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Student Name:________________________________

Exam I

**Industrial Data and Systems Analysis, ORIE 3120
**

Exam I

February 26, 2009

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**Closed Book / Closed Notes
**

Scientific calculator permitted; using any device to access information you are

expected to memorize would be a violation of academic integrity.

Point value of questions is proportional to the estimated time requirement. (1 point ≈1

minute.)

Points possible: 85

Time allowed 105 minutes.

Write your name on every page. (The exam paper will be unstapled and distributed

for grading.)

Answer all questions in the space provided. Use the back of the page if necessary but

do not answer on a different page unless the exam proctor provides it. Make sure each

additional page contains your name. Hand in a complete exam.

Academic integrity is expected of all students of Cornell University, whether in the

presence or absence of members of the faculty. Understanding this, I declare I shall

not give, use, or receive unauthorized aid in this examination.

Signature of Student:_________________________________________________

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the health records. Different data collection methods can be useful in this step. and outputs of the process.] b. This is input to the next step. These goals constrain the planning process. Implement. 2 . The final step is Evaluate. constraints. the patient family interview. All the words in italics above should appear somewhere on the diagram. Points are awarded for format. This is input to the third step. [Use the next page for your answer. The control for this step is the output of measurable goals from the Plan step. The output of the diagnose step is a patient diagnosis. There are two outputs from the evaluate step: the measure of progress towards the patient’s goals and changes to the nursing care plan. The inputs to this step are the patient interview and observation. and completeness. output from the implement step. controls. These changes are fed back into the implement step (feedback control). (10 minutes) Create an IDEF0 Page A0 (a single page) describing the steps of this process. mechanisms. It is thought that application of a standardized terminology is useful in this step. The nursing care plan is a control input to the fourth step. the patient goals are considered. resources. Student Name:________________________________ Exam I Functional Modeling (15 minutes) Nurses are trained in a five-step nursing process that can be summarized as follows. Diagnose. In this step. The output of this step is a patient database. This view should not display any inputs or outputs that are intermediate products or intermediate controls of the process.ORIE 3120 1. The patient status is both an input and output of this step (show a loop from output back to input). (5 minutes) Create an IDEF0 Page A-0 describing this process (Provide nursing services) at a high level. The output of the plan step should be a set of measurable goals and a nursing care plan. Do not supply more information than what is contained in the description above. and observations by healthcare professionals. The first step is Assess. It takes as input the patient status. but it should show the major inputs. Plan. Required: a. interpretation.

] 3 Exam I .ORIE 3120 Student Name:________________________________ [This page is intentionally blank for part (a) of the previous question.

If you need to branch. When the oven cycle finishes. suppose there is only one type of cookie arriving but there is limited space to store the cookies in front of the oven. if there are trays in the queue then it starts again. those trays just disappear. diamonds for conditions. say. If there are 10 trays already waiting to go into the oven. you must set up two condition nodes (one for one branch and another for the opposite branch). 10 trays of cookies in front of the oven.ORIE 3120 2. up to 2 trays are removed from the queue and placed into the oven. When an oven cycle starts. Describe a discrete event simulation model for this situation using the graphical modeling language introduced in class (ovals for events. and lozenges for durations). Also remember that state variables should be modified only in event nodes (not in condition or duration nodes). If there are 9 or fewer trays in the queue. uniformly distributed between 10. From the point of view of the simulation. Here is how it works: a tray arrives at random intervals.5 and 17 minutes (13. Observe all the rules for the graph and label the nodes of the graph with Visual Basic pseudo-code. The oven cycle lasts exactly 25 minutes. If a tray of cookies arrives and there are already.75 minutes on average). For the cookie example considered in class. In particular. then that tray must go somewhere else (perhaps to a refrigerator). We are interested in simulating the number of trays in the queue. recall that you cannot branch on a condition node. then this tray simply disappears. then the tray joins the queue. Be sure to introduce your state variables and explain what they mean. Student Name:________________________________ Exam I Simulation Modeling (15 minutes) A common simulation problem is to model queues with blocking: customers or jobs which are blocked or turned away because there is no place to hold them. then a tray entering the queue will trigger the start of an oven cycle. If the oven is empty. 4 .

ORIE 3120 Student Name:________________________________ Exam I [This page is intentionally left blank for the answer to the previous question.] 5 .

To answer the question. The table “Orders” lists many years worth of orders. BookID.. Q020. a) (4 points) Write a query that selects orders (all fields) placed in 2008 (i.ORIE 3120 3. Number your queries Q010. Each book is assigned to a genre (category) such as “Science Fiction” or “Romance”. All queries must be written in SQL. Each book title sold by the company is uniquely identified by a “BookID” number. The final query must consist of two fields: “State” and “FractionSF”. and State. Student Name:________________________________ Exam I Structured Query Language (20 minutes) Consider the following relational database schema. The field “Quantity” is a numeric field indicating the number of books ordered. The field “OrderDate” is a Date/Time field. Name the sales value field as “BookSalesValue”. A book retail company has many stores located around the country. etc. which is a numeric quantity. Q030. We want to discover if science fiction books sell better in one part of the country than in another. YEAR(OrderDate)=2008). “NY” for New York) in the field “State”. Each store is uniquely identified by a “StoreID” number. b) (4 points) Write one or more queries that compute the total sales value (quantity * list price) of each book grouped by Genre. in the sequence in which you create them. we want to compute the fraction of book sales (quantity * list price) in each state in 2008 that were in the “Science Fiction” category. Please use the following steps even if you see shortcuts. Stores place orders for books. In particular. Each order is for a single book title and is uniquely identified by the “OrderID” number. Table prefixes may be omitted if field names are unambiguous. The table “Books” lists all the books sold.e. 6 . together with the list price (“ListPrice”). it lists a two character abbreviation for the state (ex. The table “Stores” lists the address of each store.

