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business
introduction to materials management

Questions and Answers of Introduction To Materials Management

3.15. Given the following data, calculate the projected available balance and the planned MPS receipts. The lot size is 100. The demand time fence is 2 weeks.Week 12 34 Forecast 50 50 50 50 Customer
3.16. Complete the following problem. The lead time is one week and the demand time fence is the end of week 3. There are 20 on hand. The lot size is 60.Period 12 34 56 Forecast 20 21 22 20 28 25
3.17. Product A is an assemble-to-order product. It has a lot size of 100, and currently has an on-hand inventory of 30 units. There is a 1-week demand time fence and a 12-week planning time fence.
3.18.a. Given the following master schedule, fill in the projected available and available- to-promise rows:On hand: 10 Lot size: 75 Week 12 34 56 78 Forecast 40 40 40 40 30 30 50 50 Customer Orders
1. Develop a master schedule using the information above.The Acme Water Pump company has a problem. The pumps are fairly expensive to make and store, so the company tends to keep the inventory low.
2. A customer has just requested a major order of 45 pumps for delivery in week 5. What would you tell the customer about having such an order? Why? What, if anything, would such an order do to the
3. What are the key issues in this case? Be sure to classify them as much as possible as symptoms versus core causes. Be sure to keep in mind the constraints as defined by the type of customer and
Macarry’s Bicycle Company makes and sells high-quality bicycles, primarily to larger North American bicycle retail outlets and to some wholesalers for smaller retail shops. They have several
2. Once you have completed the tables, examine the list of orders for this model bicycle and determine specifically what information should be given to the perspective customer. For example, if the
3. Suppose Macarry’s Bicycle managers discover that a major competitor has had to shut down their production for the next three months due to a major fire. The Macarry’s managers fully expect
What is value to the user? How is it related to quality?
What are the elements in a product development cycle? For what is each responsible?
Why is product specialization important? Who is responsible for setting the level of product specialization?
What is meant by component standardization? Why is it important in eliminating waste?
Why is product design important to manufacturing? How can the design add waste in manufacturing?
Explain why each of the following are sources of waste:a. Processingb. Motionc. Transportationd. Defectse. Waiting timef. Overproduction g. Inventory
Explain how inventory affects product improvement, quality, prices, and the ability to respond quickly to the marketplace.
What is repetitive manufacturing? What are its advantages? What are its limitations?
What is a work cell? How does it operate? What conditions are necessary to establish one?What are its advantages?
Why is process flexibility desirable? What two conditions are required?
Name and describe five advantages of short setup time.
What are the two reasons why quality is important?
What is quality for manufacturing? How is it obtained?
Why is preventive maintenance important?
Describe the differences between preventive maintenance and total productive maintenance.
What are the four conditions needed for uninterrupted flow? Describe each.
What is the difference between leveling based on capacity and leveling based on material flow?
Why would a lean production manufacturer schedule 7 hours of work in an 8-hour shift?
Why are supplier relations particularly important in a lean production environment?
Why is employee involvement important in a lean production environment?
What are the differences in a master production schedule in a lean production environment?
What effect does a lean production environment have on MRP?
Describe the backflushing or post-deduct system of inventory recordkeeping.
Why is there sometimes difficulty with the MRP system?
What is the major difference between the MRP push system and the pull system?
What is the kanban system? How does it work?
What is the difference between production cards and move cards?
Where does a drum-buffer-rope system work best?
What are the 5Ss of housekeeping? What is the sixth?
What are the responsibilities of capacity management?
Describe the three steps of capacity planning.
Relate the three levels of priority planning to capacity planning. Describe each level in terms of the detail and the time horizons used.
What is capacity requirements planning? At what level of the priority planning process does it occur?
What are the inputs to the CRP process? Where is this information obtained?
Describe each of the following and the information they contain.a. Open order.b. Routing.c. Work center.
What is a shop calendar? Why is it needed?
Where would you find the following information?a. A scheduled receipt.b. A planned receipt.c. Efficiency and utilization.d. Sequence of operations on a part.
Define capacity available. What are the four factors that affect it?
Why is standard time usually used to measure capacity?
What are theoretical capacity, rated capacity, utilization, and efficiency? How are they related?
What is measured or demonstrated capacity? How is it different from rated capacity?
What is load?
What is a work center load report? What information does it contain?
What is a schedule?
Describe the process of backward scheduling.
What are the two ways of balancing capacity available and load? Which is preferred? Why?
What are some of the ways capacity available can be altered in the short run?
Why is feedback necessary in a control system?
What might be some of the problems in scheduling rated capacity too closely to the load?
How is safety capacity used?
What is the responsibility of production activity control?
What are the major functions of planning, implementation, and control?
What are the major characteristics of flow, intermittent, and project manufacturing?
Why is production activity control more complex in intermittent manufacturing?
To plan the flow of materials through manufacturing, what four things must production activity control know? Where will information on each be obtained?
What are the four types of planning data used in production activity control? What information does each contain?
What information is used for controlling production?
What should production activity control check before releasing a shop order?
What is manufacturing lead time? Name and describe each of its elements.
Describe forward and backward scheduling. Why is backward scheduling preferred?
Describe infinite and finite loading.
What is operation overlapping? What is its purpose?
What is operation splitting? What is its purpose?
What information does a load report contain? Why is it useful to production activity control?
What is a bottleneck operation?
What is the definition of throughput?
What are the seven bottleneck principles discussed in the text?
What are the five things discussed in the text that are important in managing bottlenecks?
What is a shop order? What kind of information does it usually contain?
What two things must be done to control queue and meet delivery commitments?
What is an input/output control system designed to do? How is input controlled? How is output controlled?
What is dispatching? What is a dispatch list?
Describe each of the following dispatching rules giving their advantages and disadvantages.a. First come, first served.b. Earliest due date.c. Earliest operation due date.d. Shortest processing
If the time remaining to complete a job is 10 days and the lead time remaining is 12 days, what is the critical ratio? Is the order ahead of schedule, on schedule, or behind schedule?
Would critical ratio be better utilized as a static ratio or a dynamic ratio, and why?
What is the purpose of production reporting? Why is it needed?
A student of production inventory management has decided to apply critical ratio to his homework assignments. Describe what is happening if his critical ratio for various assignments is:a.
Bottlenecks exist in many business processes that serve the public and are usually indicated by lineups. Choose a business that experiences lineups and identify the constraints in the system.Give
What is lot traceability? Why is it important to safety related products?
Choose a service industry and describe the scheduling and bottleneck issues that must be controlled in order to maintain customer service.
Provide an explanation of Drum-Buffer-Rope and give an example of how it would be used.
What is demand management? What functions does it include?
Why must we forecast?
What factors influence the demand for a firm’s products?
Describe the purpose of forecasting for strategic business planning, sales and operations planning, and master production scheduling.
The text describes three characteristics of demand. Name and describe each.
Describe trend, seasonality, random variation, and cycle as applied to forecasting.
The text discusses four principles of forecasting. Name and describe each.
Name and describe the three principles of data collection.
Describe the characteristics and differences between qualitative, quantitative, extrinsic, and intrinsic forecasting techniques.

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