BSOP 334 Resource Planning & Capacity Resource Planning
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Week 1
Week 1 DQ 1
What is the role of master production scheduling in manufacturing planning and control? What other areas interface with it?
Week 1 DQ 2
What is aggregate planning? Why might it be important to the master production scheduler?
BSOP 334 Week 1 Check Point includes:
1. (TCO 1) The Industrial Revolution began in which decade?
2. (TCO 1) Which of the following is NOT one of the three basic business strategies?
3. (TCO 1) Determine the multifactor productivity using the following data.
4. (TCO 1) Which of the following is a proper expression of productivity?
5. (TCO 1) Aggregate planners are concerned with
6. (TCO 1) The following are options when managing demand, EXCEPT
BSOP 334 Week 1 Lab Overview of Operations Planning & Control and Aggregate Planning
Chapter 11: Problems 7 and 9 (pp. 504-505)
Week 2
Week 2 DQ 1
Is inventory an asset or a liability? How do we determine if it is an asset or a liability? Might the determination be different for different people in the same organization? Please discuss, providing specific examples.
Week 2 DQ 2
Why is reorder timing so important to a business? Is it more important than when we decide to refill our cars with gas, or the refrigerator with food? Why?
BSOP 334 Week 2 CheckPoint includes:
1. (TCO 6) A concern of inventory management is
2. (TCO 6) Requirements for effective inventory management include all of the following, EXCEPT
3. (TCO 6) A basic issue of inventory ordering policy is
4. (TCO 3) Inputs to the master schedule include all of the following, EXCEPT
5. (TCO 3) The sequence of disaggregation is as follows:
BSOP 334 Week 2 Homework Includes:
Chapter 13:
3. Briefly describe each of the costs associated with inventory.
6. List the major assumptions of the EOQ model.
10. Under what circumstances would the amount of safety stock held be
11. What is meant by the term service level? Generally speaking, how is service level related to the amount of safety stock held?
14. Explain how a decrease in setup time can lead to a decrease in the average amount of inventory a firm holds, and why that would be beneficial.
BSOP 334 Week 2 Lab Determining Order Quantity for Lowest Total Cost Includes:
Chapter 13: Problems 3, 9, 10, 13, & 16 (pp. 602-604)
Week 3
Week 3 DQ 1
Discuss the inputs required for the MRP process and the role played by the bill of materials.
Week 3 DQ 2
How the bill of materials is structured, and why is low-level coding used?
BSOP 334 Week 3 Check Point includes:
1. (TCO 2) How does dependent demand differ from independent demand?
2. (TCO 2) MRP
3. (TCO 2) The master production schedule
4. (TCO 2) The hierarchical nature of a BOM means that
5. (TCO 2) Low-level coding
BSOP 334 Week 3 Homework Includes:
Discussion and Review Questions: 1, 2, 3a, 3b, & 3c (p. 542), Case: Promotional Novelties (p. 549)
Contrast independent and dependent demand.
When is MRP appropriate?
Briefly define or explain each of these terms.
How many wheels sets should the manager order?
When should the wheels sets be ordered?
BSOP 334 Week 3 Lab Bill of Materials Includes:
Chapter 12: Problems 1, 2, and 3 (pp. 543-544)
Given the following diagram for a product, determine the quantity of each component required to assemble one unit of the finished product.
The following table lists the components needed to assemble an end item, lead times, and quantities on hand.
The following table lists the components needed to assemble an end item, lead times (in weeks), and quantities on hand.
Week 4
BSOP 334 Week 4 DQ 1
How does MRP fit in the overall master planning system? Where does it fit with the other parts of the system?
BSOP 334 Week 4 DQ 2
How does MRP reflect the changing conditions of the shop floor? Why is it important that these transactions be processed properly?
BSOP 334 Week 4 CheckPoint includes:
1. (TCO 8) Of the following order quantity methods, which does not attempt to balance ordering (or setup) and holding costs?
2. (TCO 8) All the following are inputs in an MRP system, except
3. (TCO 8) Of the MRP inputs, one of the following lists the assemblies, subassemblies, parts, and raw materials needed to produce one unit of a finished product. Which of the following is it?
