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business
introduction to materials management
Introduction To Materials Management 6th Edition J. R. Tony Arnold, Chapman, Stephen N., Lloyd M. Clive - Solutions
Describe the processes of offsetting and exploding. LO.1
What are where-used and pegging reports? Give some of their uses. LO.1
Describe each of the seven uses of a bill of material described in the text. LO.1
Why do MRP computer programs store single-level bills? LO.1
Describe the following types of bills of material:a. Product tree.b. Multilevel bill.c. Single-level bill.d. Indented bill.e. Summarized parts list.f. Planning bill. LO.1
Describe the parent–component relationship. LO.1
To what does “bill of material structure” refer? Why is it important? LO.1
What is a bill of material? What are two important points about bills of material? LO.1
What data are found in a part master file or an item master file? LO.1
What are the major inputs to the MRP system? LO.1
Why is a computer necessary in an MRP system? LO.1
What is the relationship between the MPS and the MRP? LO.1
What are the objectives of the MRP? LO.1
Should an MRP be used with dependent or independent demand items? LO.1
What is the difference between dependent and independent demand? LO.1
What is a material requirements plan? LO.1
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? LO.1
Draw an operations process chart for the assembly of a ballpoint pen. The pen is made from three subassemblies (see Figure 14.15): 1.upper barrel 2.cartridge 3.lower barrel Operation 1 attach clip to upper barrel 2 insert button into upper barrel 3 insert rotor into upper barrel 4 press ball into
A firm experienced abnormal scrap and collected data to see which parts were causing the problem with the following results: part A—$5720, part B—$10,250, Part C—$820, Part D—$1130, Part F—$700. Complete the following table listing the errors in descending order of importance. Construct a
A major mail order house collected data on the reasons for return shipments over a three-month period with the following results: wrong selection 62,000, wrong size 50,000, order canceled 15,000, wrong address 3000, other 15,000. Construct a Pareto diagram.Part Number Percent Cumulative Percent
The Light Company is planning on producing a new type of light shade, the parts for which may be made or bought. If purchased, they will cost $2 per unit. Making the parts on a semiautomatic machine will involve a $5000 fixed cost for tooling and $1.30 per unit variable cost. The alternative is to
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 $180.00 Tooling $10.00 $20.00 Labor/unit $4.00 $3.75 Material/unit $2.00 $2.00 Purchase cost $6.10 LO.1
Bananas are on sale at the Cross Towne store for 69¢ per pound. They normally sell for 99¢ per pound at your corner store. If round-trip bus fare costs $2.80 to the Cross Towne store, is it worth going? Discuss other ways of taking advantage of this bargain. LO.1
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 is
A process costs $200 to set up. The run time is 5 minutes per piece and the run cost is$30 per hour. Determine:a. The fixed cost.b. The variable cost.c. The total cost and unit cost for a lot of 500.d. The total cost and unit cost for a lot of 1000. LO.1
Given the following fixed and variable costs and the volumes, calculate the total and unit costs.Fixed Variable Volume Total Unit cost cost (units) cost cost$200.00 $10.00 100$200.00 $7.00 1000$50.00 $15.00 20$1,000.00 $1.00 2000$500.00 $20.00 500 LO.1
Select a product with which you are familiar. How do you think it might be redesigned to make it easier to manufacture and possibly more useful to the user? LO.1
How might the learning curve impact standard production times used for planning? How would you possibly deal with this impact? LO.1
What might be some of the advantages and disadvantages of self-directed work teams? LO.1
Describe job design. LO.1
What are the four principles of motion economy? LO.1
What is the purpose of the analysis step? What is the basic question? LO.1
Describe each of the following:a. Operations process chart.b. Process flow diagram. LO.1
What are the six symbols used in method analysis? Are there other symbols that can be used? LO.1
Describe each of the following as it relates to recording:a. Process boundaries.b. Process flow.c. Process inputs and outputs.d. Process components.e. Suppliers.f. Environment. LO.1
Why is it necessary to record? LO.1
What is a cause-and-effect diagram, and why is it useful? LO.1
What is a Pareto diagram, and why is it useful? LO.1
Name and describe the two considerations in selecting a job to be studied. LO.1
What are the six steps in continuous process improvement? LO.1
How can the variable cost be reduced? What does this do to the fixed costs, and what is needed to economically justify this course of action? LO.1
What is the cost equalization point? LO.1
Define fixed and variable costs and give examples of each in manufacturing. What is total cost, and what is the equation for it? LO.1
When is project (fixed position) processing used? LO.1
What is intermittent processing and when is it used? Contrast it with flow processing. LO.1
What is flow processing, and what are its advantages and disadvantages? LO.1
Describe general-purpose and special-purpose machinery. Compare each for flexibility of use, operator involvement, run time per piece, setup time, quality, capital cost, and application. LO.1
Give four reasons why companies will make a product in-house and why they will outsource. LO.1
Why are product design, quantity to produce, and process design intimately related? LO.1
What are the five basic factors that must be considered when designing a process? LO.1
What is a process? What is process nesting? LO.1
What is simultaneous engineering, and what are some of its advantages? LO.1
Why is product design important to quality? LO.1
Why is product design important to operations costs? LO.1
What are the two criteria for designing a product? LO.1
How are production costs affected by:a. Standard sizes?b. Universal fit parts? LO.1
What is the advantage to modular design? LO.1
What are product focus and process focus based on? What is a focused factory? LO.1
What are the advantages and disadvantages of specialization? LO.1
What are the advantages and disadvantages of standardization? LO.1
Describe simplification, standardization, and specialization. Why are they important and why are they interrelated? LO.1
Once all the causes have been listed, try to identify the most likely root causes and work on these. LO.1
Brainstorm all possible causes for each of the main causes. LO.1
Generate some ideas about the main causes of the problem. Usually all probable root causes can be classified into six categories.• Materials. For example, from consistent to inconsistent raw materials.• Machines. For example, a well-maintained machine versus a poorly maintained one.• People.
