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earth sciences
introduction materials management
Introduction To Materials Management 8th edition Arnold J. R. Tony, Gatewood Ann K., M. Clive Lloyd N. Chapman Stephen - Solutions
Given the following data, calculate the average x of the distribution and the standard deviation (σ). Period Actual Deviation Deviation Demand Squared 500 600 425 4. 450 5 600 6. 575 375 8. 475 525 475 10 Total
For a particular SKU, the lead time is 6 weeks, the average demand is 90 units a week, and safety stock is 200 units. What is the average inventory if 10 weeks’ supply is ordered at one time? What is the order point?
For a particular SKU, the lead time is 4 weeks, the average demand is 150 units per week, and safety stock is 100 units. What is the average inventory if 1600 units are ordered at one time? What is the order point?
An item has a weekly demand of 240 units throughout the year. The item has a unit value of $42 and the company uses 20% of the item value for the annual inventory cost. When ordered, the setup cost to produce an order is $600, and the production process is able to produce 500 per week and deliver
Given the following MRP record and an EOQ of 200 units, calculate the planned order receipts using the economic order quantity. Next, calculate the period order quantities and the planned order receipts. In both cases, calculate the ending inventory and the total inventory carried over the 10
Given the following net requirements, calculate the planned order receipts based on the period order quantity. The EOQ is 250 units, and the annual demand is 4200 units. Week 4 8. 5 6 Net Requirements 100 90 630 80 85 100 85 90 Planned Order Receipts 2.
The EOQ for an item is 800 units, and the annual usage is 2300 units. What is the period order quantity?
A company manufactures five sizes of screwdrivers. Ordering costs and carrying costs are not known, but it is known that they are the same for each size. At present, each size is produced four times per year. If the demand for each size is as follows, calculate order quantities to minimize
A company manufactures three sizes of lightning rods. Ordering costs and carrying costs are not known, but it is known that they are the same for each size. Each size is produced six times per year. If the demand for each size is as follows, calculate order quantities to minimize inventories and
The local fire department uses 10,000 alkaline flashlight batteries per year, which cost $4 each. The cost of ordering batteries is estimated to be $50. The current interest rate suggested by the city council is 25%. The sales rep has recently suggested that you could get a discount of 2% for
Refer to problem 10.3. The supplier offers a 2% discount on orders of 5000 units. Calculate the purchase cost, the cost of ordering, the cost of carrying, and the total cost if orders of 5000 are placed. Compare the results and calculate the savings if the discount is taken.In Problem 10.3A company
An SKU has an annual demand of 10,000 units, each costing $15, ordering costs are $80 per order, and the cost of carrying inventory is 25%. Calculate the EOQ in units and then convert to dollars.
A company wishes to establish an EOQ for an item for which the annual demand is $800,000, the ordering cost is $32, and the cost of carrying inventory is 20%. Calculate the following:a. The EOQ in dollars.b. Number of orders per year.c. Cost of ordering, cost of carrying inventory, and total
A company decides to establish an EOQ for an item. The annual demand is 400,000 units, each costing $9, ordering costs are $35 per order, and inventory carrying costs are 22%. Calculate the following:a. The EOQ in units.b. Number of orders per year.c. Cost of ordering, cost of carrying inventory,
a. The Ajex Company has several of items they store in inventory. The table below shows the annual demand, and the item cost. Develop a logical classification for the inventory based on ABC:b. One additional item, the M22, has a very low usage (300 per year) and a low item cost ($3 per unit), but
A company has 600 units on hand and the annual usage is 7200 units. There are 240 working days in the year. What is the days of supply?
If the annual cost of goods sold is $30,000,000 and the average inventory is $5,000,000,a. What is the inventory turns ratio?b. What would be the reduction in average inventory if, through better materials management, inventory turns were increased to 10 times per year?c. If the cost of carrying
If the annual cost of goods sold is $12,000,000 and the average inventory is $2,250,000,a. What is the inventory turns ratio?b. What would be the reduction in average inventory if, through better materials management, inventory turns were increased to 10 times per year?c. If the cost of carrying
In question 9.12, how much would profit increase if the materials costs are reduced by $200,000?In question 9.12Given the following data, calculate the gross margin and the net income.Revenue = $3,000,000Direct labor = $700,000Direct material = $900,000Factory overhead = $700,000General and
Given the following data, calculate the gross margin and the net income.Revenue = $3,000,000Direct labor = $700,000Direct material = $900,000Factory overhead = $700,000General and administrative expense = $300,000
If the liabilities are $4,000,000 and the owners’ equity is $1,200,000, what are the assets worth?
