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business
operations management 6th
Questions and Answers of
Operations Management 6th
The Neptune Co. produces two models of aeration systems for aquariums: the Junior(J) and the Senior (S). The product structure trees for these products are shown below with the lead times to purchase
1. Why are dependent-demand items often managed by inventory systems that are different from those studied in Chapter 11?
2- What is the basic core of material requirements planning (MRP)?
3. What, if any, applications does MRP have beyond basic inventory control?
4. What is a master production schedule? How does it differ from a forecast? What is lead-time offsetting?
5. What basic information must be in the inventory status file? What additional information might a company want to maintain in this file?
6. Discuss some fears people might have about setting a planned lead time and not using safety stock in an MRP system.
7. Briefly describe the steps that MRP goes through in processing a master production schedule to obtain material requirements.
8. Why is data accuracy important for MRP?
9. Why do some companies develop their master production schedule for items below the end-item level in the product structure?
10. How do you distinguish between planned orders and open orders?
11. Is capacity requirements planning important? Give some reasons for your response.
12. What are pegged requirements?
13. Distinguish between net change and regenerative MRP systems.
1. A Tongue Twister lollipop is shown below. Construct a structure tree for a bag of 20 fruit-flavored lollipops. Bag
2. Given the product structure you have just drawn for the Tongue Twister lollipop, determine the quantity of each component that must be purchased or produced if there is no inventory of any
3. A Safe Rider bicycle headgear set consists of the following: box, warranty, instructions for use, helmet, extra pads for sizing, and reflective decals. The headgear assembly consists of the helmet
4. The gross requirements, on-hand inventory, and scheduled receipts for dense foam for the inner shell of the bicycle helmets described in problem 3 are indicated in thetime-phased inventory status
5. Safe Rider also manufactures the plastic water bottles that fit into metal brackets on bicycles so that cyclists can easily reach the bottles for a drink without stopping their pedaling. The
6. Given the product structure shown below, determine the quantity of each component that must be purchased or produced if there is no inventory of any component at present and the company has
7. The product structure trees for products A and Fare shown on the facing page. Part of the master schedule showing when the company will complete production operations for quantities of these
The Regular Regulator Company produces pressure regulators that are composed of two pan assemblies, a diaphragm, and six bolts. A pan assembly consists of a pan and two half collars. One sheet of
The lead time required to purchase or produce (from its immediately lower components)each component of the 16-mm equalizer is shown in parentheses below the component on the product structure tree
The Regular Regulator Company has on-hand inventory of some components for the equalizer shown in problem 9. The inventory levels and open orders for components of this equalizer are indicated on the
11. The product structure tree for a drafting table (part A) is shown below. The number of an item required to make one unit of the item above it is indicated in front of the item. The lead time
12. The product structure tree for a ceiling fan is shown below. The number of an item required to make one unit of the item above it is indicated in front of an item. The lead time required to
13. The product structure tree for a lawn sprinkler (part S) is shown below. The number of an item required to make one unit of the item above it is indicated in front of the letter representing an
14. The structure of a product is shown in the tree diagram below, with the quantity required to make one unit of the higher-level item shown to the left of each item and the lead times in weeks
15. Refer to the product structures for products A and F presented in problem 7+ ine company has 500 units of B on hand, and 1,000 units are scheduled to be received in week 3. The master schedule
16. The Crime Stopper Alarm Company produces two models, A and TJ, for which the product structures are shown at the end of this problem. The quantity required to make one of the next-higher-level
The net requirements for an item through a series of time periods are shown below.The setup cost for the item is $100 per order, and the holding cost is $0.25 per unit per period. Use the part-period
Refer to the information in problem 17. Use the period order quantity technique to determine the size and timing of the planned order receipts.
Net requirements for item R557 during a series of time periods are shown below. The order cost for this item is $30 per order, and the holding cost is $0.10 per unit per period.Using the part-period
Refer to the information in problem 19. Use the period order quantity technique to determine the size and timing of the planned order receipts.
