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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
What is meant by component standardization? Why is it important in eliminating waste?LO,1
Why is product specialization important? Who is responsible for setting the level of product specialization?LO,1
What are the elements in a product development cycle? For what is each responsible?LO,1
What is value to the user? How is it related to quality?LO,1
What is the definition of waste as it is used in this text?LO,1
Traditionally, weekly time buckets are used. This gives manufacturing an organizational buffer to plan and organize actual work flow. Because of reduced lead times and schedule stability, it is possible to use daily time buckets in a JIT environment.LO,1
The JIT system requires a stable schedule to operate. This principle is supported by using time fences. These are established based on lead times and the commitment of materials and resources. If lead times can be reduced through JIT practices, the time fences can be reduced.LO,1
The shorter lead times reduce time fences and make the master production schedule more responsive to customer demand. The ideal lead time is so short that the company can respond to actual sales, not to forecast. Whether the company builds to a seasonal demand or to satisfy promotion, a forecast is
Master scheduling tries to level capacity, and JIT tries to level the schedule based on capacity and material flow. Figure 15.9 illustrates the difference.LO,1
What must we get?LO,1
What do we have?LO,1
What do we need to make it?LO,1
What are we going to make?LO,1
A company can ship LTL direct to customers in city A or use a public warehouse located in city B. It has determined the following data.Cost per cwt. for shipping LTL to city A is Cost per cwt. for shipping TL to warehouse is Warehouse handling costs are $0.30 per cwt.Distances: Plant to city Plant
Suppose the company in problem 13.8 had another market area located between the parent plant and the proposed distribution center. The LTL costs from the plant to that market are $35 per cwt. The company estimates that LTL shipments from the distribution center will cost $4 per cwt. Should it
A company has a central supply facility and a distribution center located 500 miles away.The central supply product cost is $20, TL transportation rates from central supply to the DC are $50 per unit, and inventory-carrying costs are $4 per unit. Calculate the market boundary location and the
A company ships LTL to customers in a market in the Midwest at an average cost of $40 per cwt. It proposes establishing a distribution center in this market. If TL shipment costs $20 per cwt., the estimated inventory-carrying costs are $5 per cwt., and the local cartage (LTL) cost is estimated at
A company in Calgary serves a market in the northwestern United States. Now it ships LTL at an average cost of $28 per unit. If the company establishes a distribution center in the market, it estimates the TL cost will be $15 per unit, inventory-carrying costs will be $6 per unit, and the local LTL
A company processes feathers and ships them loose in a covered truck. The line-haul cost for an average shipment is $250, and the truck carries 2000 pounds of feathers.A bright new graduate has just been hired and has suggested that they should bale the feathers into 500-pound bales. This would
In problem 13.4, if the company can ship the units unassembled, it can ship 800 units in a truck. What is the line-haul cost per unit now? LO.1
A company ships a particular product to a market located 1000 miles from the plant at a cost of $4 per mile. Normally it ships 500 units at a time. What is the line-haul cost per unit? LO.1
For a given commodity, the line-haul cost is $13 per mile. For a trip of 200 miles and a shipment of 300 cwt., what is the cost per hundredweight? If the shipment is increased to 500 cwt., what is the saving in cost per hundredweight? LO.1
A company manufactures component parts for machine tools in North America and ships them to Southeast Asia for assembly and sale in the local market. The components are shipped by sea, transit time averages six weeks, and the shipping costs $1000 per shipment. The company is considering moving the
A company normally ships to a customer by rail at a cost of $500 per load. The transit time is 14 days. The goods can be shipped by truck for $700 per load and a transit time of four days. If transit inventory cost is $35 per day, what does it cost to ship each way? LO.1
As more warehouses are added to the system, what would we expect to happen to the following:a. Transportation costs.b. Inventory costs.c. Materials handling costs.d. Packaging costs.e. Total system costs.f. System service capability. LO.1
What are three prime objectives of materials handling? Describe the characteristics of conveyors, industrial trucks, cranes, and hoists. LO.1
What is unitization? Why is it important in physical distribution? Why is it successive? LO.1
