Introduction To Materials Management 8th edition Arnold J. R. Tony, Gatewood Ann K., M. Clive Lloyd N. Chapman Stephen - Solutions

What information is needed to develop a make-to-stock production plan?
Describe four conditions under which a firm would make-to-stock or make-to-order.
What is a hybrid strategy? Why is it used?
Describe each of the four basic strategies used in developing a production plan. What are the advantages and disadvantages of each?
What are five typical characteristics of the production planning problem?
On what basis should product groups (families) be established?
When making a production plan, why is it necessary to select a common unit or to establish product families?
In the short run, how can capacity be changed?
What two changing conditions led to the development of ERP systems?
What is MRP II?
What is the difference between strategic business planning and sales and operations planning (SOP)? What are the major benefits of SOP?
Describe the relationship among the production plan, the master production schedule, and the material requirements plan.
Describe the responsibilities and inputs of the marketing, production, finance, and engineering departments to the strategic business plan.
Describe each of the following plans in terms of their purpose, planning horizon, level of detail, and planning cycle:a. Strategic plan.b. Business plan.c. Production plan.d. Master production schedule.e. Material requirements plan.f. Production activity control.
Define capacity and priority. Why are they important in production planning?
The Williams 3D printer company was experiencing growing pains early in 2015. Jasper Williams had developed his own unique design for making a 3D printer with this relatively new technology that was growing fairly rapidly in interest and in competitors. He had started by using his engineering
What are the four questions a good planning system must answer?
1. Using the data, develop a level production plan. How much extra cost (inventory and HR costs) are involved in this plan? What additional costs (both financial and nonfinancial) might be involved with such a plan? 2. Using the data, develop a chase production plan. How much extra cost (inventory
Give an example of a postponement activity.
Which manufacturing strategies are used in a fast-food business? How does this affect the lead time from the customers’ point of view?
Describe at least three supply chains that provide products to your school book store. Do they use cooperative supply chain methods to help reduce their costs?
A computer carrying case and a backpack are familiar items to a student of manufacturing planning and control. Discuss the manufacturing planning and control activities involved in producing a variety of these products. What information from other departments is necessary for manufacturing planning
What are metrics? What are their uses?
Why can materials management be considered a balancing act?
What are the six activities involved in the physical supply/distribution system?
Name and describe the inputs to a manufacturing planning and control system.
Name and describe the three primary activities of manufacturing planning and control.
What is the purpose of materials management?
Describe how the objectives of marketing, production, and finance are in conflict over customer service, disruption to production, and inventories.
What are the objectives of production? How can these objectives be met?
What are the objectives of finance? How can these objectives be met?
What is the objective of marketing? What three ways will help it achieve this objective?
What are the four objectives of a firm wishing to maximize profit?
Name and describe the three main divisions of supply, production, and distribution systems.
What must manufacturing management do to manage a process or operation? What is the major way in which management plans and controls?
What is a supply chain? Describe five important factors in supply chains.
Describe the five primary manufacturing strategies. How does each affect delivery lead time?
What are an order qualifier and an order winner?
Name and describe four major factors affecting operations management.
What is value added, and how is it achieved?
1. What are the key issues in this case? In other words, analyze the case to try to determine the true problems from the symptoms of those problems. How do these issues relate to the issue of strategy?2. What type of data would you suggest collecting to both verify the problem identifications are
What is wealth, and how is it created?
A pallet manufacturer has measured the output of a board cutting operation. The boards have a specification of 24 inches ±0.5 inch. A sample of the boards is shown below. Calculate the capability of the board cutting operation. What suggestions would you give to the operator?24.0 24.1 24.2 23.8
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 10 ounces of shampoo. The tolerance is ±0.1 ounce. The process has a standard deviation of 0.02 ounce. For the following situations, calculate the Cpk and evaluate the process capability.a. A sample has an average of quantity of 9.95 ounces.b. A sample has an
In problem 16.6, what is the Cpk whena. The process is centered on 0.75? Is the process capable?b. The process is centered on 0.74? Is the process capable?In ProblemThe specification for the diameter of a hole is 0.80 inch ±0.020 inch. The standard deviation of the drill press is 0.007 inch. Using
If, in problem 16.5, the process is improved so the standard deviation is 0.0035, is the process capable now?In ProblemThe specification for the diameter of a hole is 0.80 inch ±0.020 inch. The standard deviation of the drill press is 0.007 inch. Using Cp, calculate whether the process is capable
The specification for the diameter of a hole is 0.80 inch ±0.020 inch. The standard deviation of the drill press is 0.007 inch. Using Cp, calculate whether the process is capable or not.