For the data provided in problem 19, calculate the mean weekly requirements, and round to the nearest integer. Use this number as a uniform weekly requirement, and use the order cost and holding cost
Use a spreadsheet to set up the master production schedule for item A and the MRP inventory status records for all the dependent items. The needed data are given below.Bill of Materials Make a
1. Ikea is known worldwide as the innovative furniture designer and manufacturer that produces high-quality, contemporary modular furniture (assembly required) at low prices. Visit Ikea’s site at
2. Woolrich has been a standard in the outdoor clothing manufacturing industry for many years. The company produces men’s and women’s clothing, as well as blankets and even a line called
Five jobs are to be run—first on process I, then on process II. The jobs are listed in the following table with their time requirements on the two processes.(a) Sequence the jobs by Johnson’s
1. The jobs listed in the first column of the accompanying table are waiting at work center 16. The shop works 16 hours per day.a. Arrange the jobs in priority sequence according to the lowest
2. The jobs listed in the following table are waiting at work center 41. The shop works 8 hours per day.a. Arrange the jobs.in sequence for work center 41 according to the shortest-processing-time
3. The jobs listed in the first column of the following table are waiting at work center 4.The shop normally works 8 hours a day.a. List the sequence in which the jobs would be done according to the
4. It is the start of work on Monday morning. The jobs listed below are the queue of work waiting to be done at work center 6, which is a single machine that is one of the bottlenecks in the shop.
5. Work center 403 is the starting work center for four relatively simple jobs whose route sheets are shown in the following four tables.Sequence the jobs according to:a. The shortest processing time
6. Today is shop day 167, and the backlogs already in queue at each of the work centers through which each of the jobs in problem 5 must flow are presented in the following table.a. Sequence the jobs
7. Sleek Auto Body Shop has five cars that must have fenders straightened and be repainted.Julie Stewart, the manager, must be present while the work is being done, although the person who
8. Six two-color printing jobs are to be run using two processes, all in the sequence of first process 1, then process 2. The table below indicates the duration (in hours) of each process.a. Sequence
9. Morris Machine Shop has four jobs waiting to be run on the milling machine, and three of them must then go to the drill press for the next operation before they are completed. There is an operator
Given below is the input part of an input/output control reporta. Compute the cumulative deviations in input.b. What is the minimum queue this work center could start with and not run out of work?c.
11. Given below is a partially completed input/ output control report for a certain work center.a. Compute the remainder of the table for the first 4 weeks.b. What problem appears to exist?c. What
Congratulations, you own a job shop manufacturing company. Your company has been requested to quote on a simple assembly: a special-size metal door for McCall Enterprises. The door assembly consists
Dan Paramesh of Hugo Optical Equipment Company is developing a production plan for the assembly of special survey equipment for offshore oil exploration. The contract calls for the following shipping
1. The company mentioned in the chapter with the discussion of the minimum feasible lot size has been working for continuous improvement. The setup time has been re- duced to 12 minutes to change
2. A company runs three items on the same machine. Demand and processing time for the three items are given in the following table. Setup time to change from pro- duction of any item to any other is
3- Awesome Auto Parts runs three items on the same machine. The table below shows the demand and processing time for the three items. Setup time to change from production of any of the items to any
4. A company runs four items on the same machine. Demand and processing time for the four items are given in the table below. Setup time to prepare the machine for production of each of the items is
13. Describe some situation in which TOC scheduling principles are applied or could be applied in a service operation.
12. Describe the DBR approach to scheduling and controlling production.
11. Describe the difference between the JIT and the TOC scheduling processes. What are the focus and primary goal of each?
10. In what ways does the role of purchasing change when a company shifts to JIT man- ufacturing?
9. What is jidoka? What messages about human resources management and the relative importance of output versus quality are conveyed by the use of jidoka?
8. Generally describe some setup reduction ideas that a manufacturing company might apply.
7. Single-minute exchange of dies (SMED) is a coveted goal of many JIT factories. Why are quick changeovers considered one of the pillars of JIT?