What are the three roles of packaging in a distribution system? Describe why each is important. LO.1
As more distribution centers are added to a system, what happens to the cost of truckload, less than truckload, and total transportation costs? LO.1
What is the laid-down cost? What is a market boundary? Why are laid-down costs important in determining market boundaries? LO.1
Name four factors that affect shipping patterns. Which can a supplier control? LO.1
Name and describe the three important roles warehouses serve. LO.1
Name and describe the two basic types of warehouses. LO.1
Why are LTL rates more expensive than TL rates? LO.1
The rates charged by a shipper vary with the commodity shipped. Name and describe four factors that affect the rates. LO.1
Describe how a shipper can reduce the following:a. Pickup and delivery costs.b. Terminal-handling costs.c. Billing and collecting costs. LO.1
On what do total line-haul costs and line-haul costs per hundredweight depend? What two ways can shippers reduce line-haul costs? LO.1
Compare common and contract carriage. How do they differ from private carriage?Which will give the highest level of service? LO.1
What are the major legal types of carriage? What are the three areas of economic regulation?To which legal type of carriage do they apply? LO.1
What are the major characteristics of water and air transport? LO.1
Why can trucks provide a fast, flexible service for the distribution of small volumes of goods to a dispersed market? LO.1
Describe why train service is cheaper than road transport for large quantities of bulky commodities moving over long distances. LO.1
What are the three physical elements in a transportation system? For each of the five modes, describe who provides them and how they are funded. LO.1
What are the five basic modes of transportation? LO.1
Why is the demand placed on a central distribution center or a factory by distribution centers considered dependent? LO.1
Describe the relationship between marketing and physical distribution. How does physical distribution contribute to creating demand? LO.1
What are the cost trade-off and total cost concepts? Why are they important? LO.1
Name and describe each of the six system activities in a physical distribution system. LO.1
What are the objectives of a physical distribution system? LO.1
Why are the total costs associated with reverse logistics increasing? Will this trend continue into the future? LO.1
Describe the reverse logistics system of a beverage company including the movement of goods and the flow of payment. What steps does the company take to reduce their costs? LO.1
The particular way that goods move depends in part on four factors. What are they? LO.1
What is the primary function of the transaction channel and the distribution channels? LO.1
Name and describe the three functions in the flow of materials from supplier to consumer.What are the differences between physical supply and physical distribution? LO.1
Order processing and communication. Order processing includes all activities needed to fill customer orders. Order processing represents a time element in delivery and is an important part of customer service. Many intermediaries are involved in the movement of goods, and good communication is
Protective packaging. Goods moving in a distribution system must be contained, protected, and identified. In addition, goods are moved and stored in packages and must fit into the dimension of the storage spaces and the transportation vehicles. LO.1
Materials handling. Materials handling is the movement and storage of goods inside the distribution center. The type of materials handling equipment used affects the efficiency and cost of operating the distribution center. Materials handling represents a capital cost, and a trade-off exists
Warehouses (distribution centers). Warehouses are used to store inventory.The management of warehouses makes decisions on site selection; number of distribution centers in the system; layout; and methods of receiving, storing, and retrieving goods. LO.1
Distribution inventory. Distribution inventory includes all finished goods inventory at any point in the distribution system. In cost terms, it is the second most important item in distribution, accounting for about 25% to 30% of the cost of distribution. Inventories create time value by placing
Transportation. Transportation involves the various methods of moving goods outside the firm’s buildings. For most firms, transportation is the single highest cost in distribution, usually accounting for 30% to 60% of distribution costs.Transportation adds place value to the product. LO.1
Develop a time-phased plan to move from the present situation to the model you developed in question 3. LO.1
Develop a model of how you think the warehouse should work in this environment. LO.1
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? LO.1
Structure what you think the problems are. Be sure to separate the problems from the symptoms. LO.1
