Deck 20: Master Scheduling and Rough-Cut Capacity Planning

Question 1

Which of the following is not a correctly stated step of the CPOPF method?

A) Determine the appropriate planning factors using forecasted demand data.
B) Multiply the MPS quantities by the appropriate planning factor.
C) Sum capacity requirements for each resource by time period.
D) Allocate capacity requirements to individual work centers based on historical percentages.
E) Evaluate the workload at each resource to validate MPS feasibility.

Answer 1

A

Question 2

What is the formula for projected available in an MPS record?

A) beginning inventory + MPS shipment  forecasted demand
B) MPS shipment from previous week  forecasted demand
C) cumulative MPS shipments  cumulative forecasts
D) forecasted demand  MPS shipment from previous week
E) beginning inventory + forecasted demand  MPS shipment

Answer 2

A

Question 3

Which of the following statements is true?

A) The "slushy" portion of the MPS comes sooner than the "liquid" portion of the MPS.
B) The planning time fence occurs before the demand time fence.
C) The "frozen" portion of the MPS occurs between the planning time fence and the demand time fence.
D) The master scheduler has more authority during the "frozen" portion of the MPS than during the "slushy" portion of the MPS.
E) The "liquid" portion of the MPS occurs before the demand time fence.

Answer 3

A

Question 4

Which of the following is not one of the rows in an MPS record?

A) time period (e.g., week)
B) forecast
C) planned orders
D) MPS
E) projected available

Question 5

What is the portion of the MPS called that lies between the demand time fence and the planning time fence?

A) gaseous
B) frozen
C) slushy
D) mucky
E) liquid

Question 6

What term refers to proven capacity calculated from actual performance data?

A) manifested capacity
B) established capacity
C) demonstrated capacity
D) confirmed capacity
E) affirmed capacity

Question 7

Which of the following is not part of the process for developing an MPS?

A) The MRP system is run.
B) Rough-cut capacity planning is used.
C) Evaluation occurs with regard to customer service, effective use of resources, and inventory investment.
D) If capacity is insufficient, the MPS is modified or capacity is expanded.
E) An MRP is proposed.

Question 8

What is the portion of the MPS called that lies between the current time and the demand time fence?

A) gaseous
B) frozen
C) slushy
D) mucky
E) liquid

Question 9

Which of the following is not a correctly stated step of the CPOPF method?

A) Determine the appropriate planning factors using historical data.
B) Multiply the MPS quantities by the appropriate planning factor.
C) Sum capacity requirements for each resource by time period.
D) Allocate capacity requirements to group work centers based on historical percentages.
E) Evaluate the workload at each resource to validate MPS feasibility.

Question 10

Which of the following is not a direct input into the MRP system?

A) MPS
B) aggregate plan
C) inventory records
D) bill of material data
E) None of these answer choices are correct

Question 11

What data are added to create an extended MPS record that allows the firm to compute available-to-promise units?

A) time period (e.g. weeks)
B) forecast
C) customer orders
D) projected available
E) MPS

Question 12

What establishes a point of time in the future inside of which changes must be made by the master scheduler, and changes outside of which can be changed by system logic?

A) demand time fence
B) supply time fence
C) system time fence
D) frozen time fence
E) planning time fence

Question 13

Demand management includes all but which of the following:

A) company's forecast
B) order planning
C) order-entry
D) order receipts
E) physical distribution activities

Question 14

To evaluate the MPS in terms of customer service, the master scheduler checks that:

A) promised raw material dates are met
B) purchasing is keeping up with requests
C) manufacturing is properly scheduling vacation time
D) promised profit margins are met
E) promised customer deliver dates are met

Question 15

In MPS terminology, what is another name for the current period?

A) the hot seat
B) the live wire
C) the live basket
D) the empty buck
E) the action bucket

Question 16

What establishes that point of time in the future inside of which changes to the MPS must be approved by a higher authority?