If the assets are $2,000,000 and liabilities are $1,600,000, what is the owners’ equity?
Given the following data, calculate a level production plan, quarterly ending inventory, and average quarterly inventory. If inventory carrying costs are $6 per unit per quarter, what is the annual carrying cost? Opening and ending inventories are zero.If the company always carries 100 units of
An importer operates a small warehouse that has the following annual costs. Wages for purchasing are $45,000, purchasing expenses are $30,000, customs and brokerage costs are $30 per order, the cost of financing the inventory is 8%, storage costs are 7%, and the risk costs are 10%. The average
In problem 6.2, what percentage of the time is the order actually running?In problem 6.2An order for 100 of a product is processed on work centers A and B. The setup time on A is 50 minutes, and run time is 5 minutes per piece. The setup time on B is 60 minutes, and the run time is 5 minutes per
Annual purchasing salaries are $65,000, operating expenses for the purchasing department are $25,000, and inspecting and receiving costs are $25 per order. If the purchasing department places 9000 orders a year, what is the average cost of ordering? What is the annual cost of ordering?
A florist carries an average inventory of $12,000 in cut flowers. The flowers require special storage and are highly perishable. The florist estimates capital costs at 10%, storage costs at 25%, and risk costs at 50%. What is the annual carrying cost?
Given the following percentage costs of carrying inventory, calculate the annual carrying cost if the average inventory is $1 million. Capital costs are 10%, storage costs are 6%, and risk costs are 9%.
A company is using a carrier to deliver goods to a major customer. The annual demand is $2,500,000, and the average transit time is 10 days. Another carrier promises to deliver in 7 days. What is the reduction in transit inventory?
If the transit time is 11 days and the annual demand for an item is 10,000 units, what is the average annual inventory in transit?
A company uses a tracking signal trigger of ±4 to decide whether a forecast should be reviewed. Given the following history, determine in which period the forecast should be reviewed. MAD for the item is 15. Is there any previous indication that the forecast should be reviewed? Period Forecast
For the following data, calculate the mean absolute deviation. Actual Demand Period Forecast Absolute Deviation 105 1 100 105 95 3 110 90 4. 115 130 100 5 120 6. 125 120 Total 675 650
Given the following forecast and actual demand, calculate the mean absolute deviation. Actual Demand Period Forecast Absolute Deviation 1 110 85 110 105 3 110 120 110 100 5 110 90 Total
The old deseasonalized forecast is 100 units, α = 30, and the actual demand for the last month was 180 units. If the seasonal index for the last month is 1.2 and the next month is 0.8, calculate:a. The deseasonalized actual demand for the last month.b. The deseasonalized forecast for next month
A company is negotiating with a potential supplier for the purchase of 100,000 widgets. The company estimates that the supplier’s variable costs are $5 per unit and that the fixed costs, depreciation, overhead, and so on, are $50,000. The supplier quotes a price of $10 per unit. Calculate the
If suppliers were to be rated on the following basis, what would be the ranking of the two suppliers listed? Rating of Suppliers Ranking of Suppliers Weight Supplier A Supplier B Supplier A Supplier B Factor Function Cost Technical Assistance Credit Terms 4 4
If purchases were 45% of sales and other expenses were 45% of sales, what would be the increase in profit if, through better purchasing, the cost of purchases was reduced to 43% of sales?
