Introduction To Materials Management 8th Global Edition J. R. Tony Arnold, Chapman, Stephen N., Lloyd M. Clive - Solutions

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a. Using the order point system, when must an order be placed?b. Why is safety stock carried?c. What is the formula for the order point?d. On what two things does the order point depend?e. Why is the demand during the lead time important? LO.1
What are independent demand items? What two basic ordering systems are used for these items? What are dependent demand items? What system should be used to order these items? LO.1
1. What are four objectives of warehouse operation?
3. What are cube utilization and accessibility?
6. Name and describe three order-picking systems.
8. What are the four steps in any transaction?
9. What are some of the results of poor inventory accuracy?
10. Six causes of poor inventory accuracy are discussed in the text. Name and describe each.
11. How should inventory accuracy be measured? What is tolerance? Why is it necessary?
12. What is the basis for setting tolerance?
13. What are the four major purposes of auditing inventory accuracy?
14. In taking a physical inventory, what are the three factors in preparation? Why is good preparation essential?
15. What are the four steps in taking a physical inventory?
16. Describe cycle counting. On what basis can the count frequency be determined?
17. Why is cycle counting a better way to audit inventory records than an annual physical inventory?
18. When are some good times to count inventory?
19. What information is typically stored in a bar code or RFID tag?
20. Give three examples where RFID would be preferred over a bar code.
21. How do bar codes and RFID reduce costs in the supply chain?
22. What is consignment inventory?
23. What is vendor-managed inventory?
24. How does vendor-managed inventory differ from consignment inventory?
12.2. A company has 6500 cartons to store on pallets. Each pallet takes 30 cartons, and the cartons are stored four high. How many pallet positions are needed?
12.3. A company has an area for storing pallets as shown in the following diagram. How many pallets measuring 48" X 40" can be stored three high if there is a 2" space between the pallets? 200 Aisle
12.4. A company has a warehouse with the dimensions shown in the following diagram. How many pallets measuring 48" X 40" can be stored three high if there is to be a 2" space between the pallets? 60' 4' Aisle Aisle 4'
12.6. A company wants to store the following seven SKUs so there is 100% accessibility. Items are stored on pallets that are stored four high.a. How many pallet positions are needed?b. What is the cube utilization?c. If the company bought racking for storing the pallets, how many pallet positions
12.7.a. Which of the following items are within tolerance?b. What is the percent accuracy by item? Part Number Shelf Count Inventory Record Difference % Difference Tolerance Within Tolerance? A 650 635 +3% B 1205 1205 0% C 1350 1500 5% D 77 80 5% E 38 40 3% Total
12.8.a. Which of the following items are within tolerance?b. What is the percent accuracy by item? Part Number Shelf Count Inventory Record Within Difference % Difference Tolerance Tolerance? A 75 80 3% B 120 120 +0% C 1400 1500 5% D 75 76 5% E 68 66 2% Total
1. Structure what you think the problems are. Be sure to separate the problems from the symptoms.One constant problem Amy had complained about when she was head clerk was the difficulties she had with the warehouse replenishing supplies for her areas of responsibility. She was sure the problem was
2. Assume Amy needs to build a data-based case to convince her boss and start to “win over” Hank. What data should she gather to help her build the case?One constant problem Amy had complained about when she was head clerk was the difficulties she had with the warehouse replenishing supplies
3. Develop a model of how you think the warehouse should work in this environment.One constant problem Amy had complained about when she was head clerk was the difficulties she had with the warehouse replenishing supplies for her areas of responsibility. She was sure the problem was not hers. The
6. What are the objectives of a physical distribution system?
10. Why is the demand placed on a central distribution center or a factory by distribution centers considered dependent?
11. What are the five basic modes of transportation?
14. Why can trucks provide a fast, flexible service for the distribution of small volumes of goods to a dispersed market?
15. What are the major characteristics of water and air transport?
20. The rates charged by a shipper vary with the commodity shipped. Name and describe five factors that affect the rates.
21. Why are LTL rates more expensive than TL rates?
22. Name and describe the two basic types of warehouses.
23. Name and describe the three important roles warehouses serve.
24. Name four factors that affect shipping patterns. Which can a supplier control?
25. What is the landed cost? What is a market boundary? Why are landed costs important in determining market boundaries?
27. What are the three roles of packaging in a distribution system? Describe why each is important.
28. What is unitization? Why is it important in physical distribution? Why is it successive?
32. Which North American shipping term has the minimum risk for:a. the buyer?b. the seller?
33. A buyer in England would like to import a HarIey-Davidson motorcycle directly from a dealer in the United States. Which Incoterm would minimize the buyer's efforts? Would arranging the shipment themselves save money for the buyer?
34. What is meant by the term green reverse logistics?
35. Describe how a 3PL would benefit a company that sells their product to individuals through the internet.
36. Describe how reverse logistics would apply to your school bookstore.
13.4. A company ships a particular product to a market located 1500 miles from the plant at a cost of $4.50 per mile. Normally it ships 500 units at a time. What is the line haul cost per unit?
13.5. In problem 13.4, if the company can ship the units unassembled, it can ship 750 units in a truck. What is the line haul cost per unit now?
1. What are the various alternatives available to Linda? Make a cost comparison for all available options.ABC Footwear Limited is a leading manufacturer and bulk exporter of leather shoes. The company procures its leather from three suppliers: A, B, and C. The distance of these suppliers from the