A) demand time fence
B) supply time fence
C) authorized time fence
D) frozen time fence
E) planning time fence

Question 17

The MPS available-to-promise row shows:

A) how many committed units the company has
B) how many units manufacturing will produce
C) inventory levels
D) how many uncommitted units the company has available
E) how many uncommitted units sales will promise to sell

Question 18

In the "liquid" portion of the MPS, the master scheduler generally has the authority to approve what changes?

A) product mix
B) changes needing extra resources (already authorized by the aggregate plan)
C) product mix and changes needing extra resources (already authorized by the aggregate plan)
D) neither product mix and changes needing extra resources (already authorized by the aggregate plan)e) there is not such a thing as a "liquid" portion of the MPS

Question 19

The Master Production Schedule is often stated in:

A) dollars
B) rubles
C) product specifications
D) labor
E) material requirements

Question 20

Demonstrated capacity is the ______ capacity ______ from the actual performance data.

A) proven, calculated
B) desired, derived
C) historical, viewed
D) forecasted, estimated
E) extreme, targeted

Question 21

What is the formula for calculating the ATP quantity in the action bucket?

A) MPS shipment  customer orders before next replenishment
B) beginning inventory + MPS shipment  (the greater of this period's forecast or the actual customer orders promised for delivery this period)
C) beginning inventory + MPS shipment  forecasted demand
D) beginning inventory + MPS shipment  customer orders before next replenishment
E) beginning inventory + MPS shipment  customer orders this period

Question 22

Johnny Now, Inc. produces two different models of outhouses. Demand next period is expected to be 12,000 and 18,000 units for Models A and B, respectively. Model A has CPOPF planning factors of 0.75 and 0.60 for direct labor and machine time, respectively. Model B has CPOPF planning factors of 0.50 and 0.80 for direct labor and machine time, respectively. Historically department G uses 24% of the direct labor and machine time for these products, while department H uses the remaining 76%. What is the machine time requirement for department G next period?

A) 5,184 hours
B) 4,320 hours
C) 7,200 hours
D) 21,600 hours
E) 16,416 hours

Question 23

Johnny Now, Inc. produces two different models of outhouses. Demand next period is expected to be 12,000 and 18,000 units for Models A and B, respectively. Model A has CPOPF planning factors of 0.75 and 0.60 for direct labor and machine time, respectively. Model B has CPOPF planning factors of 0.50 and 0.80 for direct labor and machine time, respectively. Historically department G uses 24% of the direct labor and machine time for these products, while department H uses the remaining 76%. What is the direct labor time requirement for department G next period?

A) 4,320 hours
B) 13,680 hours
C) 18,000 hours
D) 9,000 hours
E) 5,184 hours

Question 24

Consider the following partial MPS record. Beginning inventory is 100 units. When should the first MPS shipment be scheduled?

A) period 1
B) period 2
C) period 3
D) period 4
E) period 5

Question 25

Consider the following partial MPS record. Beginning inventory is 40 units. The firm uses a fixed order quantity of 70 units. What is the projected available amount in period 3?

A) 45
B) 15
C) 70
D) 50
E) 155

Question 26

Consider the following partial MPS record. Beginning inventory is 40 units. The firm uses a fixed order quantity of 70 units. What is the projected available amount in period 2?

A) 55
B) 15
C) 70
D) 50
E) 125

Question 27

What is the formula for projected available when using ATP MPS records?

A) beginning inventory + MPS shipment  forecasted demand
B) MPS shipment from previous week  forecasted demand
C) beginning inventory + MPS shipment  (the greater of the period's forecast or the actual customer orders promised for delivery that period)
D) beginning inventory + MPS shipment  (the lesser of the period's forecast or the actual customer orders promised for delivery that period)
E) beginning inventory + forecasted demand  MPS shipment

Question 28

Motorsports, Inc. builds two different types of motors. Model A has averaged 20,000 units annually, and Model B has average 30,000 units annually. The firm has historically used 80,000 direct labor hours and 10,000 hours of machine time per year to build Model A. Also, 150,000 annual direct labor hours have been allocated to Model B, along with 60,000 hours of annual machine time. What is the CPOPF planning factor for direct labor for Model A?

