. But Fortune (Oct.18,2010) expands on this topic, with a feature called “Louisville Flies High”.

It turns out that Louisville has great geography, economic incentives, and high tech logistics that have attracted more than 100 corporations this past decade. The city is within a 2-hour flight to 75% of the US population and sits just 40 miles from the exact center of the continental US on a population density map. Its also one hour below the frost line.

The clear supply chain draw is UPS, whose $2 billion Worldport has 30,000 conveyors and can sort 416,000 packages per hour. Toshiba now trains UPS employees to fix computers on site–and return them within 48 hours. Zappos moved to Louisville to be near the giant UPS facility also. If a package leaves the online shoe retailer (which my wife adores) at 12:45am, UPS will deliver the shoes anywhere in the country the same day.

This makes for a nice discussion in both the Location and Supply Chain(Ch.11) chapters.

OM in the News: Waiting Lines in the Doctor’s Office

My internist of many years, Dr. Gulden, never ceased to amaze me before he retired. For every scheduled appointment, I was seen within 5 minutes of my arrival! This led to research I did in 1994, when I found that the average wait time in doctors’ offices in the US was 20.6 minutes, costing about $15 billion per year in lost productivity.

I guess this topic was of interest since the finding made the front page of papers around the country, from the Boston Globe to the Miami Herald. Yesterday, The Wall Street Journal (Oct.19,2010), with the headline “The Doctor Will See You Eventually“, announced that the “average time patients spend waiting to see a health care professional is now 22 minutes, and some waits stretch for hours”. Are any of us who teach OM shocked?

This is a great article to discuss when you cover waiting line models in Module D. But it may also be useful in Supp.7, Capacity and Constraint Management, because the Journal talks about cutting cycle time. In one doctor’s office, patients helped measure their times from arrival until departure. By identifying bottlenecks, the doctor was able to cut 12 minutes from the typical 40 minute stay.

So why was Dr. Gulden so successful in keeping on-schedule? I think there was one main reason: he made all his staff understand that each patient’s time was as valuable as his was.

Discussion questions:

1. Ask your students to rank the seven methods the article discusses in terms of what they think are the best for time savings payoff.

2. Many hospitals now advertise their ER wait times. What have they done to improve their process flows?

3.What kind of queuing models can be used in a doctor’s office?

OM in the News: Solar–Will the U.S. Lose Out to China?

A few days ago, our blog gave the good news that BMW and Mercedes were expanding their manufacturing in the US. For our nation’s standard of living to rise, we indeed need to make things. And such jobs pay well and provide a path for middle class success.

But the New York Times headline (Oct.13,2010), “In the Future, Already Behind” brought me back to reality with a thud. The story is about Silicon Valley and its commitment to transforming the economics of solar panel production. Firms like Solyndra, Nanasolar, and MiaSole bet the farm that their “thin film” technology would make them the Intels and Apples of the exploding global solar industry.

But just as Solyndra flipped the switch on its new $733 million California factory last month, everything changed. The Chinese, using vast economies of scale and government subsidies, sent the price of panels plunging 40% and grabbed 40% of the vast California market. They also took the bulk of the European market. What looked like a chance for US manufacturing to dominate a critical growing market has crumbled to the realities of globalization.

“How do you fight against enormous subsidies, low-interest loans, cheap labor and scale, and a government strategy to make you no.1 in solar?”, asks an American CEO.

New technologies (see Ch.7), meant to be cheaper, must get there faster is one lesson we learn here.

Discussion questions:

1. What are the dangers of ceding this industry to the Chinese?

2. How can the US firms counter this threat (see Ch.2 for a strategy discussion)?

3. Should the US provide the same benefits that China does to new companies?

Teaching Tip: Why Do So Many Large Projects Overrun?

While most OM texts cover Project Management (see Chapter 3), there is little discussion as to where the time estimates for activities in PERT and CPM come from or how accurate they are. This question arises in, of all places, an easily overlooked article in The Wall Street Journal (Oct.16-17,2010).

Here we learn that “planners underestimate costs in nearly 9 out 0f 10 projects” and “cost overruns for building projects are typical”. From my decades of teaching MIS and working as a consultant in IT, I can add that completion times in software development projects are also regularly underestimated.

Why is this the case? Research, according to the WSJ, shows that “people allow their best hopes to dominate the planning process”. This case of “irrational optimism” suggests that project managers would do well to keep data from prior projects. “Looking forward makes you more optimistic”, says a Norwegian researcher in the article. “Looking backward makes you more realistic”.

So when you and your students are discussing large projects that suffered major overruns (like Boston’s “Big Dig” and others they will bring up), you may want to remind students that doing PERT charts and running MS Project is all well and good, as long as the inputs are meaningful.

