Good doctor–patient relations begin with both parties being punctual for appointments. I am Dr. Schafer, and being punctual is particularly important in my specialty: pediatrics. Mothers whose children have only minor problems don’t like them to sit in the waiting room with really sick ones, and the sick kids become fussy if they have to wait long. But lateness—no matter who’s responsible for it—can cause problems in any practice. Once you’ve fallen more than slightly behind, it may be impossible to catch up that day. And although it’s unfair to keep someone waiting who may have other appointments, the average office patient cools his heels for almost 20 minutes, according to one recent survey. Patients may tolerate this, but they don’t like it. I don’t tolerate that in my office, and I don’t believe you have to in yours. I see patients exactly at the appointed hour more than 99 times out of 100. So there are many GPs (grateful patients) in my busy solo practice. Parents often remark to me, “We really appreciate your being on time. Why can’t other doctors do that, too?” My answer is “I don’t know, but I’m willing to tell them how I do it.” Booking Appointments Realistically The key to successful scheduling is to allot the proper amount of time for each visit, depending on the services required, and then stick to it. This means that the physician must pace her- or himself carefully, receptionists must be corrected if they stray from the plan, and patients must be taught to respect their appointment times. By actually timing a number of patient visits, I found that they break down into several categories. We allow half an hour for any new patient, 15 minutes for a well-baby checkup or an important illness, and either 5 or 10 minutes for a recheck on an illness or injury, an immunization, or a minor problem like warts. You can, of course, work out your own time allocations, geared to the way you practice. When appointments are made, every patient is given a specific time, such as 10:30 or 2:40. It’s an absolute no-no for anyone in my office to say to a patient, “Come in 10 minutes” or “Come in a half-hour.” People often interpret such instructions differently, and nobody knows just when they’ll arrive. There are three examining rooms that I use routinely, a fourth that I reserve for teenagers, and a fifth for emergencies. With that many rooms, I don’t waste time waiting for patients, and they rarely have to sit in the reception area. In fact, some of the younger children complain that they don’t get time to play with the toys and puzzles in the waiting room before being examined, and their mothers have to let them play awhile on the way out. On a light day, I see 20 to 30 patients between 9 A.M. and 5 P.M. But our appointment system is flexible enough to let me see 40 to 50 patients in the same number of hours if I have to. Here’s how we tighten the schedule: My two assistants (three on the busiest days) have standing orders to keep a number of slots open throughout each day for patients with acute illnesses. We try to reserve more such openings in the winter months and on the days following weekends and holidays, when we’re busier than usual. Initial visits, for which we allow 30 minutes, are always scheduled on the hour or the half-hour. If I finish such a visit sooner than planned, we may be able to squeeze in a patient who needs to be seen immediately. And, if necessary, we can book two or three visits in 15 minutes between well-checks. With these cushions to fall back on, I’m free to spend an extra 10 minutes or so on a serious case, knowing that the lost time can be made up quickly. Parents of new patients are asked to arrive in the office a few minutes before they’re scheduled in order to get the preliminary paperwork done. At that time, the receptionist informs them, “The doctor always keeps an accurate appointment schedule.” Some already know this and have chosen me for that very reason. Others, however, don’t even know that there are doctors who honor appointment times, so we feel it’s best to warn them on the first visit. Fitting in Emergencies Emergencies are the excuse doctors most often give for failing to stick to their appointment schedules. Well, when a child comes in with a broken arm or the hospital calls with an emergency Caesarean section, naturally I drop everything else. If the interruption is brief, I may just scramble to catch up. If it’s likely to be longer, the next few patients are given the choice of waiting or making new appointments. Occasionally, my assistants have to reschedule all appointments for the next hour or two. Most such interruptions, though, take no more than 10 to 20 minutes, and the patients usually choose to wait. I then try to fit them into the spaces we’ve reserved for acute cases that require last-minute appointments. The important thing is that emergencies are never allowed to spoil my schedule for the whole day. Once a delay has been adjusted for, I’m on time for all later appointments. The only situation I can imagine that would really wreck my schedule is simultaneous emergencies in the office and at the hospital—but that has never occurred. When I return to the patient I’ve left, I say, “Sorry to have kept you waiting, I had an emergency—a bad cut” (or whatever). A typical reply