Identify the problem to be studied and state it in a few words. For example, the reject rate on machine A is 20%. LO.1
Construct a bar graph showing the percentage for each item and a line graph of the cumulative percentage. LO.1
Calculate the percentage for each item. LO.1
Calculate the total cost. LO.1
Summarize the data by ranking the items in descending order according to the selected unit of measure. LO.1
Collect data for an appropriate time interval, usually long enough to include all likely conditions. LO.1
Select the unit of measure. This is usually dollars but may be the frequency of occurrence. LO.1
Determine the method of classifying the data: by problem, cause, nonconformity, and so forth. LO.1
The handrails are then sent for sanding and varnishing. A final inspection is performed for appearance and finish. The handrail sections are then sorted by length for full size and shorts? LO.1
The handrails were then sent to the drilling machine where the holes were automatically spaced and drilled by the operator on an industrial quality drill press.Occasionally the operator inspects the dimensions of the holes using a dual purpose go-no-go gauge. On one end of the gauge is a metal rod
They were inspected again for rough grain and any knots that could cause quality problems. Any rejects were then cut into shorter usable lengths for shorter handrails or spindles? LO.1
The approved boards were run through a multihead mill that planed the bottom side and shaped the top and sides of the handrail? LO.1
Any rejects were sent to the cabinet division to be used for interior shelves or to make spindles? LO.1
The oak was purchased in 16-foot lengths and inspected for any flaws or excessive knots to ensure it was #1 grade. LO.1
Complete the three following office memos with your recommendations.INTEROFFICE MEMO TO: Lead Hand—Handrail DATE: August 17 FROM: Hank Strong SUBJECT: Customer Complaints—Bannisters INTEROFFICE MEMO TO: Lead Hand—Spindle Department DATE: August 17 FROM: Hank Strong SUBJECT: Customer
Construct histograms of the spindle and hole data to see if there is assignable cause to the problem. LO.1
Analyze the customer complaints using Pareto analysis to identify the largest cause of complaints. LO.1
Create a House of Quality for a product familiar to you and complete the House of Quality form. Pick at least three different brands of the product to make the competitive comparison. List at least three customer needs inherent in the products and three features that deliver these needs. Identify
A company fills plastic bottles with 8 ounces of shampoo. The tolerance is ± 0.1 ounces.The process has a standard deviation of .02 ounces. For the following situations, calculate the Cpk and evaluate the process capability.a. A sample has an average of quantity of 7.93 ounces.b. A sample has an
In problem 16.6, what is the Cpk when:a. The process is centered on .75? Is the process capable?b. The process is centered on .74? Is the process capable? LO.1
If in problem 16.5 the process is improved so the standard deviation is .0035, is the process capable now? LO.1
The specification for the diameter of a hole is .75 inch .015 inch. The standard deviation of the drill press is .007 inch. Using Cp, calculate whether the process is capable or not. LO.1
The specification for the weight of a chemical in a compound is .05. If the standard deviation of the weighing scales is .02, is the process considered capable? LO.1
The specification for the thickness of a piece of steel is .5 inch ; .05″. The standard deviation of the band saw is .015. Using Cp, calculate whether the process is capable or not. LO.1
In problem 16.1, if the tolerance changes to .0007 inch, approximately what percentage of the shafts will be within tolerance? LO.1
The specification for the length of a shaft is 12 inches ; .001 inch. If the process standard deviation is .00033, approximately what percentage of the shafts will be within tolerance? LO.1
What is benchmarking, and how is it different from continuous improvement? LO.1
Why was the third-party registration system established for ISO 9000 certification? LO.1
What are the consumer’s risk and the producer’s risk? LO.1
What is acceptance sampling? When is it appropriate to use? LO.1
When is it appropriate to use 100% inspection? LO.1
What is the difference between variables and attributes? LO.1
What are upper and lower control limits? LO.1
What is an and R chart? LO.1
What is a run chart? LO.1
What is the purpose of process control? What kind of variation does it try to detect? LO.1
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