Deck 12: Managing Production Across the Supply Chain

Question 1

Given the forecast and booked orders shown in the table,and a beginning inventory of 0,what is the available to promise inventory for period 3? There are no LOT quantity constraints.

A) 0
B) 12
C) 24
D) 36

Answer 1

D

Question 2

The longer the production and supplier lead times,the ________ the MRP record's ________ should be.

Answer 2

longer; planning horizon

Question 3

A unit that has not been sold or otherwise committed to any other customer should be considered available to promise.

Answer 3

True

Question 4

Material requirements planning is performed at greater level of detail than master scheduling.

Question 5

The longer the production and supplier lead times,the longer the master scheduling record's planning horizon needs to be.

Question 6

The estimated inventory level of an end item at the end of each planning period,whether the period is a week or a month is the ________.

Question 7

From a revenue standpoint,a producer would rather have higher forecasted demand than booked orders.

Question 8

Available to promise inventory is always zero for the first week in the master production schedule.

Question 9

Given the forecast and booked orders shown in the table,and a beginning inventory of 25,what is the master production schedule quantity for period 4?

A) 35
B) 40
C) 55
D) 70

Question 10

Given the forecast and booked orders shown in the table,and a beginning inventory of 75,what is the available to promise inventory for period 4? The company operates with a lot size of 50.

A) 150
B) 145
C) 155
D) 140

Question 11

Confirmed demand for products is called ________ in master scheduling.

Question 12

Which of the following statements regarding master production scheduling calculations is BEST?

A) Forecasted demand always exceeds booked orders.
B) Booked orders always exceed forecasted demand.
C) If booked orders are greater than forecasted orders, there must be a master production schedule for that period.
D) If ending inventory is greater than or equal to zero, there is no master production schedule quantity for that period.

Question 13

Given the forecast and booked orders shown in the table,and a beginning inventory of 20,what is the available to promise inventory for the first period? There are no LOT quantity constraints.

A) 0
B) 10
C) 20
D) 40

Question 14

Which step comes first in sales and operations planning?

A) master scheduling
B) material requirements planning
C) production activity control
D) vendor order management

Question 15

Given the forecast and booked orders shown in the table,and a beginning inventory of 120,what is the MPS for period 4? The company operates with a lot size of 144.

A) 432
B) 576
C) 288
D) 144

Question 16

Given the forecast and booked orders shown in the table,and a beginning inventory of 120,what is the projected ending inventory for period 4? The company operates with a lot size of 144.

A) 34
B) 38
C) 46
D) 22

Question 17

________ translates the master schedule for final products into detailed requirements.

Question 18

Given the forecast and booked orders shown in the table,and a beginning inventory of 120,what is the ATP for period 4? The company operates with a lot size of 144.

A) 92
B) 108
C) 126
D) 144

Question 19

Since the booked orders figure represents actual customer demand in a master schedule,that value is always less than or equal to forecasted demand.

Question 20

Throughout every MRP record,ending inventory is equal to the ending inventory from the previous period,plus the master production schedule quantity,minus the orders booked for that period.

Question 21

Describe the scope,inputs,and outputs of sales and operations planning,master scheduling,and MRP.

Question 22

Explain all of the information that is provided by a master schedule.

Question 23

Gross requirements in an MRP record can be met by inventory from previous weeks,scheduled receipts,or planned receipts.

Question 24

Company B has no inventory at any level and a structure tree as shown below.They will need 145 E's to make 12 units of end item X.

Question 25

MRP uses backward scheduling.

Question 26

Material requirements planning is used to manage independent demand inventory.

Question 27

Given the forecast and booked orders shown in the table,and a beginning inventory of 120,complete this master production schedule.The company operates with a lot size of 144.

Question 28

MRP nervousness refers to the notion that a small change at the top of a bill of material can have drastic effects on items farther down the bill of material.

Question 29

Consider the product structure tree shown below: With a beginning inventory of zero for all components and finished items,how many assembly E's are needed to produce 20 product X's?

A) 900
B) 1000
C) 1200
D) 1500

Question 30

In a bill of material,a parent may have many children but a child may have only one parent.

