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Status and WIP of processes: Financial Performance:

Kappa Mu Pi Rho Sigma

Vendor

Orders

Inventory

Holding

Cost

Over

Time

Cost

D - 1200 E - 3000 C - 3000 This week 0 0G - 1000 Total 0 0

Current

Week

21

Inventory

Product

AlphaBetaCommaDeltaEpsilonFiGamma0

100020003000400050006000700080009000

Inventory Position

CurrentInventory

Work inprogress

CustomerOrders

Forecast Alpha Forecast

Initialise Game Make / Alter

View Bill of Materials View D

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Late

Delivery

Penalty

Profit

from

Sales Net Profit

0 0 00 0 0

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49

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Demand Forecasting for Alpha

Week Demand Forecast

1 5352 4883 5144 4175 6006 6157 4278 588

9 64110 64111 59512 58813 69314 709

15 75016 64017 63918 65819 78420 7912122

232425262728

293031323334353637

38394041

4243

44454647484950

Main Screen MRP Forecast Beta

0

100200300400500600700800900

Demand/Forecast

We

Demand

Clear Forecast

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515253545556

575859606162

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ks

& Forecast

Demand

Forecast

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Demand Forecasting for Beta

Week Demand Forecast

1 10052 9303 9784 10335 9086 6657 9498 879

9 97010 93011 83312 83513 89414 757

15 88416 82517 84318 86719 71820 8182122

232425262728

293031323334353637

38394041

4243

44454647484950

Main Screen MRP Forecast Alpha

0

200

400

600800

1000

1200

Demand/Forecast

Wee

Demand a

Clear Forecast

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515253545556

575859606162

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k

nd Forecast

Demand

Forecast

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Master Production Schedule for Alpha and Beta Current Week

21

Alpha Safety stock = 500

Week Past 21 22 23 24 25 26 27

ForecastScheduled ReceiptsProjected on handMPS for AlphaPlanned Order Release

Past due Action Bucket

Beta Safety stock = 500

Week Past 21 22 23 24 25 26 27ForecastScheduled ReceiptsProjected on handMPS for BetaPlanned Order Release

MRP for components

Comma Safety stock = 500

Week Past 21 22 23 24 25 26 27Gross requirementsScheduled receiptsProjected on handPlanned ReceiptsPlanned Order Release

Delta Safety stock = 500

Week Past 21 22 23 24 25 26 27Gross requirements

Scheduled receiptsProjected on handPlanned ReceiptsPlanned Order Release

Epsilon Safety stock = 500

Week Past 21 22 23 24 25 26 27Gross requirementsScheduled receiptsProjected on handPlanned ReceiptsPlanned Order Release

Fi Safety stock = 500

Week Past 21 22 23 24 25 26 27

Gross requirementsScheduled receiptsProjected on handPlanned ReceiptsPlanned Order Release

Gamma Safety stock = 500

Week Past 21 22 23 24 25 26 27Gross requirementsScheduled receiptsProjected on handPlanned ReceiptsPlanned Order Release

Capacity Requirements PlanningAverage capacity needed, in hours

W k P t d 21 22 23 24 25 26 27

Forecast Alpha Forecast BetaCa

Back to MRP Main Screen

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AlphaBetaCommaDelta

EpsilonFiGamma

Overtime:

KappaMuPiRhoSigma

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BILL OF MATERIALS

This is a "GOZINTO" diagram, showing what goes into what.It shows, for example, that to build one unit of Alpha you need two units of Comma, 1 unit of Delta, andBy convention, the number of Fi 's for Epsilon shows how many Fi's (2) go into one unit of Epsilon,

not how many Fi's are required to assemble Alpha or Beta.

ROUTINGS

These drawings show the processes (shown in rectangular blocks) needed to build a finished product.The blocks show the machines, and the process time per product, including set up time.In the case of the purchased parts, it shows the lead time required by the vendor.It is important to remember that these are average times, and a variation up or down occurs in processi

Comma Delta Epsilon

Fi

Alpha

Fi

Kappa

1.2 min

Rho

0.6 minAlpha

Kappa

1.8 min

Rho

0.48 minBeta

Main Screen

View Routing

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Mu

0.5 min

Pi

0.6 min

Sigma

0.8 min

Pi

0.3 min

Sigma

0.5 min

Mu

0.6 min

Purchased Material

Vendor lead time = 2000 minGamma

Purchased Material

Vendor lead time = 1220 minComma

Purchased MaterialVendor lead time = 1440 min

Fi

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1 unit of Epsilon.

ng

Gamma Delta Epsilon

Fi

Beta

Fi

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Epsilon

Delta

View BOM Main Screen

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Model

PRODUCTS

Number of Products = 7

Products Initial inventory

Alpha List of all parts 700 This inventory will be available at time = 0Beta 800

Comma 1200Delta 2500Epsilon 2500Fi 8500Gamma 900

PROCESSES

Number of work centers = 5

Name

Number of

units

Time

Between

Failures Repair Time Time in minutesKappa 1 0 30 A TBF of zero signifies no breakdowns