A) 0.25
B) 4.00
C) 4.50
D) 5.00
E) 4.60

Question 29

Johnny Now, Inc. produces two different models of outhouses. Demand next period is expected to be 12,000 and 18,000 units for Models A and B, respectively. Model A has CPOPF planning factors of 0.75 and 0.60 for direct labor and machine time, respectively. Model B has CPOPF planning factors of 0.50 and 0.80 for direct labor and machine time, respectively. Historically department G uses 24% of the direct labor and machine time for these products, while department H uses the remaining 76%. What is the machine time requirement for department H next period?

A) 5,184 hours
B) 13,680 hours
C) 14,400 hours
D) 21,600 hours
E) 16,416 hours

Question 30

Consider the following partial MPS record. Beginning inventory is 40 units. The firm uses a fixed order quantity of 70 units. What is the projected available amount in period 5?

A) 70
B) 50
C) 10
D) 40
E) 220

Question 31

Which of the following statements is true?

A) The "slushy" portion of the MPS comes later than the "liquid" portion of the MPS.
B) The planning time fence occurs before the demand time fence.
C) The "frozen" portion of the MPS occurs between the planning time fence and the demand time fence.
D) The master scheduler has more authority during the "frozen" portion of the MPS than during the "slushy" portion of the MPS.
E) The "liquid" portion of the MPS occurs after the demand time fence.

Question 32

Motorsports, Inc. builds two different types of motors. Model A has averaged 20,000 units annually, and Model B has average 30,000 units annually. The firm has historically used 80,000 direct labor hours and 10,000 hours of machine time per year to build Model A. Also, 150,000 annual direct labor hours have been allocated to Model B, along with 60,000 hours of annual machine time. What is the CPOPF planning factor for direct labor for Model B?

A) 0.20
B) 4.00
C) 7.00
D) 5.00
E) 4.60

Question 33

Consider the following partial MPS record. Beginning inventory is 80 units. When should the first MPS shipment be scheduled?

A) period 1
B) period 2
C) period 3
D) period 4
E) period 5

Question 34

Consider the following partial ATP MPS record. Beginning inventory is 40 units. The firm uses a fixed order quantity of 70 units. What is the projected available amount in period 2?

A) 0
B) 60
C) 70
D) 50
E) 55

Question 35

What is the formula for calculating the ATP quantity at future replenishment periods?

A) MPS shipment  customer orders between the current MPS shipment and the next scheduled replenishment
B) beginning inventory + MPS shipment  (the greater of the period's forecast or the actual customer orders promised for delivery that period)
C) beginning inventory + MPS shipment  forecasted demand
D) beginning inventory + MPS shipment  customer orders between the current MPS shipment and the next scheduled replenishment
E) beginning inventory + MPS shipment  customer orders that period

Question 36

Consider the following partial MPS record. Beginning inventory is 60 units. When should the first MPS shipment be scheduled?

A) period 1
B) period 2
C) period 3
D) period 4
E) period 5

Question 37

Motorsports, Inc. builds two different types of motors. Model A has averaged 20,000 units annually, and Model B has average 30,000 units annually. The firm has historically used 80,000 direct labor hours and 10,000 hours of machine time per year to build Model A. Also, 150,000 annual direct labor hours have been allocated to Model B, along with 60,000 hours of annual machine time. What is the CPOPF planning factor for machine time for Model A?

A) 0.50
B) 2.00
C) 1.40
D) 4.50
E) 0.33

Question 38

A negative number in the projected available row is ___________ a problem.

A) always
B) never
C) sometimes
D) usually
E) 50%

Question 39

A negative number in the available-to-promise row is ___________ a problem.

