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Status and WIP of processes: Vendor Orders C - 3000 G - 1000

Kappa

Mu D - 1200

Pi E - 3000

Rho

Sigma

Financial Performance: Inventory Over Holding Time Cost Cost This week 0 Total 0
View Bill of Materials

0 0

View Decisions

Forecast Alpha

Forecast Beta

Initialise Game

Make / Alter Decisions

Inventory Position
9000 8000 7000 6000 5000 4000 3000 2000 1000 0

Current Week 21 Inventory Position: Product Alpha Beta Comma Delta Epsilon Fi Gamma

Current Inventory Work in progress Customer Orders

Late Delivery Penalty 0 0
View Decisions

Profit from Sales 0 0

Net Profit 0 0 << Your net result Slow

View Routing

Forecast Beta

MRP / CRP

Make / Alter Decisions

Simulate! Simulate!

Fast Animation Speed
Information

Day 1

View Model Details

Inventory Position: Current Work in Customer Inventory progress Orders 700 0 0 800 0 0 1200 3000 0 2500 1200 0 2500 3000 0 8500 0 0 900 1000 0

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Demand Forecasting for Alpha Main Screen MRP Forecast Beta Clear Forecast Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Demand 535 488 514 417 600 615 427 588 641 641 595 588 693 709 750 640 639 658 784 791 Forecast Demand & Forecast 900 800 700 600 500 400 300 200 100 0 Weeks Demand / Forecast .

51 52 53 54 55 56 57 58 59 60 61 62 .

Clear Forecast Demand & Forecast Demand Forecast Weeks .

Demand Forecasting for Beta Main Screen MRP Forecast Alpha Clear Forecast Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Demand 1005 930 978 1033 908 665 949 879 970 930 833 835 894 757 884 825 843 867 718 818 Forecast Demand and Forecast 1200 Demand / Forecast 1000 800 600 400 200 0 Week .

51 52 53 54 55 56 57 58 59 60 61 62 .

Demand and Forecast Demand Forecast Week .

Master Production Schedule for Alpha and Beta Alpha Week Forecast Scheduled Receipts Projected on hand MPS for Alpha Planned Order Release Past due Current Week 21 22 500 23 24 25 26 27 28 29 30 31 32 Past Safety stock = 21 Action Bucket Beta Week Forecast Scheduled Receipts Projected on hand MPS for Beta Planned Order Release MRP for components Past Safety stock = 21 22 500 23 24 25 26 27 28 29 30 31 32 Forecast Alpha Forecast Beta Capacity Requirement Planning Main Screen Comma Week Gross requirements Scheduled receipts Projected on hand Planned Receipts Planned Order Release Delta Week Gross requirements Scheduled receipts Projected on hand Planned Receipts Planned Order Release Epsilon Week Gross requirements Scheduled receipts Projected on hand Planned Receipts Planned Order Release Fi Week Gross requirements Scheduled receipts Projected on hand Planned Receipts Planned Order Release Gamma Week Gross requirements Scheduled receipts Projected on hand Planned Receipts Planned Order Release Past Safety stock = 21 22 500 23 24 25 26 27 28 29 30 31 32 Past Safety stock = 21 22 500 23 24 25 26 27 28 29 30 31 32 Past Safety stock = 21 22 500 23 24 25 26 27 28 29 30 31 32 Past Safety stock = 21 22 500 23 24 25 26 27 28 29 30 31 32 Past Safety stock = 21 22 500 23 24 25 26 27 28 29 30 31 32 Capacity Requirements Planning Average capacity needed. in hours Week Kappa Mu Pi Rho Sigma Past due 21 Back to MRP Main Screen 22 23 24 25 26 27 28 29 30 31 32 Summary of order releases: .

Alpha Beta Comma Delta Epsilon Fi Gamma Overtime: Kappa Mu Pi Rho Sigma .

the number of Fi 's for Epsilon shows how many Fi's (2) go into one unit of Epsilon.48 min Beta Purchased Material . including set up time. it shows the lead time required by the vendor. ROUTINGS These drawings show the processes (shown in rectangular blocks) needed to build a finished product. 1 unit of Delta. It shows.2 min Rho 0. and the process time per product. that to build one unit of Alpha you need two units of Comma.8 min Rho 0. and a variation up or down occurs in processing Kappa 1. The blocks show the machines. not how many Fi's are required to assemble Alpha or Beta. In the case of the purchased parts.6 min Alpha Kappa 1.BILL OF MATERIALS Alpha Main Screen View Routing Comma Delta Epsilon Fi Fi This is a "GOZINTO" diagram. It is important to remember that these are average times. showing what goes into what. and 1 unit of Epsilon. By convention. for example.

3 min Sigma 0.5 min Sigma 0.6 min Pi 0.6 min Purchased Material Vendor lead time = 1440 min Fi Purchased Material Vendor lead time = 2000 min Gamma .5 min Pi 0.8 min Mu 0.Purchased Material Vendor lead time = 1220 min Comma Mu 0.

ed product.Main Screen Beta View Routing Gamma Delta Epsilon Fi Fi of Delta. and 1 unit of Epsilon. s in processing View BOM Main Screen .

