The safety stock on an SKU is set at 500 units. The supplier says it has to increase the lead time from 4 to 5 weeks. What should be the new safety
When is it appropriate to use 100% inspection?
Given the following data, calculate the three-month moving average forecasts for months 4, 5, 6, and 7.
Complete the following table. Lead time for the part is 2 weeks. The lot size is 50. What is the projected available at the end of week 3? When is it
Complete the following table. Lead time for the part is 2 weeks. The lot size is 100. What is the projected available at the end of week 3? When is
Given the following product tree, explode, offset, and determine the gross and net requirements. All lead times are 1 week, and the quantities
Complete the following table. Lead time for the part is 2 weeks, and the order quantity is 50. What action should be taken?
Using the following product tree, determine the planned order receipts and planned order releases if 200 As are to be produced in week 5. All lead
What does the acronym VOC stand for?
What is a run chart?
In which two ways can a process create defects?
Quality costs fall under two categories. Name each category and think of an example to illustrate the category.
What is empowerment, and why is it important in TQM?
In which four areas must quality be considered? How do they interrelate?
Give an example of a visual management system.
How does takt time work?
Provide an example of value stream mapping.
Can MRP and kanban be used at the same time and if so, how?
Where does a drum-buffer-rope system work best?
Where does a kanban system work best?
Where does an MRP system work best?
After a product is designed, what is the responsibility of manufacturing engineering?
The following MPS summary schedule is leveled for capacity. Using the following table, level the schedule for material as well.
What is the definition of waste as it is used in this text?
A firm experienced abnormal scrap and collected data to see which parts were causing the problem, with the following results: part A—$5720, part
A major mail order house collected data on the reasons for return shipments over a 3-month period with the following results: wrong selection 62,000;
Given the following fixed and variable costs and the volumes, calculate the total and unit costs.
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
If the weekly standard deviation is 140 units, what is it if the lead time is 3 weeks?
If the safety stock for an item is 200 units and the lead time is 3 weeks, what should the safety stock become if the lead time is extended to 6
If the standard deviation is calculated from weekly demand data at 100 units, what is the equivalent sigma for a 3-week lead time?
Calculate K for the following data:
Calculate the new lot size for the following if K = 5
A company is presently ordering on the basis of an EOQ. The demand is 10,000 units a year, unit cost is $10, ordering cost is $30, and the cost of
An SKU costing $10 is ordered in quantities of 500 units, annual demand is 5200 units, carrying costs are 20%, and the cost of placing an order is
Analyze the following data to produce an ABC classification based on annual dollar usage.
Over the past year, a company has sold the following 10 items. The following table shows the annual sales in units and the cost of each item.a.
Given the following data, calculate a level production plan, quarterly ending inventory, and average quarterly inventory. If inventory carrying costs
A company manufactures and sells a seasonal product. Based on the sales forecast that follows, calculate a level production plan, quarterly ending
The Fast Track Ski Shoppe sells ski goggles during the four months of the ski season. Average demand follows:a. Calculate the deseasonalized sales
Calculate the deseasonalized demands for the following:
Given the following average demand for each month, calculate the seasonal indices for each month.Your answer, if done correctly, should have all the
Weekly demand for an item averaged 100 units over the past year. Actual demand for the next eight weeks is shown in what follows:a. Plot the data on
Using exponential smoothing, calculate the forecasts for months 2, 3, 4, 5, and 6. The smoothing constant is 0.2, and the old forecast for month 1 is
Monthly demand over the past 10 months is given in what follows.a. Graph the demand.b. What is your best guess for the demand for month 11?c. Using a
Jobs A, B, and C are in queue at work center 10 before being completed on work center 20. The following information pertains to the jobs and the work
Complete the following input/output report. What is the actual backlog at the end of period 5?
International Door Slammers has an order to deliver 500 door slammers on day 130. Draw up a backward schedule under the following conditions:a. Only
Amalgamated Skyhooks, Inc., has an order for 200 Model SKY3 Skyhooks for delivery on day 200. The Skyhook consists of three parts. Components B and C
In problem 6.4, what percentage of time is the order actually running?In problem 6.4An order for 50 of a product is processed on work centers A and
Given the following product tree, determine the low-level codes and the gross and net quantities for each part. There is a requirement for 100 As in
Given the following product tree, complete the MRP records for parts X, Y, W, and Z. Note that parts X and Y have specified order quantities.
Given the following product tree, explode, offset, and determine the gross and net requirements. The quantities required are shown in parentheses.
MPS parent X has planned order releases of 30 in weeks 2 and 4. Given the following product tree, complete the MRP records for parts Y and Z.
Given the following partial product tree, explode, offset, and determine the gross and net requirements for components H, I, J, and K. There are
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.
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
Given the following data, calculate the projected available balance and the planned MPS receipts. The lot size is 200. The demand time fence is 2
Using the scheduled receipts, calculate the ATP. There are 45 units on hand.
Using the scheduled receipts, calculate the ATP. There are zero units on hand.
Given the following data, calculate how many units are available to promise. There are 5 units on hand.
Calculate the available to promise using the following data. There are 90 units on hand.
The Shades Sunglass Company assembles sunglasses from frames, which it makes, and lenses, which it purchases from an outside supplier. The sales
The Wicked Witch Whisk Company manufactures a line of broomsticks. The most popular is the 36-inch model, and the sales department has prepared a
From the bookstore example in question 21, describe how one of the supply chains would use a supply chain “channel master.”Data from question
Why is a computer necessary in an MRP system?
What is the relationship between the MPS and the MRP?
Should an MRP be used with dependent or independent demand items?
1. Complete the master schedule for Product X, including the projected available inventory and the ATP numbers.2. From the master schedule for
1. What are the key issues brought about in the conversation? What are the key symptoms, and what are the underlying problems? Be specific in your
What is a material requirements plan?
What types of production environments might use both the FAS and the MPS? Why?
What potential problem might arise if time fences are not used? Why?
What would happen if the planning horizon for the master schedule were too short? Why?
What is the purpose of time fences? Name and describe the three main divisions.
What is the ATP (available to promise)? How is it calculated?
How do the production plan and the MPS relate to sales and to the sales forecast?
What is a planning horizon? What decides its minimum time? Why would it be longer?
What is a final assembly schedule (FAS)? What is its purpose?
At what level should master production scheduling take place?a. In a make-to-stock environment?b. In a make-to-order environment?c. In an
Where is the resource bill used?
What is the purpose of a rough-cut capacity plan?
What are the three steps in making an MPS?
Where does the information come from to develop an MPS?
Does the MPS work with families of products or with individual items?
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
What functions does the MPS perform between sales and production?
1. Develop a master schedule using the information above.2. A customer has just requested a major order of 45 pumps for delivery in week 5. What
What four functions does the master production schedule (MPS) perform in the production planning system?
What is Hoshin planning?
Describe some of the possible advantages of a company developing a reverse supply chain.
What should a company approach be to risks? What are some of the methods they can use to minimize the impact of negative risks?
Describe sustainability for production. What are some of the ways that a company can practice sustainability?
What does the concept of “green production” mean? How will it potentially impact production planning?
What kind of production environment would you expect to see if a company uses a chase strategy? What if it uses a level strategy?
What is a resource bill? At what level in the planning hierarchy is it used?
What is the general procedure for developing a level production plan in a make-to-order environment?
What information is needed to develop a make-to-order production plan? How does this differ from that needed for a make-to-stock plan?
What is the difference between make-to-order and assemble-to-order? Give an example of each.
What are the steps in developing a make-to-stock production plan?
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