Calculate the critical ratios for the following orders and establish in what order they should be run. Today’s date is 75. Lead Time Remaining (days) Actual Time Remaining (days) Order Due Date 89 CR A 10 25 95 B 100 20
Complete the following table to determine the run sequence for each of the sequencing rules. Sequencing Rule Process Arrival Due Operation Due Date Time (days) Date Date EDD ODD SPT Job FCFS 123 A. 5 142 132 124 144 131 131 140 129 D 6. 132 146 135
Complete the following input/output report. What are the planned and actual backlogs at the end of period? 3 Total 4 Period Planned Input 39 38 35 36 Actual Input 33 33 40 31 Cumulative Variance Planned Output 40 40 40 40 Actual Output 38 35 40 38 Cumulative Variance
In problem 6.12, what would be the manufacturing lead time if the second machine could not be set up until the setup on the first machine was completed? Would there be any reduction in manufacturing lead time?Problem 6.12An order for 100 of a product is run on work center 40. The setup time is 4
An order for 100 of a product is run on work center 40. The setup time is 4 hours, and the run time is 3 minutes per piece. Since the order is a rush and there are two machines in the work center, it is decided to split the order and run it on both machines. Calculate the manufacturing lead time
What would be the reduction in manufacturing lead time if the second machine could not be set up until the setup was completed on the first machine?An order for 100 of a product is processed on operation A. The setup time is 50 minutes, and the run time per piece is 9 minutes. Since this is a rush
An order for 100 of a product is processed on operation A. The setup time is 50 minutes, and the run time per piece is 9 minutes. Since this is a rush order, it is to be split into two lots of 50 each and run on two machines in the work center. The machines can be set up simultaneously.a. Calculate
An order for 250 bell ringers is processed on work centers 10 and 20. The setup and run times are as follows. It is decided to overlap the lot on the two work centers and to split the lot into two lots of 100 and 150. Move time between operations is 30 minutes. Work center 20 cannot be set up until
An order for 100 of a product is processed on operation A and operation B. The setup time on A is 50 minutes, and the run time per piece is 9 minutes. The setup time on B is 30 minutes, and the run time is 6 minutes per piece. It takes 20 minutes to move a lot between A and B. Since this is a rush
An 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 is 5 minutes per piece. The setup time on B is 30 minutes, and the run time is 4 minutes per piece. Wait time between the two operations is 8 hours. The move time between A and B is 60
An order for 100 of a product is processed on work centers A and B. The setup time on A is 50 minutes, and run time is 5 minutes per piece. The setup time on B is 60 minutes, and the run time is 5 minutes per piece. Wait time between the two operations is 5 hours. The move time between A and B is
Shop order 7777 is for 600 of part 8900. From the routing file, it is found that operation 20 is done on work center 300. The setup time is 3.5 hours, and run time is 0.233 hours per piece. What is the required capacity on work center 300 for shop order 7777?
If the actual demand for April was 1440 units and the seasonal index was 2.5, what would be the deseasonalized April demand?
The average demand for January has been 80, and the average annual demand has been 1800. Calculate the seasonal index for January. If the company forecasts annual demand next year at 2000 units, what is the forecast for January next year?
Using the data in problem 8.9, if the forecast for next year is 800, calculate the forecast for first quarterly demand next year.In Problem 8.9If the average demand for the first quarter was 140 and the average demand for all quarters was 175, what is the seasonal index for the first quarter?
If the average demand for the first quarter was 140 and the average demand for all quarters was 175, what is the seasonal index for the first quarter?
Using exponential smoothing, calculate the forecasts for the same months as in problem 8.3c. The old average for month 3 was 96 and α = 0.4. What is the difference between the two forecasts for month 11? Month Actual Demand Forecast 1 102 91 3 95 4 105 94 100 106 95 105 10 98 11 2.
If the old forecast is 100 and the latest actual demand is 83, what is the exponentially smoothed forecast for the next period? Alpha is 0.25.
If the forecast for February was 122 and actual demand was 135, what would be the forecast for March if the smoothing constant (a) is 0.15? Use exponential smoothing for your calculation.
Over the past three months, the demand for a product has been 255, 219, and 231. Calculate the three-month moving average forecast for month 4. If the actual demand in month 4 is 228, calculate the forecast for month 5.