View BOM Main Screen Delta Epsilon .

6 0.8 0. it is a purchased part A purchased part has no need of processing for it to be finished Number of components Components Number off 3 Comma Delta Epsilon 0 3 Gamma Delta Epsilon 1 Fi 1 Fi 0 0 Product Alpha 2 1 1 1 1 2 2 1 Comma Beta Epsilon Delta Fi Gamma ROUTINGS Number of processes 2 2 3 Routing Alpha Beta Delta Work Center 1 4 1 4 2 3 5 Process time Units are minutes 1.5 Page 28 .Model PRODUCTS Number of Products = 7 Main Screen Products Initial inventory Alpha List of all parts 700 This inventory will be available at time = 0 Beta 800 Comma 1200 Delta 2500 Epsilon 2500 Fi 8500 Gamma 900 PROCESSES Number of work centers = Number of units 1 1 1 1 1 Time Between Failures 5 Name Kappa Mu Pi Rho Sigma 0 0 0 0 0 Repair Time Time in minutes 30 A TBF of zero signifies no breakdowns 15 20 25 100 Bill of Materials (Got to list all parts) If any item does not have components.3 0. but order does not matter 0.6 Unit processing times for manufactured parts 1.2 All parts must be shown here.48 0.

not unit processing time Customer Ordering process Number of products to be ordered = Pending Customer Orders Product Batch Size Date 2 Number of orders = 0 Work in Process Number of orders = Product Batch size Process Step Priority Delta 1200 1 2 Epsilon 3000 3 5 2 Pending Vendor Orders Product Gamma Comma Batch size 1000 3000 Remaining Time 500 600 Number of orders = Priority 2 5 2 Costs and Profits Over Time Penalty Inventory cost Profit 150 20 0.8 0.Model Epsilon 3 5 2 3 Gamma Comma Fi 0 0 0 0.5 0.25 65 $/hour of overtime on any process $/unit/day when an order is late from the date of order $/unit/day for any product or work in process held at the factory. but not at the vendor $/unit for each product sold Page 29 . shows lead time in minutes For purchased parts.6 2000 1220 Number of processes = 0 for purchased parts 1440 Purchased part. process times show vendor lead times.

but order does not matter Page 30 .Model here.

but not at the vendor Page 31 .Model 0 for purchased parts ocess times show vendor lead times. Main Screen actory.

in days 2 Alpha 137 109 5 1 .Order Releases (Got to list all parts) Current Item Inventory Order Release Priority Alpha 700 0 Beta 800 0 Comma 1200 0 Delta 2500 0 Epsilon 2500 0 Fi 8500 0 Gamma 900 0 Overtime hours Work Center Normal Hours Overtime Hrs Kappa 40 Mu 40 Pi 40 Rho 40 Sigma 40 Total 0 0 0 0 0 1 1 1 1 1 1 1 Items here must be in the same order as in the worksheet "Model" The higher the number the higher the priority If there is no order. enter 0 40 40 40 40 40 Overtime in hours All the machines must be listed in 1 to n order Current work being processed at the factory Work in Process Product Batch size Process Step Priority Delta 1200 1 Epsilon 3000 3 Delta 1000 3 Pending orders from your customers Pending Customer Orders Product Batch Date.

still to be received Pending Vendor Orders Product Batch Comma 3000 Gamma 1000 .Main Screen Your orders to vendors.

For every item sold. Before you begin the game. the orders are filled from available inventory. the others are manufactured at your plant. Once you have decided what to order for next week.INFORMATION In this game you play the role of the production planner of the Greek Manufacturing Company. To help you decide the quantities of order releases. When the order from your customer (customer order) arrives. Once the orders are released. the factory swings into action (simulates a week). the shop order will not be released until the components are available. Your job is to release orders to the factory workers and to your vendors. Then the game sequence is: Make decisions. View the model to acquaint yourself with the particulars of the factory. you may look at the past history of orders for the products. at the beginning of a week. You may create material requirements planning and capacity requirements planning worksheets to help you in your planning. and the cycle repeats. These are made out of components. costs and profit/loss are then reported. At the end of the week. some of which are ordered from a vendor. the net profit made by you is shown. penalty costs for each product in the customer order for each day it is late. and the routings. For purchased components. You can visit the other worksheets to help you make decisions in between. . a tally of costs and profits are calculated. Unfilled orders are kept on file. You have two finished products (Alpha and Beta) to offer to your customers. The current inventory position. Make decisions. you need to initialise the game. Please be aware that if you do not have the required comopnents for an order. Simulate. You then release another order for the next week. there is no need of components. Orders may be filled partially. See the bill of materials. over time costs per hour for each machine that you order to work over time. and filled when the product is available. and so on until the game is over. At the end of the game. Then you may reinitialise and play again. A penalty is charged for each day an ordered item is late. press the Make / Alter Decisions button to enter your decisions. you receive a profit. Simulate. You do this once a week. You incur three kinds of costs: inventory holding costs for every item in the factory each day.

Main Screen View the Model Details View Bill of Materials View Routing Forecast Alpha MRP / CRP .