4. (TCO 4) Of the MRP inputs, one of the following stores information on the status of each item by time period (e.g., on-hand, scheduled receipts, lead time, lot size). Which of the following is it?
5. (TCO 5) Under lot-for-lot ordering, planned order receipts are
6. (TCO 4) In MRP, the multiplication process used to determine lower level requirements is called
BSOP 334 Week 4 Homework Includes:
Chapter 12: Discussion and Review Questions: 8,13 (p. 542), Critical Thinking Exercise 1 (p. 543), Problem 14 (p. 547)
Briefly discuss the requirements for effective MRP.
Contrast planned-order receipts and scheduled receipts.
Suppose you work for a furniture manufacturer, one of whose products is the chair depicted in Figure 12.5. Finished goods inventory is held in a central warehouse in anticipation of customer orders. Finished goods are controlled using EOQ/ROP methods. The warehouse manager, Juan Villa, has suggested using the same methods for controlling component inventory. Write him a brief memo outlining your opinion on doing that.
Using the diagram below, do the following:
a. Draw a tree diagram for the scissors.
b. Prepare an MRP for scissors. Lead times are one day for each component and final scissor assembly, but two days for the plastic grips. Six hundred pairs of scissors are needed on Day 6. Note: There are 200 straight blades and 350 bent blades on hand, and 40 top blade assemblies on hand.
BSOP 334 Week 4 Lab Material Requirements Planning and Dependent Demand includes:
Chapter 12: Problems 8, 10, 12, 13 (pp. 545-547)
Oh No!, Inc., sells three models of radar detector units. It buys the three basic models (E, F, and G) from a Japanese manufacturer and adds one, two, or four lights (component D) to further differentiate the models. D is bought from a domestic producer.
Assume that you are the manager of Assembly, Inc. You have just received an order for 40 units of an industrial robot, which is to be delivered at the start of week 7 of your schedule. Using the following information, determine how many units of subassembly G to order and the timing of those orders, given that subassembly G must be ordered in multiples of 80 units and all other components are ordered lot-for-lot. Assume that the components are used only for this particular robot.
A firm that produces electric golf carts has just received an order for 200 carts, which must be ready for delivery at the start of week 8. Information concerning the product structure, lead times, and quantities on hand is shown in the following table. Use this information to do each of the following:
Refer to Problem 12. Assume that unusually mild weather has caused a change in the quantity and timing of orders for golf carts. The revised plan calls for 100 golf carts at the start of week 6, 100 at the start of week 8, and 100 at the start of week 9.
Week 5
BSOP 334 Week 5 DQ 1
How does an MRP-II system or an ERP system help a company be more successful in managing its business and achieving its strategic objectives? Relate this to actual situations of companies you are familiar with.
BSOP 334 Week 5 DQ 2
It is said that successful supply chain management will help the various organizations that are part of the same supply chain operate like a flock of birds, which can suddenly turn in unison as the lead birds change direction! Please elaborate on this saying, and explain why is this good for those organizations, the end user, and the industry at large? How does it work?
BSOP 334 Week 5 CheckPoint covers the Following questions:
1. (TCO 9) The following feature of ERP makes it valuable as a strategic planning tool
2. (TCO 7) Which MRP approach is used for components or subassemblies to compensate for variations in lead time?
3. (TCO 5) Net requirements for Component J are as follows: 60 units in Week 2, 40 units in Week 3, and 60 units in Week 5. If a fixed-period, three-period lot-sizing method is used, what will be the quantity of the first planned receipt?
4. (TCO 9) Which statement concerning MRP II is false?
5. (TCO 7) Small changes in consumer demand can result in large variations in orders placed because of the _____.
6. (TCO 7) Effective supply chain management has all of the following benefits, except
BSOP 334 Week 5 Homework includes:
Chapter 12: Discussion and Review Questions: 11, 14, 15, & 16 (p. 542)
11. Briefly describe MRP II and closed-loop MRP.
14. If seasonal variations are present, is their incorporation into MRP fairly simple or fairly difficult? Explain briefly.