Question 31

A manufacturing company enters 2016 with a forecast and customer orders as shown in the table.They have a beginning inventory of 25 units and a batch size of 25 units (all MPS quantities must be in multiples of 25).Complete the rest of the master production schedule by filling in the projected ending inventory,master production schedule quantity,and available to promise rows.

Question 32

If a manufacturer had no inventory of any kind but had orders for 10 finished units of their sole product,their buyer would know what parts to order if they were supplied with a:

A) backward schedule.
B) bill of material.
C) rough-cut capacity plan.
D) planning horizon order sheet.

Question 33

Consider the product structure tree shown below: With a beginning inventory of twenty for all components on level one,five for all components on level two,and zero for all components on level three and finished items,how many more K's than F's are needed to produce 25 product X's?

A) 15
B) 10
C) 5
D) 0

Question 34

The planning technique that uses the master production schedule to monitor key resource requirements is:

A) rough-cut capacity planning.
B) horizon planning.
C) resource planning.
D) handfield planning.

Question 35

Consider the product structure tree shown below: With a beginning inventory of twenty for all components on level one,five for all components on level two,and zero for all components on level three and finished items,how many K's are needed to produce 25 product X's?

A) 530
B) 540
C) 550
D) 560

Question 36

Consider the product structure tree shown below: With a beginning inventory of zero for all components and finished items,how many assembly A's are needed to produce 25 product X's?

A) 125
B) 250
C) 325
D) 400

Question 37

Consider the product structure tree shown below: With a beginning inventory of ten for all components on level one,five for all components on level two,and zero for all components on level three and finished items,how many assembly E's are needed to produce 20 product X's?

A) 1175
B) 1500
C) 1325
D) 1225

Question 38

Given the forecast and booked orders shown in the table,and a beginning inventory of 12,complete this master production schedule.The company operates with a lot size of 144.

Question 39

Component J is ordered on February 1,is received,and is ready to use on February 8.Its planning lead time is seven days.

Question 40

With a beginning inventory of zero for all components and finished items,how many assembly E's are needed to produce 20 product X's with the product structure tree as shown below?

A) 180
B) 220
C) 260
D) 300

Question 41

A mechanical cat is made of two front leg assemblies,a body assembly,one tail,one head assembly,and two back leg assemblies.Each head assembly has two eyes,one nose,one mouth,and 24 whiskers.Each back leg assembly has one foot,five claws,one each fibula,tibia,and femur.The cat production company runs a lot for lot system on everything except the legs,which they order in cases of 36,and the claws,which come by the gross.Lead time for assembly and shipping is shown in the table.Use the master production schedule for mechanical cats to complete the MRP record.What's the planned order release for leg assemblies in week 3?

A) 504
B) 612
C) 468
D) 596

Question 42

A deluxe model mechanical cat is made of two front leg assemblies,a body assembly,one tail,two head assemblies,and two back leg assemblies.Each head assembly has two eyes,one nose,one mouth,and 24 whiskers.Each back leg assembly has one foot,five claws,one each fibula,tibia,and femur.The cat production company runs a lot for lot system on everything except the heads,which they order in cases of 250,and the whiskers,which come in boxes of 600.Lead time for assembly and shipping is shown in the table.Use the master production schedule for mechanical cats to complete the MRP record.What is the planned order release for whiskers in week 2?

A) 18,000
B) 16,000
C) 14,000
D) 12,000

Question 43

A deluxe model mechanical cat is made of two front leg assemblies,a body assembly,one tail,two head assemblies,and two back leg assemblies.Each head assembly has two eyes,one nose,one mouth,and 24 whiskers.Each back leg assembly has one foot,five claws,one each fibula,tibia,and femur.The cat production company runs a lot for lot system on everything except the heads,which they order in cases of 125,and the whiskers,which come in boxes of 333.Lead time for assembly and shipping is shown in the table.Use the master production schedule for mechanical cats to complete the MRP record.What is the planned order release for whiskers in week 1?

A) 18,000
B) 16,000
C) 14,000
D) 12,000

Question 44

Which of these actions would tend to make an MRP system less nervous?