from the parent: “No problem, Doctor. In all the years I’ve been coming here, you’ve never made me wait before. And I’d surely want you to leave the room if my kid were hurt.” Emergencies aside, I get few walk-ins, because it’s generally known in the community that I see patients only by appointment except in urgent circumstances. A nonemergency walk-in is handled as a phone call would be. The receptionist asks whether the visitor wants advice or an appointment. If the latter, he or she is offered the earliest time available for nonacute cases. Taming the Telephone Phone calls from patients can sabotage an appointment schedule if you let them. I don’t. Unlike some pediatricians, I don’t have a regular telephone hour, but my assistants will handle calls from parents at any time during office hours. If the question is a simple one, such as “How much aspirin do you give a one-year-old?” the assistant will answer it. If the question requires an answer from me, the assistant writes it in the patient’s chart and brings it to me while I’m seeing another child. I write the answer in— or she enters it in the chart. Then, she relays it to the caller. What if the caller insists on talking with me directly? The standard reply is “The doctor will talk with you personally if it won’t take more than one minute. Otherwise, you’ll have to make an appointment and come in.” I’m rarely called to the phone in such cases, but if the mother is very upset, I prefer to talk with her. I don’t always limit her to one minute; I may let the conversation run two or three. But the caller knows I’ve left a patient to talk with her, so she tends to keep it brief. Dealing with Latecomers Some people are habitually late; others have legitimate reasons for occasional tardiness, such as a flat tire or “He threw up on me.” Either way, I’m hard-nosed enough not to see them immediately if they arrive at my office more than 10 minutes behind schedule, because to do so would delay patients who arrived on time. Anyone who is less than 10 minutes late is seen right away, but is reminded of what the appointment time was. When it’s exactly 10 minutes past the time reserved for a patient and he hasn’t appeared at the office, a receptionist phones his home to arrange a later appointment. If there’s no answer and the patient arrives at the office a few minutes later, the receptionist says pleasantly, “Hey, we were looking for you. The doctor’s had to go ahead with his other appointments, but we’ll squeeze you in as soon as we can.” A note is then made in the patient’s chart showing the date, how late he was, and whether he was seen that day or given another appointment. This helps us identify the rare chronic offender and take stronger measures if necessary. Most people appear not to mind waiting if they know they themselves have caused the delay. And I’d rather incur the anger of the rare person who does mind than risk the ill will of the many patients who would otherwise have to wait after coming in on schedule. Although I’m prepared to be firm with parents, this is rarely necessary. My office in no way resembles an army camp. On the contrary, most people are happy with the way we run it, and tell us so frequently. Coping with No-Shows What about the patient who has an appointment, doesn’t turn up at all, and can’t be reached by telephone? Those facts, too, are noted in the chart. Usually there’s a simple explanation, such as being out of town and forgetting about the appointment. If it happens a second time, we follow the same procedure. A third-time offender, though, receives a letter reminding him that time was set aside for him and he failed to keep three appointments. In the future, he’s told, he’ll be billed for such wasted time. That’s about as tough as we ever get with the few people who foul up our scheduling. I’ve never dropped a patient for doing so. In fact, I can’t recall actually billing a no-show; the letter threatening to do so seems to cure them. And when they come back—as nearly all of them do—they enjoy the same respect and convenience as my other patients. Questions 1. What features of the appointment scheduling system were crucial in capturing “many grateful patients”? 2. What procedures were followed to keep the appointment system flexible enough to accommodate the emergency cases, and yet be able to keep up with the other patients’ appointments? 3. How were the special cases such as latecomers and no-shows handled? 4. Prepare a schedule starting at 9 A.M. for the following patients of Dr. Schafer: Johnny Appleseed, a splinter on his left thumb. Mark Borino, a new patient. Joyce Chang, a new patient. Amar Gavhane, 102.5 degree (Fahrenheit) fever. Sarah Goodsmith, an immunization. Tonya Johnston, well-baby checkup. JJ Lopez, a new patient. Angel Ramirez, well-baby checkup. Bobby Toolright, recheck on a sprained ankle. Rebecca White, a new patient. Dr. Schafer starts work promptly at 9 A.M. and enjoys taking a 15-minute coffee break around 10:15 or 10:30 A.M. Apply the priority rule that maximizes scheduling efficiency. Indicate whether or not you see an exception to this priority rule that might arise. Round up any times listed in the case study (e.g., if the case study stipulates 5 or 10 minutes, then assume 10 minutes for the sake of this problem).