Name the sales value field as “SFSalesValue”. e) (4 points) Write one or more queries that computes the fraction of 2008 book sales that are science fiction. Do not worry about division by zero. matched by State. Name the ratio field as “FractionSF”. This is simply the ratio of the numbers computed in (d) and (c). grouped by State. d) (4 points) Write one or more queries that computes the total sales value of all science fiction books (i. Name the sales value field as “TotalSalesValue”.ORIE 3120 Student Name:________________________________ Exam I c) (4 points) Write one or more queries that compute the total sales value of all books sold in 2008. grouped by State. Genre=”Science Fiction”) sold in 2008. 7 . grouped by State.e.

The lead time to acquire this product is 10 days. The press fails approximately every three hours but it can be repaired in about 15 minutes. Mark up the chart below to show how you would compute the normalized reorder point for this problem and then use the table below to interpolate a more exact answer.ORIE 3120 4. what is the effective throughput if we also must set up the equipment for 20 minutes after every 600 parts produced? b) Safety Stock (6 minutes).5%. A product has an average daily demand of 50 units with a standard deviation of 12 units. i. We would like to achieve a fill rate of at least 99. we order 800 units. The scrap rate is 2% and the rework rate is 3%. ii. Using your answer from (i). The nominal throughput from a stamping operation is 120 pieces per hour. “What should be the reorder point for this product?” 8 . Student Name:________________________________ Exam I Inventory Models (20 minutes) a) Throughput (6 minutes). rework. Whenever the product is ordered. answer the question. Finally. and failure) are independent and you can simply multiply their effects together. What is the effective throughput of the press? You may assume all of the effects (scrap.

5 Norm alized Reorder Point.9 E[max(Z-k.000761087 0.25 0.5 1 1.7 2.00146388 0.3 2.39894228 0.9 3 E[max(Z-k.5 3 3.029306794 0.8 0.ORIE 3120 Student Name:________________________________ Exam I Std.011054351 k 2.35 0.002720444 0.1 0.6 2.5 1.083315471 0.3 1. k k 0 0.000541674 0.7 1.3 0.3 0.266761242 0.2 1.45 0. E[max(Z-k.2 2.1 0.2 0.1 1.120207234 0.8 1.100431137 k 1 1.4 2.018287791 0.306894636 0.4 0.8 2.003661585 0.6 1.045527962 0.5 2.05 0 0 0.15 0.056102451 0.7 0.0)] 0.4 1.014275584 0.350935331 0.6 0. Normal Backorders.230438837 0.0) 0.0) 0.036668143 0.023241968 0.000382154 .2 0.001060106 0.4 0.06861951 0.006468313 0.142879377 0.5 0.5 2 2.0) 0.168672732 0.002004137 0.9 9 E[max(Z-k.004887008 0.197796557 0.1 2.

The coefficient of variation in processing times is 0. Recall that the queue factor is the ratio of the time spent in the system (queue time plus valued added time) to the value added time.5 minutes per job at station 1 and 2. The coefficient of variation in arrival times is 1. on average.25 at each station.) The coefficient of variation of the departure process from a queue is approximated by: 2 2 2 c d = ρ 2 c e + (1 − ρ 2 )c a Consider two workstations in series. 10 . Kingman’s approximation for the expected waiting time in a single server queue is ⎛ c a 2 + ce 2 ⎞⎛ ρ ⎞ ⎟⎜⎜ Wq = ⎜⎜ ⎟⎝ 1 − ρ ⎟⎟⎠me 2 ⎝ ⎠ (The notation was explained in class. Use Little’s Law and the queueing formulas above to estimate the queueing factor for this system.8 minutes per job. Jobs arrive at station 1 at the rate of 20 per hour. Value added time corresponds to expected process time in this example. Jobs can wait in queue in front of each workstation. When a job has finished being processed at station 1 it enters the queue in front of station 2. at station 2.5.ORIE 3120 Student Name:________________________________ Exam I c) Decoupling Stock and Little’s Law (8 minutes). Workstation 1 precedes workstation 2. On average. the processing time is 2.

b) In the THRUPUT game. we can reduce lot sizes in a factory.” What was the reason for this or what was implemented to correct this? c) By reducing setup times. a major category of lost throughput was classified as “unexplained. what is the significance of the painted floor areas? f) Describe a cycle of activities that a worker performs in a manufacturing cell [Hint: MO-CO-MOO]? g) What do the acronyms RETAD and SMED stand for? 11 . What will happen to fill rates as we reduce the lot sizes and how must we change the reorder point to compensate? d) List any four items of information that can be found on a General Motors pull ticket.ORIE 3120 5. during the initial weeks of play. the THRUPUT Game. and the PULL Game (15 minutes) a) Identify four major categories of throughput loss in a factory. e) In “Pull” play of the PULL game. Student Name:________________________________ Exam I Lean Manufacturing.

or Americanized versions)? k) What is the first thing that the new Quality Control manager for Matsushita did to improve the quality at a former Quasar TV plant? l) Explain what is a pokayoke or give an example. m) What is the difference between leveling and balancing in the Toyota Production System? n) As a forklift truck driver.ORIE 3120 Student Name:________________________________ Exam I h) What does it mean to “convert internal setup to external?” i) Give two practical examples of ways to reduce setup or changeover time. if someone hands me a production kanban. what should I do with it? o) As a production cell supervisor. if someone hands me a withdrawal kanban. English. j) What are the “5 S’s” (Japanese. what should I do with it? 12 .

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