The specification for the weight of a chemical in a compound is ±0.06. If the standard deviation of the weighing scales is 0.02, is the process considered capable?
The specification for the thickness of a piece of steel is 0.5 inch ±0.05 inch. The standard deviation of the band saw is 0.015. Using Cp, calculate whether the process is capable or not.
In problem 16.1, if the tolerance changes to ±0.0004 inch, approximately what percentage of the shafts will be within tolerance?In ProblemThe specification for the length of a shaft is 12 inches ±0.001 inch. If the process standard deviation is 0.00033, approximately what percentage of the shafts
A company produces a line of golf putters composed of three models. The demand for model A is 500 per month, for B is 400, and for C is 300. What would be the mixed-model sequence if some of each were made each day?
a. Which of the following items are within tolerance?b. What is the percent accuracy by item? Part Shelf Inventory Within Tolerance? Number Count Record Difference % Difference Tolerance 635 A 650 +3% 1205 B 1205 +0% 1350 1500 ±5% +5% D 77 80 +3% 38 40 Total
Parent S requires three of component T and two of component U. Both T and U are run on work center 30. Setup time for T is 7 hours, and run time is 0.1 hour per piece. For component U, setup time is 8 hours, and run time is 0.2 hour per piece. If the rated capacity of the work center is 120 hours,
Parent W requires one of component B and two of component C. Both B and C are run on work center 10. Setup time for B is 2 hours, and run time is 0.1 hour per piece. For component C, setup time is 2 hours, and run time is 0.15 hour per piece. If the rated capacity of the work center is 80 hours,
Bill builds benches in a small shop and he plans to operate five 8-hour days per week. Each bench has two ends and a top. It takes 5 minutes to cut and sand each end and 2 minutes to make each top. Assembly requires 8 minutes per bench, and painting requires 5 minutes per bench. Bill has one
A company has an annual demand for a product of 2000 units, a carrying cost of $20 per unit per year, and a setup cost of $100. Through a program of setup reduction, the setup cost is reduced to $20. Run costs are $2 per unit. Calculate:a. The EOQ before setup reduction.b. The EOQ after setup
In problem 15.1, if the annual carrying cost is 18% per unit, what will be the annual savings in carrying cost?In problem 15.1A company carries 10 items in stock, each with an economic order quantity of $20,000. Through a program of component standardization, the 10 items are reduced to 5. The
A company carries 10 items in stock, each with an economic order quantity of $20,000. Through a program of component standardization, the 10 items are reduced to 5. The total annual demand is the same, but the annual demand for each item is twice what it was before. In Chapter 10, we learned that
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?
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?
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?
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? Process A Process B Buy Setup Tooling Labor/unit Materialunit Purchase cost $40.00 $130.00 $15.00 $4.10 $20.00 $3.90 $2.00 $2.00 $6.10
Bananas are on sale at the Cross Towne store for 79¢ per pound. They normally sell for 99¢ 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 bargain.
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:a. What is the cost equalization point?b. Should the company have the heat treating done by an outside
A process costs $200 to set up. The run time is 5 minutes per piece and the run cost is $30 per hour. Determine the following:a. The fixed cost.b. The variable cost.c. The total cost and unit cost for a lot of 600.d. The total cost and unit cost for a lot of 1200.
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 pound for shipping LTL to city A is $0.70 + $0.30 per mile.Cost per pound for shipping TL to warehouse is $0.40 + $0.15 per mile.Warehouse handling costs
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 $6 per cwt. Should it
A company has a central supply facility and a distribution center located 400 miles away. The central supply product cost is $75, TL transportation rates from central supply to the DC are $60 per unit, and handling costs at the DC 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. TL shipment costs to the DC would be $20 per cwt., the estimated inventory carrying costs are $5 per cwt., and the local cartage (LTL) cost
A company in Calgary serves a market in the northwestern United States. Now it ships LTL at an average cost of $30 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 $7 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 $600, 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 750 units in a truck. What is the line haul cost per unit now?