A) using the same component, such as a fastener, at multiple levels throughout the product structure tree
B) eliminating lot size requirements wherever possible
C) increasing the number of levels in a product structure tree
D) increasing the minimum order quantities only at the highest level of a bill or materials

Question 45

MRP is NOT capable of:

A) lowering inventory levels.
B) helping a firm meet their master schedule commitments.
C) telling a firm's suppliers what needs to be made and by when.
D) sequencing jobs at a machining center.

Question 46

With an inventory as shown in the table,how many assembly E's should be produced or purchased to produce 15 product X's with this product structure tree?

A) 91
B) 147
C) 193
D) 225

Question 47

A mechanical cat is made of two front leg assemblies,a body assembly,one tail,one head assembly,and two back leg assemblies.Each head assembly has two eyes,one nose,one mouth,and 24 whiskers.Each back leg assembly has one foot,five claws,one each fibula,tibia,and femur.The cat production company runs a lot for lot system on everything except the heads,which they order in cases of 24,and the whiskers,which come in boxes of 1000.Lead time for assembly and shipping is shown in the table.Use the master production schedule for mechanical cats to complete the MRP record.What's the planned order release for whiskers in week 2?

A) 6000
B) 5000
C) 4000
D) 8000

Question 48

Cow Company used the master schedule to determine how many workers and the number of machine hours would be needed for each production period.This approach is known as ________.

Question 49

An MRP system cannot answer the question:

A) "how much?"
B) "when?"
C) "what?"
D) "why?"

Question 50

In material requirements planning,units already on order are referred to as ________ receipts and new orders are termed ________ receipts.

Question 51

There is no beginning inventory.What are the net requirements in week 4 if there is a scheduled receipt of 100 units each week and a two week production lead time?

A) 250
B) 300
C) 350
D) 400

Question 52

Using this MRP record and a lead time of 3 weeks,what should the planned orders be in week 1?

A) 200
B) 300
C) 400
D) 500

Question 53

There are 200 units in inventory at the start of week 1.What are the net requirements in week 4 if there is a scheduled receipt of 100 units every other week and a two week production lead time?

A) 250
B) 300
C) 350
D) 400

Question 54

There are 50 units in inventory at the start of week 1 for this company,which runs a lot-for-lot MRP system.There is a one week lead time for all shipping and production quantities regardless of volume.What are the quantities of the planned order releases for this item for the first six weeks?

A) 20, 30, 0, 40, 20, 0
B) 35, 0, 60, 0, 0, 0
C) 5, 30, 0, 40, 20, 0
D) 35, 0, 0, 40, 20, 0

Question 55

Consider the product structure tree shown below: Assume that the company using this product structure tree has 5 items each at the 0 level,10 items each at the 1 level and 20 items each at the 2 level.How many units of A,B,and E will the company need to acquire in order to ship an order of 20 X's?

Question 56

A mechanical cat is made of two front leg assemblies,a body assembly,one tail,one head assembly,and two back leg assemblies.Each head assembly has two eyes,one nose,one mouth,and 24 whiskers.Each back leg assembly has one foot,five claws,one each fibula,tibia,and femur.The cat production company runs a lot for lot system on everything except the legs,which they order in cases of 50,and the claws,which come in boxes of 60.Lead time for assembly and shipping is shown in the table.Use the master production schedule for mechanical cats to complete the MRP record.What are the net requirements for claws in week 3?

A) 2,275
B) 2,295
C) 2,325
D) 2,455

Question 57

The process of ________ occurs when a planner works backwards from the master production schedule and the product structure tree to determine when all parts and subassemblies must be ordered and assembled in order to meet MPS due dates.

Question 58

A mechanical cat is made of two front leg assemblies,a body assembly,one tail,one head assembly,and two back leg assemblies.Each head assembly has two eyes,one nose,one mouth,and 24 whiskers.Each back leg assembly has one foot,five claws,one each fibula,tibia,and femur.The cat production company runs a lot for lot system on everything except the heads,which they order in cases of 250,and the whiskers,which come in boxes of 800.Lead time for assembly and shipping is shown in the table.Use the master production schedule for mechanical cats to complete the MRP record.What are the net requirements for whiskers in week 2?

