Case Study: The Realco Breadmaster
- Develop a master production schedule for the breadmaker. What do the projected ending inventory and available-to-promise numbers look like? Has Realco "overpromised"? In your view, should Realco update either the forecast or the production numbers?
- Comment on Jack's approach to order promising. What are the advantages? The disadvantages? How would formal master scheduling improve this process? What organizational changes would be required?
- Following up on Question 2, which do you think is worse, refusing a customer's order upfront because you don't have the units available or accepting the order and then failing to deliver? What are the implications for master scheduling?
- Suppose Realco produces 20,000 breadmakers every week, rather than 40,000 every other week. According to the master schedule record, what impact would this have on average inventory levels?
Case Study: Supply-Chain Challenges in Post-Earthquake Japan
- What are some of the advantages of the supply chain used in the Japanese auto industry before the March 11 earthquake and tsunami? What were some of its disadvantages?
- Is Toyota's plan for a "foolproof" supply chain consistent with the Lean production philosophy? Explain.
- Can you think of any additional ways Toyota (and its competitors in the Japanese auto industry) can improve upon the company's plan to create a "foolproof" supply chain?
- What impact do you think Toyota's plan will have on the way it handles relationship management in its supply chain?