> Joe has achieved a position of some power in the institution in which he currently resides and works. In fact, things have gone so well that he has decided to divide the day-to-day operations of his business activities among four trusted subordinates: Bi
> In a workcenter, six machinists were uniquely qualified to operate any one of the five machines in the shop. The workcenter had considerable backlog, and all five machines were kept busy at all times. The one machinist not operating a machine was usually
> The following matrix shows the costs in thousands of dollars for assigning Individuals A, B, C, and D to Jobs 1, 2, 3, and 4. Solve the problem showing your final assignments in order to minimize cost. Assume that each job will be assigned to one individ
> Schedule the following six jobs through two machines in sequence to minimize the flow time using Johnson’s rule. Operations Time Job Machine 1 Machine 2 5 2 16 15 1 9 13 11 E 17 18 N LO AB
> Joe is the production scheduler in a brand-new custom refinishing auto service shop located near the border. This system is capable of handling 10 cars per day. The sequence is customizing first, followed by repainting. In what sequence should Joe sche
> Hoosier Manufacturing operates a production shop that is designed to have the lowest unit production cost at an output rate of 100 units per hour. In the month of July, the company operated the production line for a total of 175 hours and produced 16,90
> Jobs A, B, C, D, and E must go through Processes I and II in that sequence (Process I first, then Process II). Use Johnson’s rule to determine the optimal sequence in which to schedule the jobs to minimize the total required time.
> Seven jobs must be processed in two operations: A and B. All seven jobs must go through A and B in that sequence—A first, then B. Determine the optimal order (shortest flow time to complete all the jobs) in which the jobs should be sequ
> Discuss the nature of the costs that affect inventory size. a. How does shrinkage (stolen stock) contribute to the cost of carrying inventory? How can this cost be reduced? b. How does obsolescence contribute to the cost of carrying inventory? How can
> What is the term used for the bundle of goods and services that are provided in some environment by every service operation?
> What term refers to a schedule that pulls material into final assembly at a constant rate?
> Bill Edstrom, managing partner at a biomedical consulting firm, has requested your expert advice in devising the best schedule for the following consulting projects, starting on February 2. The consulting firm charges a flat rate of $4,000 per day. All
> The following table contains information regarding jobs that are to be scheduled through one machine. a. What is the first-come, first-served (FCFS) schedule? b. What is the shortest operating time (SOT) schedule? c. What is the slack time remaining (S
> A manufacturing facility has five jobs to be scheduled into production. The following table gives the processing times plus the necessary wait times and other necessary delays for each of the jobs. Assume that today is April 3, that the facility will wor
> What do we generally call an area in a business where productive resources are organized and work is completed?
> What is the term used for an information system that links, schedules, dispatches, tracks, monitors, and controls customer encounters with a service organization?
> Which simple scheduling concept can be applied to help schedule workers for service operation with changing staffing requirements throughout the day?
> What feature of manufacturing planning and control systems operates under the premise that planned work input to a work center should never exceed the planned work output?
> What shop-floor control document tells the supervisor which jobs are to be run, in what order, how long each will take?
> Distinguish between in-process inventory, safety stock inventory, and seasonal inventory.
> A company has a factory that is designed so that it is most efficient (average unit cost is minimized) when producing 15,000 units of output each month. However, it has an absolute maximum output capability of 17,250 units per month, and can produce as
> Which graphical tool commonly used in project management is also very useful in shop-floor control?
> What lean concept relates to eliminating non-value-added steps and waste in product storage processes?
> A psychological therapist treats patients according to their individual needs. Patients are all treated in the same office on a scheduled basis. Each patient’s treatment is customized for the individual according to the therapist’s professional trainin
> What is another common term for shop-floor control?
> A key part of work-center scheduling is job sequencing – deciding in what order jobs are scheduled to start/complete. What is the term for the simple rules used to aid this process using a single bit of data about the jobs?
> What type of inventory are we trying to minimize as the result of work-center scheduling?
> If you have five exams to study for, how many alternative schedules exist?
> What priority rule do you use in scheduling your study time for midterm examinations?
> What practical considerations are deterrents to using the SOT rule?
> Meritor is so pleased with the outcome from previous suggestions that the consultants are invited back for more work. The consultants now suggest a more complete robotic automation of the making of muffler assemblies and also a reduction in container siz
> How might planning for a special customer affect the personnel schedule in a service?
> Explain why scheduling personnel in a service operation can be challenging.
> Data integrity is a big deal in industry. Why?
> The following represents a project that should be scheduled using CPM: a. Draw the network. b. What is the critical path? c. What is the expected project completion time? d. What is the probability of completing this project within 16 days? TIMES (
> Suppose that operators have enough training to operate both the bronze machines and the injection molding machine for the plastic sprinklers. Currently, AlwaysRain has 10 such employees. In anticipation of the ad campaign described in problem 5, manageme
> Flowcharts are a common process design and analysis tool used in both manufacturing and services. What is a key feature on flowcharts used in service operations that differentiates between the front-office and back-office aspects of the system?