Finally, did you ever wonder about the the empirical basis of PERT’s 3 time estimates and the use of the Beta distribution in project management? If large projects do consistantly underestimate activity times, should we be giving more weight in the PERT formula to the “pessimistic” time estimate, b? Perhaps the formula in Equation (3-6) in our text should be t=(1a+3m+2b)/6 instead of t=(1a+4m+1b)/6?

OM in the News: BMW Loves Making Cars in the U.S.

As the Big 3 auto makers still struggle to reclaim markets and manufacturing leadership, BMW announces that employment will hit 7,600 workers in its South Carolina plant next year. Its $750 million expansion means the plant will be the largest car factory in the U.S., dwarfing any Detroit operation.

Of course, with the economy so bad, this is good news, even if some profits end up in the company’s German headquarters. And because of high-tech firms like BMW, South Carolina is the 4th largest net importer of college-educated adults.

Why did BMW decide to make its luxury SUVs here, when it exports 70% of these vehicles to the rest of the world? The Wall Street Journal (Oct.14,2010) reports that US production helps BMW hedge against currency fluctuations around the globe. Another reason…according to U.S.-BMW President Josef Kerscher (in Fortune, Oct.15,2010): This U.S. group has absenteeism of “less than 3%, better than in Germany”.

Similar good news is that Mercedes plans to shift some production of its best-seller, the C-class sedan, from Germany to the US in 2014. Its not only a currency issue for Mercedes, but the strategy reduces labor and other costs. As we note in Ch.8 (Location), Mercedes already makes SUVs in it Vance , Alabama plant.

Discussion questions:

1. What others reasons are there for foreign car makers to be attracted to the US?

2.Why is South Carolina a primary destination for auto manufacturers?

3. What brought Mercedes to Alabama (see Ch.8’s OM in Action box)?

OM in the News: Starbucks’ Lean Teams Slowing Down

I always like to use Starbucks examples in class. Its the kind of “hip” company that students can relate to. Over the past few years , Starbucks has been applying lean manufacturing techniques to study every move its baristas make in order to shave seconds off each order. Chapter 1 in our text has an OM in Action box describing these productivity improvements.

But The Wall Street Journal (Oct.13, 2010) just reported that Starbucks now wants to reign in its baristas, an act that will result in longer lines and waits. Baristas are being told to stop making multiple drinks at one time, to steam milk one drink at a time instead of a pitcher at a time, to rinse pitchers after each use, and to use 1 espresso machine instead of 2.

Why would the company do this? The new methods have “doubled the amount of time it takes to make some drinks” says one employee. But the company is concerned about quality, with customers indicating that Starbucks espresso drinks are just “average”.

It is definitely an interesting class topic to see the lean techniques being reversed and I am sure many students will have a comment about such changes.

Discussion questions:

1. Why would baristas be opposed to slowing down the process?

2. What are some of the lean techniques the company has introduced over the years?

3. What other changes has Starbucks made recently in product and process?

Video Tip: Arnold Palmer Hospital’s Culture of Quality

A few weeks ago, I visited my neighbor Artie while he was in the hospital. It was a typical large facility, with long hallways, nice private rooms…some of which had great views of the lake. But when I entered his room, the first thing I noticed was that the trash can was not only filled, it was overflowing! As I left, I stopped at the nurses’ station to report this “defect”. The response: “Maybe you should call management to let them know”.

I can say that at Arnold Palmer Hospital for Women and Children (APH) this would never have happened. When you show this 10 minute video in class, you will see why. The culture of quality is ingrained deep at APH.

Let me give you a little off-the -record background about our filming experience, which was a fantastic learning exercise that resulted in 7 APH video cases in the text. I first sat through the new employee orientation period. One of the 1st cultures I learned was that hospital employees always keep a positive face in all public spaces. No one may be heard talking about how bad their day is, problems at home, or troubling patients. The hospital has private staff corridors that parallel the public ones. Only there can staff speak openly. Second, all top administrators at APH are former nurses, who worked their way up. Kathy Swanson, the director, has an MBA, and others also have business training. I believe they have a culture of caring about patients above all else. Note in the film how they each take calls from patients 24/7.

We have 2 videos dealing with service TQM in Ch.6, the other being Quality at the Ritz-Carlton Hotel (7.5 min.). I prefer to show the APH film because the hospital incorporates several Ritz concepts, including empowering any staff member (even janitors) to hand up to $200 in gift cards to any patient with a complaint. My friend Artie could have gotten rich if his hospital had such an attitude!

Jay and I are especially proud of this APH video as it took 1st place in the annual Addy video competition in 2005. Out of 13,000 entries, it won the highest award, the Silver Telly.

