- 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 stock?
- 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. Month 1 2 3 ترا 4 5 6 7 Actual Demand 60 70 40 50 70 65 Forecast
- 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 planned to release an order? Week Gross
- 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 it planned to release an order? Week Gross
- Given the following product tree, explode, offset, and determine the gross and net requirements. All lead times are 1 week, and the quantities required are shown in parentheses. The master production
- Complete the following table. Lead time for the part is 2 weeks, and the order quantity is 50. What action should be taken? Week Gross Requirements Projected Available Net Requirements Planned Order
- 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 times are 1 week except for component E, which has a
- 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. Week Model A Model B Model C Total 1 2 600 1600 1000 3 800 800 4 1600
- 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 B?$10,500, part C?$890, part D?$1130, and part F?$700.
- 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; wrong size 50,000; order canceled 15,000; wrong
- Given the following fixed and variable costs and the volumes, calculate the total and unit costs. Fixed cost $200.00 $200.00 $50.00 $800.00 $500.00 Variable cost $8.00 $7.00 $15.00 $2.00 $20.00
- 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
- 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 weeks?
- 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: Item 11 2 3 Total Annual Demand $14,400 4900 1600 Orders per Year 5 5 VAD
- Calculate the new lot size for the following if K = 5 Item 1 2 3 Annual Demand 2500 900 121 VAD New Lot Size
- 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 carrying inventory is 20%. The supplier offers a
- 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 $50. Calculate the following:a. Average inventory.b.
- Analyze the following data to produce an ABC classification based on annual dollar usage. Part Number 1 2 3 دیا 4 5 6 7 8 9 10 Annual Unit Usage 200 17,000 60,000 15,000 1500 120 25,000 700
- 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. Calculate the annual dollar usage of each item. b.
- Given the following data, calculate a level production plan, quarterly ending inventory, and average quarterly inventory. If inventory carrying costs are $3 per unit per quarter, what is the annual
- A company manufactures and sells a seasonal product. Based on the sales forecast that follows, calculate a level production plan, quarterly ending inventories, and average quarterly inventories.
- The Fast Track Ski Shoppe sells ski goggles during the four months of the ski season. Average demand follows: a. Calculate the deseasonalized sales and the seasonal index for each of the four
- Calculate the deseasonalized demands for the following: Quarter 1 2 3 4 Total Actual Demand 130 170 375 90 Seasonal Index 0.62 1.04 1.82 0.52 Deseasonalized Demand
- Given the following average demand for each month, calculate the seasonal indices for each month. Your answer, if done correctly, should have all the seasonal indices add up to the number of
- 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 graph paper.b. Letting α = 0.25, calculate the
- 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 245. Month 1 2 3 نیا 4 5 6 Actual Demand 260
- 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 three-month moving average, calculate the
- 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 centers. For this problem, there is no move time.
- Complete the following input/output report. What is the actual backlog at the end of period 5? Period Planned Input Actual Input Cumulative Variance 1 78 84 2 78 80 3 78 78 4 78 82 78 80 Total
- 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 one machine is assigned to each operation. b.
- 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 form subassembly A. Subassembly A and component D
- 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 B. The setup time on A is 45 minutes, and run time
- 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 week 4 and 50 Bs in week 5. There is a scheduled
- 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. Z(1) Y(3) W(1) X Z(2) Part X Lead Time: 1 week Lot
- Given the following product tree, explode, offset, and determine the gross and net requirements. The quantities required are shown in parentheses. The master production schedule calls for the
- 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. Quantities required are shown in brackets. Z(2) Y(1) X
- Given the following partial product tree, explode, offset, and determine the gross and net requirements for components H, I, J, and K. There are other components, but they are not connected to this
- 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. Period Forecast Customer Orders Projected
- 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 weeks. Week Forecast Customer Orders Projected
- 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 weeks. Week Forecast Customer Orders Projected
- Using the scheduled receipts, calculate the ATP. There are 45 units on hand. Week Customer Orders MPS ATP 1 45 2 50 100 3 35 4 40 100 5 30 6 40 100 7 20 8 18 100
- Using the scheduled receipts, calculate the ATP. There are zero units on hand. Week Customer Orders MPS ATP 1 10 50 2 3 10 4 5 60 50 6 16 7 8 9 10 50 10
- Given the following data, calculate how many units are available to promise. There are 5 units on hand. Week Customer Orders MPS ATP 1 21 30 2 3 17 30 4 8 30 5 6 3
- Calculate the available to promise using the following data. There are 90 units on hand. Week Customer Orders MPS ATP 1 70 2 70 100 3 20 4 40 100 5 10 6 100
- The Shades Sunglass Company assembles sunglasses from frames, which it makes, and lenses, which it purchases from an outside supplier. The sales department has prepared the following 6-week forecast
- 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 forecast for 6 weeks. The opening inventory is 30. As
- From the bookstore example in question 21, describe how one of the supply chains would use a supply chain “channel master.”Data from question 21Describe at least three supply chains that provide
- 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 Product X and using the data given for components A, B,
- 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 answers.? 2. Use the product information to develop
- 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 assemble-to-order environment?
- 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 constraints as defined by the type of customer and 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 would you tell the customer about having such an
- 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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