1. Homework Assignment EM 530 Applications in Constraints Management © Washington State University-20131 jholt@wsu.edu http://etm.wsu.edu/ James R. Holt, Ph.D., PE Professor Engineering Management Manual Simulation: The Dice Game And Your Assignment! And, Getting Used to On-Line Education

2. © Washington State University-20132 TOC Overview I’m glad to have you in class! There is so much to learn about the Theory of Constraints. We will study several different aspects of TOC in an effort to see the similarities between them (take a more holistic approach). You will see that each part of TOC improves your understanding of the other parts. If you haven’t seen the TOC Overviews I made public, I suggest you view them. They will help you better understand where we are going and how TOC fits into different environments Videos: http://www.wsu.edu/~engrmgmt/holt/em526/ConstraintsOverview/TOCOverViews.htm http://www.wsu.edu/~engrmgmt/holt/em526/ConstraintsOverview/TOCOverViews.htm

3. © Washington State University-20133 Welcome to the Self Study portion of EM 530 Applications in Constraints Management Now you are on board and figured out how to get this file, you are on your way to learning the theory and practice of the Theory of Constraints Proven Solutions. These self study portions, give you lecture type material, interactive assignments and future information to assist you in your study of texts, software and other materials. Did you Know? I never sleep. You can call almost any time. I know you have questions at odd times. I’m usually available from 7:00 AM to 8:00 PM Monday through Friday at my Home Office: 540-412-5315 when I’m not in class. You can also send email to me (or even the full class) in ANGEL (https://lms.wsu.edu/) using the Tab.https://lms.wsu.edu/ My direct email is jholt@wsu.edujholt@wsu.edu

4. © Washington State University-20134 More About the On-Line Course Inside ANGEL, the Tab shows you the days Elluminate WebStreamed Lecture. You can search for archived lectures too. You can also click on the Calendar to find the WebStream for that day. I encourage you to attend live, if at all possible. When you are watching a recording, it’s just too easy to walk away and thing, “If I need this stuff, I can always watch this lecture later.” But, later you will be out of sequence and it will be hard to find what you need to know.

5. © Washington State University-20135 Class Documents The class document (syllabus, homework status sheet, handouts, software downloads, homework assignments, nice to have things, and misc. links) are all available in ANGEL under the tab. You need to check the class homework page to see if you are enrolled and on my grading sheet. Check out the Homework Status. The Dice Game Assignment (Homework #1) is explained later in this presentation. Due Dates: When assignments are made, try to do them right away. It is much easier on you. If you get behind, it will be much harder and you won’t understand the other materials I’m presenting. Otherwise, I’m flexible. This is a self paced course. If you want, you can move ahead of the rest of the class and study on your own, even do the homework early.

6. © Washington State University-20136 Now for the Homework. The Dice Game-Set Up For your homework, I want you to simulate the ‘match game’ found in The Goal, pages 104-112. But we will do it in a more fun way. You will need six fair dice (one die will do if you share). Gather some tokens (lima beans, marbles, or toothpicks work well. Note: Jelly beans and chocolate chips tend to disappear) Get two cups, one for Raw Material and one for Finished Goods Arrange your play area as on the left. Create Six Processes (A, B, C, D, E, F) between Raw Material and Finished Goods. RMFG A B C D E F Processes (move token across the line) Storage areas for Work- in-Process Storage of Raw Material and Finished Goods

7. © Washington State University-20137 The Play You play the game for ten days, one day at a time(each process gets to roll a die ten times-once each day-in the order prescribed). The work progresses from left to right. Each day, A rolls first, takes however many tokens are rolled from the RM cup and moves them across the line to the WIP (Work in Process) location between Line A and B. B then rolls and tries to move tokens from the left WIP location between A and B to the right WIP location between B and C, if available. Click a few times and I’ll show you the sequence. RMFG A B C D E F

8. © Washington State University-20138 The Play RMFG A B C D E F Day 1. A Rolls a 5 You play the game for ten days, one day at a time(each process gets to roll a die ten times-once each day-in the order prescribed). The work progresses from left to right. Each day, A rolls first, takes however many tokens are rolled from the RM cup and moves them across the line to the WIP (Work in Process) location between Line A and B. B then rolls and tries to move tokens from the left WIP location between A and B to the right WIP location between B and C, if available. Click a few times and I’ll show you the sequence.

9. © Washington State University-20139 The Play RMFG A B C D E F Day 1. A Rolls a 5, B Rolls a 3 You play the game for ten days, one day at a time(each process gets to roll a die ten times-once each day-in the order prescribed). The work progresses from left to right. Each day, A rolls first, takes however many tokens are rolled from the RM cup and moves them across the line to the WIP (Work in Process) location between Line A and B. B then rolls and tries to move tokens from the left WIP location between A and B to the right WIP location between B and C, if available. Click a few times and I’ll show you the sequence.

10. © Washington State University-201310 The Play RMFG A B C D E F Day 1. A Rolls a 5, B Rolls a 3, C Rolls a 3 You play the game for ten days, one day at a time(each process gets to roll a die ten times-once each day-in the order prescribed). The work progresses from left to right. Each day, A rolls first, takes however many tokens are rolled from the RM cup and moves them across the line to the WIP (Work in Process) location between Line A and B. B then rolls and tries to move tokens from the left WIP location between A and B to the right WIP location between B and C, if available. Click a few times and I’ll show you the sequence.