OM in the News: The Outsourcing Controversy

Outsourcing has been a controversial topic and a political football for well over a decade now. We have tried to maintain a balanced view of the pros and cons. But with the elections nearing in a month, many Congressional candidates and the AFL-CIO have been unveiling an anti-outsourcing campaign. And the Senate fell just 7 votes shy of passing the “Creating American Jobs and Ending Offshoring Act”.

If you teach this topic and plan to cover Chapter 2, today’s Wall Street Journal (Oct.12, 2010)carries an interesting editorial piece by William Cohen, former Defense Secretary. He states, “Most people treat outsourcing as a zero-sum game–one foreign worker replaces one American worker. But this is not how the dynamic global economy works…The fact is that that for every job outsourced to Bangalore, nearly two jobs are created in …American cities”.

Discussion questions:

1. If anyone in your class has seen the new NBC comedy “Outsourced”, ask them to comment on this issue.

2. Should the government raise taxes on companies that move operations abroad (the Senate voted 53-45 last month to do so)?

3. Should we discourage skilled workers from India and other countries from coming to the U.S. to work?

OM in the News: Wal-Mart’s Drive to Squeeze the Supply Chain

Wal-Mart trying to squeeze more out of its supply chain? Not exactly shocking news, but here is a new twist in BusinessWeek (Oct. 7, 2010). With the title VP for International Purchase Leverage (I don’t think I have heard that one before), Hernan Muntaner is convinced he can get even better deals from suppliers by consolidating Wal-Mart’s purchases with its current partners. For example, Muntaner wants to buy potatoes jointly with Pepsi’s Frito-Lay, so that both can get lower prices.

Although Pepsi doesn’t seem interested so far, and may indeed be more sophisticated than Wal-Mart in procuring raw materials like potatoes, Muntaner has already signed on a sugar supplier in England and a paper supplier in Chile. “We can do this with anything that is sold”, he says.

Collaborative sourcing, as Wal-Mart calls it, is detailed in a book by that title by Michael Philippart, Christian Verstraete, and Serge Wynen.

Discussion questions:

1. Why might suppliers be wary of the new Wal-Mart push?

2. Look at the Ethical Dilemma in Ch.11 that compares Wal-Mart to Sears. Does this purchasing concept tie in to the ethical issue?

OM in the News: Airlines and the Capacity Issue

Because of my early career experience in the aerospace industry (design team for McDonnell Douglas’ DC-10, then the engine for that jet at GE), I have always followed the airline industry closely. Capacity issues have haunted airlines for 6 decades now, going back all the way to 1942, when demand plummeted during that recession. Buying planes is a long term decision, but difficulties after 9-11 and during our current trying times created dramatic drops in demand for seats. This is a great classroom example when you are teaching Capacity in Supp.7.

How do airlines respond? As today’s New York Times reports, airlines trim capacity by grounding planes, reducing the number of flights between cities, and flying smaller planes. At the nation’s largest parking lot near the California Mojave Desert, some 200 aircraft of all sizes (from A320s to 747s) sit tip to wing tip. The dry air keeps the planes from rust and corrosion. Students will enjoy the photo in Supp. 7 showing this image.

The cost, up to $60,000 per month per plane. But the 7% cut in capacity last year helped raise ticket prices modestly. Airlines now fly at 80% of seat capacity, a full 10% higher than their traditional measure.

With the mergers of Delta with Northwest, United with Continental, Midwest with Frontier, and Southwest with AirTran, there is little growth in demand for more jets forecast in the US. Only 38 wide body planes are on order for delivery in this country by 2015. By contrast, 627 are going to be delivered to foreign carriers during that same 5 year period.

Discussion questions:

1. Why are airlines willing to spend enormous sums to park their planes in the desert?

2. Who can benefit from airline overcapacity?

3. The new Boeing 787 Dreamliner has run into such bad supply chain problems (Ch.11) that it is now 2 years late. How does this impact the airlines that ordered them?

Teaching Tip: Helping Your Students Find Jobs

We all know the economy is still weak ( to put it mildly), and this means our students are in tough positions to find their first jobs. Where we stand in Florida, it seems as though the alligators are nipping at our economic feet. With a quarter of the economy here in Orlando driven by construction, you can buy a nice condo that sold for $160,000 in 2007 for $20k today!

So what can we do to help our OM students to be more competitive as they enter the job market? Since everyone graduating already has the same basic set of skills (eg., Excel, Powerpoints, etc.), how can OM add value? Here are 2 suggestions:

1.Project management is an interesting topic (Ch.3) that is certainly useful in so many jobs. We cover MS Project lightly towards the end of the chapter. But I am convinced that mastering MS Project can give a competitive edge. Last year, I provided all 75 of my students the chance to build their resumes by offering a 1-credit independent study course called “Using MS Project in Project Management”. All they had to do was find a project with at least 30 activities, and create a series of MS Project charts, along with a 1-page report. Our publisher’s reps at Pearson will provide you with as many free copies of the full-blown MS Project ( time limited) as you request. It includes an excellent Tutorial, which picks up where the text leaves off. Amazingly, 25 students signed up to build their transcripts/resumes. They produced some impressive reports and picked up a useful skill.