A company does an ABC analysis of its inventory and calculates that out of 10,000 items 19% can be classified as A items, 30% as B items, and the remainder as C items. A decision is made that A items are to be cycle counted twice a month, B items every 3 months, and C items once a year. Calculate
A company does an ABC analysis of its inventory and calculates that out of 5000 items 22% can be classified as A items, 33% as B items, and the remainder as C items. A decision is made that A items are to be cycle counted once a month, B items every 3 months, and C items twice a year. Calculate the
a. Which of the following items are within tolerance?b. What is the percent accuracy by item?Part Shelf Inventory Within Number Count Record 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 LO.1
a. Which of the following items are within tolerance?b. What is the percent accuracy by item?Part Shelf Inventory Within Number Count Record Difference % Difference Tolerance Tolerance?A 650 635 ±3%B 1205 1205 ±0%C 1350 1500 ±5%D 77 80 ±5%E 38 40 ±3%Total LO.1
A company wants to store the following 10 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 are needed
A company wishes to store the following SKUs so there is 100% accessibility. The items are stored on pallets that can be stacked three 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 are
A company has a warehouse with the dimensions shown in the following diagram. How many pallets measuring 48″ × 40″ can be stored three high if there is to be a 2″ space between the pallets?Aisle 60'4'4'Aisle 4'4 LO.1
A company has an area for storing pallets as shown in the following diagram. How many pallets measuring 48″ × 40″ can be stored three high if there is a 2″ space between the pallets? LO.1
A company has 7000 cartons to store on pallets. Each pallet takes 30 cartons, and the cartons are stored four high. How many pallet positions are needed? LO.1
A company wants to store an SKU consisting of 5000 cartons on pallets each containing 30 cartons. They are to be stored three high in the warehouse. How many pallet positions are needed? LO.1
When are some good times to count inventory? LO.1
Why is cycle counting a better way to audit inventory records than an annual physical inventory? LO.1
Describe cycle counting. On what basis can the count frequency be determined? LO.1
What are the four steps in taking a physical inventory? LO.1
In taking a physical inventory, what are the three factors in preparation? Why is good preparation essential? LO.1
What are the two major purposes of auditing inventory accuracy? LO.1
What is the basis for setting tolerance? LO.1
How should inventory accuracy be measured? What is tolerance? Why is it necessary? LO.1
Six causes of poor inventory accuracy are discussed in the text. Name and describe each. LO.1
What are some of the results of poor inventory accuracy? LO.1
What are the four steps in any transaction? LO.1
What are three prime objectives of materials handling? Describe the characteristics of conveyors, industrial trucks, and cranes. LO.1
Name and describe three order-picking systems. LO.1
Describe fixed and floating systems for assigning locations to SKUs. LO.1
Why is stock location important in a warehouse? Name and describe four basic systems of stock location and give examples of each system from a retail setting. LO.1
What are cube utilization and accessibility? LO.1
Describe the eight warehouse activities as they would apply to a supermarket. Include in your description where each activity takes place and who performs the activity. LO.1
What are four objectives of warehouse operation? LO.1
Effective use of labor and equipment. Materials handling equipment represents the second-largest capital cost and labor the largest operating cost. There is a trade-off between the two in that labor costs can be reduced by using more materials handling equipment. Warehouse management will need
Maximum use of space. Usually the largest capital cost is for space. This means not only floor space but cubic space as well since goods are stored in the space above the floor as well as on it. LO.1
Operate an information system. A record must be maintained for each item in stock showing the quantity on hand, quantity received, quantity issued, and location in the warehouse. The system can be very simple, depending on a minimum of written information and human memory, or it may be a
Dispatch the shipment. Orders are packaged, shipping documents prepared, and goods loaded on the right vehicle. LO.1
Marshal the shipment. Goods making up a single order are brought together and checked for omissions or errors. Order records are updated. LO.1
Pick goods. Items required from stock must be selected from storage and brought to a marshalling area. LO.1
Hold goods. Goods are kept in storage and under proper protection until needed. LO.1
Dispatch goods to storage. Goods are sorted and put away. LO.1
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