> How would a flowchart help in planning the servicescape layout? What sorts of features would act as focal points or otherwise draw customers along certain paths through the service? In a supermarket, what departments should be located first along the c
> Why is it desired to have smooth, continuous flow on the shop floor?
> The chapter discusses the use of Gantt charts in shop floor control. You were introduced to Gantt charts in Chapter 4, “Project Management.” Projects and workcenter processes are rather different in nature. Why is it that the same tool can be used in bot
> Under what conditions is the assignment method appropriate?
> Distinguish between dependent and independent demand in a McDonald’s, in an integrated manufacturer of personal copiers, and in a pharmaceutical supply house.
> Why is managing bottlenecks so important in workcenter scheduling?
> What job characteristics would lead you to schedule jobs according to “longest processing time first”?
> Why does batching cause so much trouble in workcenters?
> The SOT rule provides an optimal solution in a number of evaluation criteria. Should the manager of a bank use the SOT rule as a priority rule? Why?
> List at least four of the seven prominent types of waste that should be eliminated from the supply chain.
> Distinguish between a work center, a GT cell, and an assembly line.
> What are the objectives of work-center scheduling?
> An important difference between service and manufacturing operations is that customers induce far more variability into the operation in a service system. Name at least three of the basic types of variation that customers bring to a service system.
> In anticipation of the ad campaign, AlwaysRain bought an additional bronze machine. Will this be enough to ensure that adequate capacity is available?
> What are some capacity balance problems faced by the following organizations or facilities? a. An airline terminal b. A university computing lab c. A clothing manufacturer
> Assume that product Z is made of two units of A and four units of B. A is made of three units of C and four of D. D is made of two units of E. Lead times for the purchase or fabrication of each unit to final assembly are: Z takes two weeks; A, B, C, and
> In the following MRP planning schedule for item J, indicate the correct net requirements, planned-order receipts, and planned-order releases to meet the gross requirements. Lead time is one week. Week Number Item J 2 3 4 Gross requirements 75 50 70
> Semans is a manufacturer that produces bracket assemblies. Demand for bracket assemblies (X) is 130 units. The following is the BOM in indented form: The following is a table indicating current inventory levels: a. Using Excel, create the MRP using t
> Match the industry type to the expected benefits from an MRP system as High, Medium, or Low. Industry Type Expected Benefit (High, Medium, or Low) Assemble-to-stock Assemble-to-order Make-to-stock Make-to-order Engineer-to-order Proce
> Product A consists of two units of subassembly B, three units of C, and one unit of D. B is composed of four units of E and three units of F. C is made of two units of H and three units of D. H is made of five units of E and two units of G. a. Construct
> What term refers to the optimization of value-adding activities and elimination of non-value adding activities that are part of a value stream?
> The MRP gross requirements for item X are shown here for the next 10 weeks. Lead time for A is two weeks, and setup cost is $9. There is a carrying cost of $0.02 per unit per week. Beginning inventory is 70 units. Use the least total cost or the least
> The MRP gross requirements for item A are shown here for the next 10 weeks. Lead time for A is three weeks and setup cost is $10. There is a carrying cost of $0.01 per unit per week. Beginning inventory is 90 units. Use the least total cost or the leas
> Audio Products, Inc., produces two AM/FM/CD players for cars. The radio/CD units are identical, but the mounting hardware and finish trim differ. The standard model fits intermediate and full-sized cars, and the sports model fits small sports cars.
> Product A is an end item and is made from two units of B and four of C. B is made of three units of D and two of E. C is made of two units of F and two of E. A has a lead time of one week. B, C, and E have lead times of two weeks, and D and F have lead t
> How have price and variety competition changed McDonald’s basic formula for success?
> As the degree of customer contact increases in a service system, what worker skills would be more important, clerical skills or diagnostic skills?
> Each unit of A is composed of one unit of B, two units of C, and one unit of D. C is composed of two units of D and three units of E. Items A, C, D, and E have on-hand inventories of 20, 10, 20, and 10 units, respectively. Item B has a scheduled rece
> Suppose that AlwaysRain Irrigation’s marketing department will undertake an intense ad campaign for the bronze sprinklers, which are more expensive but also more durable than the plastic ones. Forecast demand for the next four years is
> One unit of A is composed of two units of B and three units of C. Each B is composed of one unit of F. C is made of one unit of D, one unit of E, and two units of F. Items A, B, C, and D have 20, 50, 60, and 25 units of on-hand inventory, respectivel
> One unit of A is made of two units of B and one unit of C. B is made of three units of D and one unit of F. C is composed of three units of B, one unit of D, and four units of E. D is made of one unit of E. Item C has a lead time of one week; items A, B,
> One unit of A is made of one unit of B and one unit of C. B is made of four units of C and one unit each of E and F. C is made of two units of D and one unit of E. E is made of three units of F. Item C has a lead time of one week; items A, B, E, and F ha
> What phrase refers to the idea that every step in supply chain processes that deliver goods and services to the customer should create value?