2. The 2nd hot button I like is to get a Six-Sigma Green Belt while in school. My colleague Jim Gilbert offers his TQM course every Fall semester. As an option, Jim arranges (at an extra lab fee of $900) for students to get certified as Green Belts. Over 30 students a year take this option and enter the workforce with a wonderful credential.

OM in the News(and Video): Ford’s Lean Auto Plant in Brazil

Ford’s most progressive plant in the world may well be in northeast Brazil, where it uses lean manufacturing, sophisticated supply chains, and a vast array of robotics to produce the EcoSport SUV and Fiesta. A colleague in that country, who is using the Portuguese edition of our text, just emailed me the link to a video about which he is justifiably proud. This 3.5 minute video illustrates all 3 concepts: lean, SCM, and automation and makes a nice presentation in Ch11 or Ch.16. (I do need to warn you that the last few seconds are a bit anti-union).

In 2009, the Ford plant produced over 207,000 vehicles. This South American operation brings so much profit to the parent company in Dearborn,Michigan,that the firm was able to turn down federal loans in 2009 that both GM and Chrysler accepted.

Brazil is becoming a leader in lean auto making, with another plant churning out VWs with a similar layout in which suppliers produce, on-site, with their own employees, the parts that are installed in the final vehicle. If you look at the Global Company Profile that opens Ch.16 in our text, you will see a layout at the Toyota Tundra plant in San Antonio, Texas that also resembles what we see in the video.

Discussion Questions:

1. Why is it doubtful that this Ford plant will be replicated in the US?

2. How does the supply chain differ from most US plants?

3. Why is this an example of lean manufaturing?

OM in the News: Toyota’s Quality Problems

Toyota’s sterling reputation for quality took a major hit in 2009-2010 with the recall of 5 million vehicles for unintended acceleration and braking issues. The auto maker was also slow to tell federal regulators about sticky accelerator pedals and was fined a record $16.4 million…not exactly the quality image the firm had built up over the past 4 decades! These quality problems led to a temporary shutdown of all US plants and a halt in the sales of 8 popular models.

The Wall Street Journal (Oct.5,2010) has just reported that all 2011 Toyota, Lexus, and Scion models are equipped with “black boxes” to help identify the cause of accidents.

Toyota’s situation would likely cause my mentor Phil Crosby to turn over in his grave. “There is absolutely no reason for having errors or defects in any product or service”, he wrote in his 1979 book Quality is Free.

Quality, it turns out, is not to be taken for granted, even when one is the leader in the field. Mercedes faced this same recall issue in 2004-2005, when its suppliers cut corners on quality in response to Mercedes’ desire to pump up corporate profits. Its recall was 1.3 million cars, costing $600 million. You may recall seeing a photo in Ch.6 of our book’s 9th ed. of an E -Class Mercedes setting itself on fire in Tokyo.

Companies that take their eye off the quality ball find that “quality is not free”, and that it may take several years to rebuild a reputation.

Discussion questions:

1.What was Toyota’s initial response to the “floor mat problem” (which it claimed caused the accelerator to stick)?

2.What is Toyota doing today to deal with customer complaints?

3. Name some other recent major recalls of cunsumer items. How were they handled?

Video Tip: SPC at Frito-Lay

Of the 30+ videos Jay and I have produced to accompany our books, I would have to say my favorite is the one called “Frito-Lay’s Quality Controlled Potato Chips” (to accompany Supp.6, SPC). Why is it top of my list?

There are a few reasons. First, its the only video we ever made where I got to star! Normally, our films are narrated, then Jay and I come on at the end to summarize a few points. But in this one, I act as narrator. Second, this is a pretty exciting topic…watching how chips are made and seeing how critical a role SPC and TQM take. Third, because my older son and some of his friends were given a cameo eating chips (early in the video).

But the most important reason I like to show this 10 minute video in class is because it shows the SPC process from start to finish. We see how the chips are inspected and tested at 9 checkpoints. Even better, we create, from scratch, an X-bar chart. This means setting the upper and lower control limits in a real company, for a real process that every student can relate to. So this video is a tutorial of sorts.

When I teach SPC, I stop the video at each math step along the way and recreate the numbers in the video on the board. I like to take my time and make sure the students comprehend each calculation in the video. Supp.6 takes on a more important role when the class sees that an everyday firm has to use all the tools we talk about.