A) 5733
B) 5600
C) 5453
D) 5853

Question 59

A(n)________ is a record or graphical rendering that shows how all the subassemblies,intermediates,parts,and raw materials are put together to make the Level 0 item.

Question 60

A mechanical cat is made of two front leg assemblies,a body assembly,one tail,one head assembly,and two back leg assemblies.Each head assembly has two eyes,one nose,one mouth,and 24 whiskers.Each back leg assembly has one foot,five claws,one each fibula,tibia,and femur.The cat production company runs a lot for lot system on everything except the legs,which they order in cases of 50,and the claws,which come by the gross.Lead time for assembly and shipping is shown in the table.Use the master production schedule for mechanical cats to complete the MRP record.What's the planned order release for claws in week 2?

A) 2,304
B) 2,376
C) 2,448
D) 2,880

Question 61

In distribution requirements planning the MRP records do not use the term gross requirements; instead the amount is shown as:

A) net requirements.
B) total requirements.
C) distributed requirements.
D) forecasted demand.

Question 62

What are the third,fourth,and fifth jobs in a critical ratio sequence?

A) Job 6, Job 5, Job 2
B) Job 2, Job 5, Job 7
C) Job 6, Job 4, Job 7
D) Job 4, Job 2, Job 7

Question 63

If a job has a negative critical ratio then it must be early.

Question 64

Determine a schedule for these jobs using the critical ratio criterion and calculate the average lateness.Then develop an earliest due date sequence and calculate average lateness.

Question 65

RFID tags can be used to trace the movement and location of materials.

Question 66

What are three advantages of using an MRP system?

Question 67

What is the average lateness of these seven jobs if they are scheduled using the earliest due date criterion?

A) 19.2
B) 18.7
C) 17.8
D) 16.5

Question 68

What organizational disciplines are required in order for an organization to successfully run a material requirements planning system?

Question 69

There are six jobs that are awaiting processing at a machining center.The jobs are shown in the table with their processing time and scheduled completion time.Schedule the jobs by earliest due date,shortest processing time and the critical ratio rule and calculate average lateness for all the jobs.Which scheduling technique performs BEST?

Question 70

Distribution requirements planning is identical to material requirements planning except instead of gross requirements,a DRP record shows forecasted demand.

Question 71

Consider the product structure tree shown below: With a beginning inventory of twenty for all components on level one,five for all components on level two,and zero for all components on level three and finished items,how many of each component on level three are needed to produce 25 product X's?

Question 72

Consider the product structure tree shown below: With a beginning inventory of fifteen for all components on level one,twenty for all components on level two,and zero for all components on level three and finished items,how many of each component on level three are needed to produce 20 product X's?

Question 73

Calculate the average lateness using the earliest due date criterion to determine the schedule for these five jobs.

A) 3
B) 10
C) 12.4
D) 14

Question 74

What is the average lateness of these seven jobs if they are scheduled using the critical ratio criterion?

A) 24.3
B) 21.7
C) 22.5
D) 23.4

Question 75

Forecasts in a company using a distribution requirements planning system are typically based on:

A) historical data from upstream supply partners.
B) historical data from downstream supply partners.
C) upstream supply partners' requirements.
D) downstream supply partners' requirements.

Question 76

The table shows a master schedule for end item Z that is produced according to the product structure tree shown below.Beginning inventories and lead times for components of Z are given in the table.The lot sizes for A,B,and C are 100 units.Complete a materials requirement plan for components A,B,and C.

Question 77

For a given job,the amount of processing time remaining divided by the amount of time until the job is due is its ________.

Question 78

Distribution requirements planning is used to synchronize supply chain partners at the production activity control level.

Question 79

Using the information in the table,determine a schedule for these five jobs using the critical ratio sequence.

A) C-D-B-E-A
B) A-C-E-B-D
C) C-A-E-B-D
D) A-D-B-E-C

Question 80

A time-phased planning approach that uses planned orders at the point of demand to determine forecasted demand at the source level is:

A) RFID.
B) EDD.
C) DRP.
D) MRP.