2. Linda has to make a decision soon. Given the information provided in the case, what would you advise her to do?ABC Footwear Limited is a leading manufacturer and bulk exporter of leather shoes. The company procures its leather from three suppliers: A, B, and C. The distance of these suppliers
1. Describe simplification, standardization, and specialization. Why are they important and why are they interrelated?
5. What is the advantage to modular design?
7. What are the three criteria for designing a product?
8. Why is product design important to operations costs?
9. Why is product design important to quality?
10. What is simultaneous engineering, and what are some of its advantages?
11. What is a process? What is process nesting?
12. What are the five basic factors that must be considered when designing a process?
13. Why are product design, quantity to produce, and process design intimately related?
14. Give four reasons why companies will make a product in-house and why they will outsource.
16. What is flow processing, and what are its advantages and disadvantages?
17. What is intermittent processing and when is it used? Contrast it with flow processing.
18. When is project processing used?
20. What is the cost equalization point?
22. What are the six steps in continuous process improvement?
23. Name and describe the two considerations in selecting a job to be studied.
24. What is a Pareto diagram, and why is it useful?
25. What is a cause-and-effect diagram, and why is it useful?
26. Why is it necessary to record?
28. What are the six symbols used in method analysis? Are there other symbols that can be used?
29. Describe each of the following:a. Operations process chart.b. Process flow diagram.
30. What is the purpose of the analysis step in continuous process improvement? What is the basic question?
31. What are the four approaches that should be taken when developing a better method?
32. What are the four principles of motion economy?
33. Describe job design.
34. What is the learning curve?
35. What might be some of the advantages and disadvantages of self-directed work teams?
37. How might an application of Little’s Law prove useful?
38. What is meant by the term “business environment”?
14.1. Given the following fixed and variable costs and the volumes, calculate the total and unit costs.Fixed cost Variable cost Volume(units)Total cost Unit cost$200.00$8.00 100$200.00$7.00 1000$50.00$15.00 50$800.00$2.00 2000$500.00$20.00 500
14.3. A manufacturer has a choice of purchasing and installing a heat-treating oven or having the heat treating done by an outside supplier. The manufacturer has developed the following cost estimates:Heat Treat In-house Purchase Services Fixed cost$28,000.00$0.00 Variable cost$10.00$17.00a. What
14.4. Bananas are on sale at the Cross Towne store for 790 per pound. They normally sell for 99(2 per pound at your corner store. If round-trip bus fare costs $3.60 to the Cross Towne store, is it worth going? What is the cost equalization point? Discuss other ways of taking advantage of this
14.5. Given the following costs, which process should be used for an order of 400 pieces of a given part? What will be the unit cost for the process selected?Buy Process A Process B Setup$40.00$130.00 Tooling$15.00$20.00 Labor/unit$4.10$3.90 Material/unit$2.00$2.00 Purchase cost$6.10
14.9. A process has a production rate of 30 units per hour. If it takes 50 minutes for a single unit to be completed in the process, what is the inventory of units in the process?
14.10. Draw an operations process chart for the assembly of a ballpoint pen. The pen is made from three subassemblies (see figure): -2 1 -3 4 -S/A-1 -5 -6 1. upper barrel 2. cartridge 3. lower barrel Operation attach clip to upper barrel 2 insert button into upper barrel 3 insert rotor into upper
14.11. Draw a process flow diagram for your activities from the time you wake up until you arrive at work. Can you think of ways to improve the process?
14.12. A process can produce a final product at the rate of 2 products per minute. If an individual product takes 30 minutes to pass through the process, what is the inventory of products in the process at any time?
14.13. A university registration process can register a person every 4 minutes. If there are an average of 12 people in line for the registration, how long will each person have to wait in line?
1. Identify the underlying problems here. Try to be as specific as possible.Rory Thomas has been working as a production manager at YD Furniture Limited for the last six years. During his tenure, he has been part of teams responsible for designing and launching new products as well as for exploring
2. What could be the best solution for these problems? Again, try to be specific.Rory Thomas has been working as a production manager at YD Furniture Limited for the last six years. During his tenure, he has been part of teams responsible for designing and launching new products as well as for
3. Evaluate potential trade-offs and process changes that might be required for the outsourcing decision. What decision should be taken?Rory Thomas has been working as a production manager at YD Furniture Limited for the last six years. During his tenure, he has been part of teams responsible for
4. Suggest how continuous process improvement techniques or quality management could be applied to the identified problems.Rory Thomas has been working as a production manager at YD Furniture Limited for the last six years. During his tenure, he has been part of teams responsible for designing and
5. If Rory can hire one more laborer, which department would you prefer the labor to join in the current situation?Rory Thomas has been working as a production manager at YD Furniture Limited for the last six years. During his tenure, he has been part of teams responsible for designing and
1. What is the definition of waste as it is used in this text?
2. What is value to the user? How is it related to quality?
10. What is repetitive manufacturing? What are its advantages? What are its limitations?
11. What is a work cell? How does it operate? What conditions are necessary to establish one? What are its advantages?

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Introduction To Materials Management 8th Global Edition J. R. Tony Arnold, Chapman, Stephen N., Lloyd M. Clive - Solutions

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