Mu 1 0 15

Pi 1 0 20Rho 1 0 25Sigma 1 0 100

Bill of Materials (Got to list all parts)If any item does not have components, it is a purchased part

A purchased part has no need of processing for it to be finished

Product

Number of

components Components Number off

Alpha 3 Comma 2Delta 1

Epsilon 1

Comma 0Beta 3 Gamma 1

Delta 1Epsilon 2

Epsilon 1 Fi 2Delta 1 Fi 1Fi 0

Gamma 0

ROUTINGS

Routing

Number of

processes Work Center Process time Units are minutes

Alpha 2 1 1.2 All parts must be shown here, but order does4 0.6 Unit processing times for manufactured parts

Beta 2 1 1.84 0.48

Delta 3 2 0.6

3 0.35 0.5

Main Screen

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Model

Epsilon 3 5 0.82 0.53 0.6

Gamma 0 2000Comma 0 1220 Number of processes = 0 for purchased partsFi 0 1440 Purchased part, shows lead time in minutes

For purchased parts, process times show vennot unit processing time

Customer Ordering process

Number of products to be ordered = 2

Pending Customer Orders Number of order 0

Product Batch Size Date

Work in Process Number of order 2

Product Batch size Process Step PriorityDelta 1200 1 2Epsilon 3000 3 5

Pending Vendor Orders Number of order 2

Product Batch size

RemainingTime Priority

Gamma 1000 500 2Comma 3000 600 5

Costs and Profits

Over Time 150 $/hour of overtime on any processPenalty 20 $/unit/day when an order is late from the date of order Inventory c 0.25 $/unit/day for any product or work in process held at the factory, but not at the vProfit 65 $/unit for each product sold

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Model

not matter

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Model

dor lead times,

endor

Main Screen

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Order Releases

(Got to list all parts)

Item

Current

Inventory Order Release Priority

Alpha 700 0 1 Items here must be in the same order as

Beta 800 0 1 in the worksheet "Model"Comma 1200 0 1 The higher the number the higher the priorityDelta 2500 0 1 If there is no order, enter 0Epsilon 2500 0 1Fi 8500 0 1Gamma 900 0 1

Overtime hours

Work Center Normal Hours Overtime Hrs Total Overtime in hoursKappa 40 0 40 All the machines must be listedMu 40 0 40 in 1 to n order Pi 40 0 40Rho 40 0 40

Sigma 40 0 40

Current work being processed at the factory Pending orders from your customers

Work in Process Pending Customer Orders

Product Batch size Process Step Priority Product Batch Date, in days

Delta 1200 1 2 Alpha 137 109

Epsilon 3000 3 5Delta 1000 3 1

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Your orders to vendors, still to be received

Pending Vendor Orders

Product Batch

Comma 3000

Gamma 1000

Main Screen

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INFORMATION

In this game you play the role of the production planner of the Greek Manufacturing Company. Your job is torelease orders to the factory workers and to your vendors. You do this once a week, at the beginning of a week.Once the orders are released, the factory swings into action (simulates a week). At the end of the week, a tally ofcosts and profits are calculated. The current inventory position, costs and profit/loss are then reported. You then

release another order for the next week, and the cycle repeats.

View the model to acquaint yourself with the particulars of the factory. You incur three kinds of costs: inventoryholding costs for every item in the factory each day, over time costs per hour for each machine that you order towork over time, penalty costs for each product in the customer order for each day it is late. For every item sold,you receive a profit.

Before you begin the game, you need to initialise the game. Then the game sequence is: Make decisions,Simulate, Make decisions, Simulate, and so on until the game is over. Then you may reinitialise and play again.You can visit the other worksheets to help you make decisions in between.

You have two finished products (Alpha and Beta) to offer to your customers. These are made out of components,

some of which are ordered from a vendor, the others are manufactured at your plant. See the bill of materials,and the routings. When the order from your customer (customer order) arrives, the orders are filled fromavailable inventory. Unfilled orders are kept on file, and filled when the product is available. Orders may be filledpartially. A penalty is charged for each day an ordered item is late.

Once you have decided what to order for next week, press the Make / Alter Decisions button to enter yourdecisions. Please be aware that if you do not have the required comopnents for an order, the shop order will notbe released until the components are available. For purchased components, there is no need of components.

To help you decide the quantities of order releases, you may look at the past history of orders for the products.

You may create material requirements planning and capacity requirements planning worksheets to help you in

your planning.

At the end of the game, the net profit made by you is shown.

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View Bill of Materials

View Routing

MRP / CRP

Forecast Alpha

View the Model Details

Main Screen