Back schedule the following shop order. All times are given in days. Move time between operations is 1 day, and wait time is 1 day. Due date is day 200. Assume orders start at the beginning of a day and finish at the end of a day. Queue Time (days) Operation Operation Time (days) Finish Work Center
Back schedule the following shop order. All times are given in days. Move time between operations is 1 day, and wait time is 1 day. Due date is day 150. Assume orders start at the beginning of a day and finish at the end of a day. Operation Time (days) Arrival Queue Time (days) Operation Number
Complete the following load report and suggest possible courses of action. Week Total 18 19 20 21 Released Load 160 155 100 70 485 Planned Load 70 80 150 Total Load Rated Capacity 150 150 150 150 600 (OverVUnder Capacity
Using the following route information, open order information, and MRP planned orders, calculate the load on the work center. Part 123: Routing: Setup time Run time per piece = 3 standard hours per piece Setup time Run time per piece = 1 standard hour per piece = 2 standard hours = 3 standard hours
A work center has the following open and planned orders for week 4. Calculate the total standard time required (load). Order Quantity Setup Time (hours) Total Time Run Time (hours/piece) (hours) Released Orders 125 200 0.50 0.10 345 70 0.75 0.05 Planned Orders 565 80 1.00 0.25 1.50 0.15 785 35
A work center has the following open and planned orders for week 4. Calculate the total standard time required (load). Setup Time (hours) Order Run Time Total Time Quantity (hours/piece) (hours) Released Orders 120 300 1.00 0.10 340 200 2.50 0.30 300 Planned Orders 560 3.00 0.25 0.15 780 500 2.00
A firm wishes to determine the efficiency and utilization of a work center composed of 5 machines each working 16 hours per day for 5 days a week. A study undertaken by the materials management department found that over the past 50 weeks the work center was actually working for 16,000 hours, and
How many standard hours are needed to run an order of 500 pieces if the setup time is 2.0 hours and the run time 0.3 hours per piece? How many actual hours are needed at the work center if the efficiency is 110% and the utilization is 85%?
How many standard hours are needed to run an order of 200 pieces if the setup time is 1.3 hours and the run time 0.3 hours per piece? How many actual hours are needed at the work center if the efficiency is 130% and the utilization is 70%?
A work center consisting of 3 machines operates 40 hours a week. In a 4-week period, it actually worked 355 hours and produced 475 standard hours of work. Calculate the utilization and efficiency of the work center. What is the demonstrated weekly capacity of the work center?
In 1 week, a work center produces 75 standard hours of work. The hours scheduled are 80, and 72 hours are actually worked. Calculate the utilization and efficiency of the work center.
In an 11-week period, a work center produces 1050 standard hours of work. What is the measured capacity of the work center?
Over a period of 4 weeks, a work center produced 50, 45, 42, and 52 standard hours of work. What is the demonstrated capacity of the work center?
A work center consists of 4 machines working 8 hours a day for a 5-day week. If the utilization is 80% and the efficiency is 90%, what is the rated capacity of the work center?
A work center consisting of 7 machines is operated 16 hours a day for a 5-day week. Utilization is 80%, and efficiency is 110%. What is the rated weekly capacity in standard hours?
If the efficiency of the work center in problem 5.1 is 120%, what is the rated capacity of the work center?
The work center in problem 5.1 is utilized 75% of the time. What are the hours per week actually worked?In problem 5.1A work center consists of 3 machines each working a 16-hour day for 5 days a week. What is the weekly available time?
A work center consists of 3 machines each working a 16-hour day for 5 days a week. What is the weekly available time?
The following bill of materials represents the major components for a computer system.Complete the MRP records below. Note the following:■ Production plans (the MPS) for the 800 Deluxe computer system are as follows:Start assembling 2500 in week 2Start assembling 3000 in weeks 3, 4, and 5Start
It is Monday morning, and you have just arrived at work. Complete the following MRP record as it would appear Monday morning. Lead time is 2 weeks, and the lot size is 100.During the week, the following events occur. Enter them in the MRP record.a. The planned order for 100 in week 1 is released.b.
Complete the following MRP record. The lead time is 4 weeks, and the lot size is 200. What will happen if the gross requirements in week 3 are increased to 150 units? As a planner, what actions can you take? Initial MRP Week 2 3 4 5 Gross Requirements Scheduled Receipts Projected Available 100 Net
Given the following product tree, develop a material requirements plan for the components. Quantities per are shown in parentheses. The following worksheet shows the present active orders, the available balances, and the lead times. C(2) D(2) Low-Level Code Week 4 5 Part A Gross Requirements
Given the following product tree, determine the low-level codes for all the components. A Н G н G Н Н Item А В С D E F G н Low-Level Code
Given the following product tree, determine the low-level codes for all the components. A D B Item A B D Low-Level Code
Given the following parents and components, construct a product tree. Figures in parentheses show the quantities per item. How many Gs are needed to make one A? Parent Component A B C E B(2) E(2) G(3) G(4) C(4) F(1) D(4) F(3) Н(2)
Using the following product tree, construct the appropriate single-level trees. How many Cs are needed to make 50 Xs and 100 Ys? х A(2) C(2) E(2) E(2) C(2)
a. Given the following master schedule, fill in the projected available and available to promise rows:b. A customer wants an order of 100 in period 4. What can you tell him?c. The customer from part (b) cancels his request, but then says he wants 120 in period 5. What do you tell him now?d. Sales
Product A is an assemble-to-order product. It has a lot size of 150, and currently has an on-hand inventory of 110 units. There is a 2-week demand time fence and a 12-week planning time fence. The following table gives the original forecast and the actual customer orders for the next 12 weeks:a.