11. © Washington State University-201311 The Play RMFG A B C D E F Day 1. A Rolls a 5, B Rolls a 3, C Rolls a 3, D Rolls 6 RMFG A B C D E F You play the game for ten days, one day at a time(each process gets to roll a die ten times-once each day-in the order prescribed). The work progresses from left to right. Each day, A rolls first, takes however many tokens are rolled from the RM cup and moves them across the line to the WIP (Work in Process) location between Line A and B. B then rolls and tries to move tokens from the left WIP location between A and B to the right WIP location between B and C, if available. Click a few times and I’ll show you the sequence.

12. © Washington State University-201312 The Play RMFG A B C D E F Day 1. A Rolls a 5, B Rolls a 3, C Rolls a 3, D Rolls 6, E Rolls a 2 You play the game for ten days, one day at a time(each process gets to roll a die ten times-once each day-in the order prescribed). The work progresses from left to right. Each day, A rolls first, takes however many tokens are rolled from the RM cup and moves them across the line to the WIP (Work in Process) location between Line A and B. B then rolls and tries to move tokens from the left WIP location between A and B to the right WIP location between B and C, if available. Click a few times and I’ll show you the sequence.

13. © Washington State University-201313 End of Day One RMFG A B C D E F Day 1. A Rolls a 5, B Rolls a 3, C Rolls a 3, D Rolls 6, E Rolls a 2, F Rolls 1 and puts it in the cup. You play the game for ten days, one day at a time(each process gets to roll a die ten times-once each day-in the order prescribed). The work progresses from left to right. Each day, A rolls first, takes however many tokens are rolled from the RM cup and moves them across the line to the WIP (Work in Process) location between Line A and B. B then rolls and tries to move tokens from the left WIP location between A and B to the right WIP location between B and C, if available. Click a few times and I’ll show you the sequence.

14. © Washington State University-201314 The Play Continues Day 2 starts with the WIP (tokens in places left from Day 1) and continues in the same fashion. Starting Day 2, worker A rolls, takes from the RM cup and moves more tokens to the space between A and B. Each process takes it’s turn moving tokens during the day. The last process F ends the day by rolling an moving the number of tokens shown on the die (if they are available) into the FG cup. All players move the maximum of what they roll or what inventory is available to process for that day’s roll. RMFG A B C D E F

15. © Washington State University-201315 The Results Now, we play for ten days. How many tokens will be in the Finished Goods Cup? Take a guess before you play. Each die averages 3.5 dots per roll. There are 10 rolls. Each process should produce 35 dots on the average over ten days. Do you expect 35 in the FG Cup? To make sure we understand what is happening in this game, lets keep some records. For one, we need to make sure we are using Fair Die. RMFG A B C D E F ?

16. © Washington State University-201316 Keeping Track of our Rolls Keep track of the rolls you make. Make sure each process (die) produces as the company expects--close to 35. In fact, lets reward the workers. Any process who rolls better than 35 dots in 10 days receives a “Superior Performance Award” Any process who does better than 40 receives a “Sustained Superior Performance Award” But, if any process rolls less than 25 dots, we will have to let them go. Your Team will probably earn a few Awards. Process A B C D E F 5 3 3 6 2 1 2 4 2 5 1 4 1 5 3 2 4 6 and so on … __ __ __ Sum Totals for each Process Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7 Day 8 Day 9 Day 10

17. © Washington State University-201317 Keep Track of Your Inventory When you finish the Dice Game, you will have some unexpected results. We need to produce at least 30 items to make a profit. The plant has such a bad history, one more 10 day period of loss (deliveries below 30) and we will have to close the plant. So, you’ll probably want to keep records of your inventory so you can figure out what happened. Record the WIP (Work in Process) remaining between each workstation at the end of each day as you go. Similar to below: Process A Wip B Wip C Wip D Wip E Wp F FG FG Total 5 2 3 0 3 0 6 1 2 1 1 1 1 2 0 4 2 2 0 5 2 1 0 4 2 3 1 0 5 0 3 1 2 0 4 0 6 4 7 and so on … __ __ __ __ __ __ __ Sum Totals for each Process Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7 Day 8 Day 9 Day 10 You see the WIP changes as the days go by. If you want, you can calculate the average WIP for each position to see who is the problem. Knowing the WIP at the End of the 10 periods also helps you understand your system.

18. © Washington State University-201318 Report to Dr Holt Play the Dice Game for ten days. Record the individual Process results. Determine which of your Processes received which awards (or were laid off). Summarize this record for Dr Holt. Submit in your record along with your observations about this simple game by email to jholt@wsu.edu.jholt@wsu.edu Some of you are pretty concerned about my letting a person go if they produce less than 25 parts. But, this is a very rare case. Rolling a fair die multiple times soon generates a near normal distribution. There is less than a 5% chance of producing less than 25 dots in ten rolls. Besides, this is more than generous in light of our production demands. Cooperate has told us, “If you don’t produce at least 30 tokens in that FG Cup, they are going to close the plant!” What we want is everyone to do good so we can keep the plant open. In your report, determine if the plant will remain open or not. Make any recommendations you want on how to improve the plant.

19. © Washington State University-201319 More on Dice Games Some of you will find the Dice Game fascinating. You will play it over and over and dumbfound your friends. That’s ok, but don’t blame me if your social life goes to pot. If you can’t get enough, you can try a few more options I’ve documented at: http://www.wsu.edu/~engrmgmt/holt/em530/Docs/DiceGames.htm http://www.wsu.edu/~engrmgmt/holt/em530/Docs/DiceGames.htm And, if you invent some better dice games, let me know For now, KEEP THINKING! Dr Holt