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?
For a given commodity, the line haul cost is $13 per mile. For a trip of 200 miles and a shipment of 300 lbs., what is the cost per pound? If the shipment is increased to 500 lbs., what is the saving in cost per pound?
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 6 weeks, and the shipping costs $2700 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 4 days. If transit inventory cost is $35 per day, what does it cost to ship each way?
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. Which of the following items are within tolerance?b. What is the percent accuracy by item? Within Part Shelf Inventory Record Tolerance Tolerance? Number Count Difference % Difference 75 +3% A 80 ±0% 120 120 +5% 1400 1500 75 ±5% D 76 ±2% 68 66 Total
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 are
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? 60 4' Aisle 4' 4' Aisle 4'
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? 200' 4' Aisle 4'
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?
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?
A regional warehouse orders items once a week from a central warehouse. The truck arrives 3 days after the order is placed. The warehouse operates 5 days a week. For a particular brand and size of chicken soup, the demand is fairly steady at 20 cases per day. Safety stock is set at 2 days’
A firm orders a number of items from a regional warehouse every 2 weeks. Delivery takes 1 week. Average demand is 200 units per week, and safety stock is held at 2 weeks’ supply.a. Calculate the target level.b. If 600 units are on hand, how many should be ordered?
A company that manufactures snow shovels has one plant and two distribution centers (DCs). Given the following information for the two DCs, calculate the gross requirements, projected available, and planned order releases for the two DCs and the gross requirements, projected available, and planned
A company that manufactures stoves has one plant and two distribution centers (DCs). Given the following information for the two DCs, calculate the gross requirements, projected available, and planned order releases for the two DCs and the gross requirements, projected available, and planned order
The annual demand for an item is 10,000 units, the order quantity is 250, and the service level is 90%. Calculate the probable number of stockouts per year.
If in problem 11.15, management said that it is considering increasing the service level to one stockout every 2 years, what would the new safety stock be? If the cost of carrying inventory on this item is $10 per unit per year, what is the cost of increasing the inventory from one stockout per
Management has stated that it will tolerate one stockout per year. The forecast of annual demand for a particular SKU is 100,000 units, and it is ordered in quantities of 10,000 units. The lead time is 2 weeks. Sales history for the past 10 weeks follows. Calculate:a. Sigma for the demand history
The safety stock on an SKU is set at 220 units. The supplier says it can reduce the lead time from 8 to 6 weeks. What should be the new safety stock?
A company stocks an SKU with a weekly demand of 600 units and a lead time of 4 weeks. Management will tolerate one stockout per year. If sigma for the lead time is 100 and the order quantity is 2500 units, what is the safety stock, the average inventory, and the order point?
A company stocks an SKU with a weekly demand of 225 units and a lead time of 3 weeks. Management will tolerate one stockout per year. If sigma for the lead time is 175 and the order quantity is 800 units, what is the safety stock, the average inventory, and the order point?
For an SKU, the standard deviation of demand during the lead time is 150 units, the annual demand is 10,000 units, and the order quantity is 750 units. Management says it will tolerate only one stockout per year. What safety stock should be carried? What is the average inventory? If the lead time
The standard deviation of demand during the lead time is 100 units.a. Calculate the safety stock required for the following service levels: 75%, 80%, 85%, 90%, 95%, and 99.99%.b. Calculate the change in safety stock required to increase the service levels from 75 to 80%, 80 to 85%, 85 to 90%, 90 to
If sigma is 130 units, and the demand during the lead time is 250 units, calculate the safety stock and order point for:a. A 50% service level.b. An 85% service level.Use the table in Figure 11.5 as help to calculate your answer. Service Level (%) Safety Factor 50 0.00 75 0.67 80 0.84 85 1.04 90
Given the following data, calculate the average demand and the standard deviation. Period Actual Deviation Deviation Demand Squared 1700 2100 1900 4 2200 5 2000 6. 1800 7. 2100 2300 8. 2100 10 1800 Total

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Introduction To Materials Management 8th edition Arnold J. R. Tony, Gatewood Ann K., M. Clive Lloyd N. Chapman Stephen - Solutions

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