Given the following data, can an order for 40 more units for delivery in week 5 be accepted? If not, what do you suggest can be done? There are zero units on hand. 5 2 3 6. 8. Week Customer Orders 70 15 20 40 10 10 50 15 100 MPS 100 100 ATP 2.
Given the following data, can an order for 20 for delivery in week 4 be accepted? Calculate the ATP using the following table. On hand = 50 units. Week 2 3 5 4 8. 40 30 Customer Orders 50 50 40 15 50 30 MPS 100 100 100 100 ATP 3. 2.
Calculate the available to promise using the following data. There are 50 units on hand. Week 1 2 3 5 4 30 30 Customer Orders 20 50 30 50 MPS 100 100 ATP 2.
The Acme Widget Company makes widgets in two models, and the bottleneck operation is in work center 10. Following is the resource bill (in hours per part).The master production schedule for the next 5 weeks isa. Using the resource bill and the master production schedule, calculate the number of
In the example given earlier in the chapter, the MPS was unsatisfactory because there were poor inventory balances compared to the production plan. There was also a stockout for product C in periods 2 and 3. Revise the production plans for the three products to cut out or reduce these problems.
Worldwide Can-Openers, Inc., makes a family of two hand-operated can openers. The production plan is based on months. There are 4 weeks in this month. Opening inventory is 2000 dozen, and it is planned to increase that to 4000 dozen by the end of the month. The MPS is made using weekly periods. The
The Amalgamated Mailbox Company manufactures a family of two mailboxes. The production plan and the MPS are developed on a quarterly basis. The forecast for the product group follows. The opening inventory is 270 units, and the company wants to reduce this to 150 units at the end of the year.
A production line is to run at 1000 units per month. Sales are forecast as shown in the following. Calculate the expected period-end inventory. The opening inventory is 600 units. All periods have the same number of working days. 3 4 6. Period Forecast 1050 850 1000 750 800 1600 Planned Production
In problem 2.3, how much will be produced in each of the three months?In problem 2.3A company plans to produce 25,000 units in a 3-month period. The months have 22, 21, and 20 working days, respectively. What should the average daily production be?
In problem 2.2, how much will be produced in each of the three months?In Problem 2.2A company wants to produce 480 units over the next three months at a uniform rate. The months have 19, 20, and 21 working days, respectively. On the average, how much should the company produce each day to level
For the following data, calculate the number of workers required for level production and the resulting month-end inventories. Each worker can produce 9 units per day, and the desired ending inventory is 800 units. Why is it not possible to reach the exact ending inventory target? 1 5 Total 3 4 6.
For the following data, calculate the number of workers required for level production and the resulting month-end inventories. Each worker can produce 15 units per day, and the desired ending inventory is 9000 units. 1 3 4 Month Total Working Days 20 24 19 12 Forecast Demand 27,500 28,500 28,500
The opening backlog is 1100 units. Forecast demand is as shown here. Calculate the weekly production for level production if the backlog is to be increased to 1200 units. 3 2 5 Total 4 6. Week Forecast Demand 1200 1200 1100 1200 1100 1000 Planned Production Projected 1100 Backlog
The opening backlog is 800 units. Forecast demand is as shown here. Calculate the weekly production for level production if the backlog is to be reduced to 100 units. 3 5 2 4 6. Week Total Forecast Demand 550 600 750 700 700 500 Planned Production Projected 800 Backlog
If the opening backlog is 450 units, forecast demand is 700 units, and production is 800 units, what will be the ending backlog?
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