> What is value stream mapping?
> One unit of A is made of two units of B, three units of C, and two units of D. B is composed of one unit of E and two units of F. C is made of two units of F and one unit of D. E is made of two units of D. Items A, C, D, and F have one-week lead times; B
> One unit of A is made of three units of B, one unit of C, and two units of D. B is composed of two units of E and one unit of D. C is made of one unit of B and two units of E. E is made of one unit of F. Items B, C, E, and F have one-week lead times; A a
> Consider a department store. Which departments probably should not be located near each other? Would any departments benefit from close proximity?
> Big10Sweaters.com is a new company started last year by two recent college graduates. The idea behind the company was simple. It will sell premium logo sweaters for Big Ten colleges with one major, unique feature. This unique feature is a special large m
> What category of planning covers a period from a day to six months, with daily or weekly time increments?
> Major operations and supply planning activities can be grouped into categories based on the relevant time range of the activity. What time range category does sales and operations planning fit into?
> What strategy do the following organizations seem to use to manage customer-introduced variability? a. EBay b. Ritz-Carlton Hotels c. New airline check-in procedures
> List some practical limits to economies of scale; that is, when should a plant stop growing?
> The essence of yield management is the ability to manage what?
> In a yield management system, pricing differences must appear logical and justified to the customer. The basis for this justification is commonly called what?
> Under what type of demand is yield management most effective?
> The widespread scientific application of yield management began within what industry?
> Refer to Example 14.1 as the basis for this problem. Meritor hires a team of consultants. The consultants suggest a partial robotic automation, as well as an increase in safety stock to 12.5 percent. Meritor implements these suggestions. The result is an
> How would you show a pull system in VSM Symbols between the blanking and CNC stages of the bolt manufacturing solved problems?
> Which of the four costs relevant to aggregate production planning is the most difficult to accurately measure?
> List at least three of the four costs relevant to the aggregate production plan.
> What is the term for a more complex production strategy that combines approaches from more than one basis strategy?
> In the agriculture industry, migrant workers are commonly employed to pick crops ready for harvest. They are hired as needed and are laid off once the crops are picked. This approach is made necessary by the realities of the industry. Which production p
> Plan production for the next year. The demand forecast is: spring, 20,000; summer, 10,000; fall, 15,000; winter, 18,000. At the beginning of spring you have 70 workers and 1,000 units in inventory. The union contract specifies that you may lay off work
> Suppose you were the manager of a restaurant and you were told honestly that a couple eating dinner had just seen a mouse. What would you say to them? How would you recover from this service crisis?
> Plan production for a four-month period: February through May. For February and March, you should produce to exact demand forecast. For April and May, you should use overtime and inventory with a stable workforce; stable means that the number of workers
> What capacity problems are encountered when a new drug is introduced to the market?
> Develop a production plan and calculate the annual cost for a firm whose demand forecast is fall, 10,000; winter, 8,000; spring, 7,000; summer, 12,000. Inventory at the beginning of fall is 500 units. At the beginning of fall, you currently have 30 worke
> Helter Industries, a company that produces a line of women’s bathing suits, hires temporaries to help produce its summer product demand. For the current four-month rolling schedule, there are three temps on staff and 12 full-time employ
> A bottling plant fills 2,400 bottles every two hours. The lead time is 40 minutes and a container accommodates 120 bottles. The safety stock is 10 percent of expected demand. How many kanban cards are needed?
> Develop a production schedule to produce the exact production requirements by varying the workforce size for the following problem. Use the example in the chapter as a guide (Plan 1). The monthly forecasts for Product X for January, February, and March a
> Shoney Video Concepts produces a line of video streaming servers that are linked to computers for storing movies. These devices have very fast access and large storage capacity. Shoney is trying to determine a production plan for the next 12 months.
> Alan Industries is expanding its product line to include three new products: A, B, and C. These are to be produced on the same production equipment, and the objective is to meet the demands for the three products using overtime where necessary. The deman
> Old Pueblo Engineering Contractors creates six-month “rolling” schedules, which are recomputed monthly. For competitive reasons (it would need to divulge proprietary design criteria, methods, and so on), Old Pueblo