A) sometimes
B) always
C) usually
D) never
E) 25%

Question 40

Consider the following partial MPS record. Beginning inventory is 120 units. When should the first MPS shipment be scheduled?

A) period 1
B) period 2
C) period 3
D) period 4
E) period 5

Question 41

A master production schedule incorporates production lead time.

Question 42

Consider the following partial ATP MPS record. Beginning inventory is 20 units. The firm uses a fixed order quantity of 60 units. Fill out the rest of the table.

Question 43

Discuss the Master scheduler responsibility.

Question 44

Discuss the master scheduler's objectives when developing the MPS.

Question 45

Consider the following partial MPS record. Beginning inventory is 0 units. The firm uses a fixed order quantity of 60 units. Fill out the last two rows of the table.

Question 46

Engines Corp. builds two different types of motors. Model A has averaged 120,000 units annually, and Model B has average 230,000 units annually. The firm has historically used 80,000 direct labor hours and 210,000 hours of machine time per year to build Model A. Also, 250,000 annual direct labor hours have been allocated to Model B, along with 60,000 hours of annual machine time. Calculate the four relevant CPOPF planning factors.

Question 47

CPOPF is the acronym for Capacity Planning (using) Overall Promising Factors.

Question 48

The projected available quantity row in an MPS record keeps track of how many units are available at the beginning of each time period.

Question 49

Consider the following partial MPS record. Beginning inventory is 70 units. The firm uses an order quantity of POQ = 2 periods. Fill out the last two rows of the table.

Question 50

Describe what CPOPF is.

Question 51

Consider an MPS record. An MPS shipment amount is always set equal to the absolute value of the amount in the projected available row if that amount is negative.

Question 52

The master production schedule is a statement of upcoming demand.

Question 53

Changes to the MPS that are requested inside of the demand time fence must be approved by a higher authority.

Question 54

A primary objective of the master production schedule is to achieve the desired customer service level.

Question 55

In an MPS record, the forecast row shows the forecasted supply for the product.

Question 56

The available-to-promise row in an extended MPS record shows how many committed units the company has available for delivery at a given time.

Question 57

Consider the following partial MPS record. Beginning inventory is 70 units. The firm uses a fixed order quantity of 100 units. Fill out the last two rows of the table.

Question 58

In the "slushy" portion of the MPS, changes in the product mix are possible, but changes needing additional resources are not.

Question 59

Engines Corp. builds two different types of motors in three departments. Historically, department X uses 20%, department Y uses 50%, and department Z uses 30% of direct labor and machine time, respectively. In the next quarter, demand for Model A is expected to be 40,000 units, and demand for Model B is expected to be for 50,000 units. The CPOPF planning factors are: direct labor for Model A = 0.667 hrs./unit, machine time for Model A = 1.75 hrs./unit, direct labor for Model B = 1.087 hrs./unit, machine time for Model B = 0.261 hrs./unit. Calculate the amount of labor and machine time that will need to be allocated to each of the three departments next quarter.

Question 60

In an MPS record, MPS shipments arrive at the beginning of the time period.

Question 61

When Projected Available is negative, the Master Production Schedule must include ________________________.

Question 62

In the current period, Available-to-Promise adds ________________________ to the formula used for future periods.

Question 63

The MPS is said to be ________________________ between the current time and the time needed for final assembly.

Question 64

In future periods, MPS Shipments - Customer orders between current and next scheduled MPS shipment is called ________________________.

Question 65

Beginning Inventory + MPS Shipment - maximum of (forecast and customer orders) is called ________________________.

Question 66

The MPS is said to be ________________________ between final assembly and cumulative manufacturing lead times.

Question 67

Discuss how the MPS is evaluated in terms of cost.

Question 68

The ______ _____ shows how many products or services are planned for each time period.

Question 69

Discuss why a negative number in the available-to-promise row is always a problem.