6. Why is preventive maintenance important in JIT production?
5. How do small lots contribute to high quality? To flexibility? To cost efficiency?
4. Compare the push and the pull methods of coordinating work at work stations.
3. Name the elements that work together to make JIT flow occur so effectively in repet- itive manufacturing.
2. What are the three major components of JIT manufacturing?
5. Shown on the next page is a flowchart that provides selling prices, demand, production times, and material cost information for two products a company produces. The company has worked to reduce
1. Briefly distinguish between JIT manufacturing and JIT flow.
3. Construction companies such as custom home builders are essentially make-to-order companies and must schedule their production in this manner. Leeside Construction Company, located on Cape Cod, a
2. Repetitive manufacturing is anything but dull. In fact, it can involve hectic scheduling for managers. Consider the Clarks footwear company, which has been producing shoes since 1825 and is
1. Information system linkages are vital for all types of production planning and control, including retail operations that link manufacturing with services. Williams-Sonoma is one such organization.
A landscaping contractor has received a contract to plant shrubs for a new subdivision in a nearby city. He intends to send one of his supervisors, who will employ a crew of workers in that city to
16. The Adams Company has just completed development of a new leaf blower. The first one required 47 minutes to produce, and it is estimated that the company will have a 95 percent improvement
15. Talk To Me Communications Company produces communications systems for small businesses. The first of its new model TTMC-10 systems required 8.5 labor hours to complete. The company has
14. Steadman Electronics is introducing a remote pager model. The company works at continuous improvement and has achieved a 90 percent improvement rate on similar small electronic devices, so a 90
13. The Paper Chase Company recycles paper for packaging. Currently, the process requires 22 labor-hours per 8-ton batch to recover a certain amount of material. Because much of the labor time during
12. The Silver Bullet Aircraft Company has just produced the first of its model R-80 airplanes, which required 36,500 direct labor-hours. The company has experienced a 90 percent learning curve for
7. Why is it necessary to continually replan priorities in a production system?
6.a. Discuss the objectives of input/output control.b. How can input and output be properly controlled and delivery performance still be mediocre?
5. What problems could result if a company’s dispatching rules were always to work on the item with the shortest processing time? To work on the item with the longest processing time?
6. Shown below is a flowchart that provides selling prices, demand, production times, and material cost information for two products a company produces. The company has worked to reduce setup times
4, What is dispatching? Describe a few rules of thumb (heuristics) that may be used in dispatching.
3. Why should production control bother to keep track of the amount of work that has been completed?
2. What is a backlog report?
1. Why is it difficult to select one criterion that will ensure optimum performance of a production system?
1. As you read in the chapter, Ocean Spray Cranberries has been able to reduce cycle times and lead times significantly by sharing cost information with suppliers. Access the Ocean Spray Web site at
2. On its Web site, Pizza Hut claims that it uses “2.5 percent of all the milk (over 3.2 billion pounds) produced in the United States every year for cheese.” In addition, the company uses
3. Rollerblading has become so popular that the brand name for inline skates has now become a generic term. Visit the Web site for Rollerblade at www.rollerblade.com, and — www.rollerblade.com
1. Discuss the difference between preventive and remedial maintenance. Give examples of each.
2. How might managing a maintenance operation incorporate some features of managing both a job shop and a make-to-stock operation at the same time?
3. What is predictive maintenance?
4. What are some of the advantages of a predictive maintenance program?
1. The Ecstasy Inn motel has 100 television sets in its rooms. The manager has an opportunity to sign a maintenance contract that calls for an annual payment of $12 per television set. The contract
Safeway Rentals has a fleet of 30 rental cars. It is in the process of reviewing its preventive maintenance program. The cost of performing preventive maintenance is $25 per car. The probability
A style product must be ordered by a store . several months before. the season and can be purchased at $16.25 per unit. The retail price for the item will be $26.95 during the season. No
Assume the same cost and sales prices for the item in the previous problem, but assume that the probability distribution is stated a different way. It is estimated that the probability distribution
1.a. Should a company be concerned about its upstream suppliers other than its immediate suppliers?b. Why?
2. What are some of the challenges faced by companies that either cause them to want to work more closely with their suppliers or that make it more difficult to work more closely with them?
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