Financial Models and Tools for Managing Lean Manufacturing

Chapter 4: Analytical Findings from Lean Manufacturing Factory Operation

In this chapter, the results of the data analysis are discussed and detailed analysis is presented. Analysis is based on the data collected using the modeling tools described in Chapter 3, Experimental Design section. Microsoft Excel was used for the development and operation of a pseudoproduction planning and control system as well as for financial reporting. ProModel simulation software was used for the development and operation of a model manufacturing environment. Microsoft VBA was used to act as a data bridge between the Excel and ProModel packages. The data was analyzed using MINITAB release 14. ANOVA was employed for testing of the research hypotheses presented in Chapter 3 and the Tukey all pairwise comparison method was employed to determine which factor levels had the greatest effect on the measurements of interest.

Raw Data and Descriptive Statistics

A sample of the raw data can be seen in Table 4.1 and a complete dataset for all inventory reduction policies at one sales stochasticity setting is included in the Appendices.

Table 4.1: Raw Data, Gross Profit for the Full-Absorption Costing Method with No Inventory Reduction Target

Dollars

January

February

March

April

May

June

Series (Year)

1

62,512.78

218,387.4

96,471.45

88,444.78

167,306.9

131,101.6

2

74,384.54

190,270.8

135,024.7

94,349.53

75,907.17

230,553.4

3

99,957.47

119,442.3

163,868.3

143,971.1

75,954.97

161,201.6

4

135,156.5

123,652.3

90,084.61

92,479.76

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