15. How does the purpose of ERP differ from the purpose of MRP II?
16. What are some unforeseen costs of ERP?
Chapter 15: Discussion and Review Questions: 5, 9, & 11 (p. 695)
5. What is the bullwhip effect, and why does it occur? How can it be overcome?
9. What impact has e-business had on supply chain management?
11. What are some of the trade-offs that might be factors in designing a supply chain?
BSOP 334 Week 5 Lab MRP Complicating Factors and MRP-II, ERP, & Supply Chain Management includes:
Chapter 12: Problems 5, 6, 7 (pp. 544-545)
5. End item P is composed of three subassemblies: K, L, and W. K is assembled using 3 Gs and 4 Hs; L is made of 2 Ms and 2 Ns; and W is made of 3 Zs. On-hand inventories are 20 Ls, 40 Gs, and 200 Hs. Scheduled receipts are 10 Ks at the start of week 3, 30 Ks at the start of week 6, and 200 Ws at the start of week 3.
6. A table is assembled using three components, as shown in the accompanying product structure tree. The company that makes the table wants to ship 100 units at the beginning of day 4, 150 units at the beginning of day 5, and 200 units at the beginning of day 7. Receipts of 100 wood sections are scheduled at the beginning of day 2. There are 120 legs on hand. An additional 10 percent of the order size on legs is added for safety stock. There are 60 braces on hand with no safety stock requirement for braces. Lead times (in days) for all items are shown in the following table. Prepare a material requirements plan using lot-for-lot ordering.
7. Eighty units of end item X are needed at the beginning of week 6, and another 30 units are needed at the beginning of week 8. Prepare a material requirements plan for component D. D can only be ordered in whole cases (50 units per case). One case of D is automatically received every other week, beginning in week 1 (i.e., weeks 1, 3, 5, 7). Also, there are 30 units of B and 20 units of D now on hand. Lead times for all items are a function of quantity: one week for up to 100 units, two weeks for 101 to 200 units, three weeks for 201 to 300 units, and four weeks for 301 or more units.
Week 6
BSOP 334 Week 6 DQ 1
Compare and contrast rough-cut capacity planning with CRP.
BSOP 334 Week 6 DQ 2
How does CRP relate to the MPS? How does a nervous MPS affect CRP?
BSOP 334 Week 6 Homework includes:
Chapter 5: Discussion and Review Questions: 1, 2, 6, 11, 15 (p. 208), Problem 13 (p. 210)
1.Contrast design capacity and effective capacity.
2.List and briefly explain three factors that may inhibit capacity utilization.
11. Why is it important to match process capabilities with product requirements?
15. Why is capacity planning for services more challenging than it is for goods production?
Problem 13. The following diagram shows a 4-step process that begins with Operation 1 and ends with Operation 4. The rates shown in each box represent the effective capacity of that operation.
BSOP 334 Week 6 Lab Strategic Capacity Planning and CRP Logic includes:
Chapter 5: Problems 1 & 3 (pp. 208-209)
1. Determine the utilization and the efficiency for each of these situations:
3. A producer of pottery is considering the addition of a new plant to absorb the backlog of demand that now exists. The primary location being considered will have fixed costs of $9,200 per month and variable costs of 70 cents per unit produced. Each item is sold to retailers at a price that averages 90 cents.
Chapter 12: Problems 15 & 16 (pp. 547-548)
15. A company that manufactures paving material for driveways and parking lots expects the following demand for its product for the next four weeks:
16. A company produces two very similar products that go through a three-step sequence of fabrication, assembly, and packaging. Each step requires one day for a lot to be completely processed and moved to the next department. Processing requirements for the departments (hours per unit) are
Week 7
BSOP 334 Week 7 DQ 1
What are the three basic principles of lean systems, and how do they support each other in achieving lean-system goals?
BSOP 334 Week 7 DQ 2
It is said that the U.S. economy is turning into a service economy, as opposed to service and manufacturing. Much of U.S. manufacturing has been outsourced to cheap labor markets, which also operate at higher productivity levels than U.S. manufacturing. Is this a lost battle, or can we regain our advantage? Suggest some strategies and tactics that may make this possible.
BSOP 334 Week 7 CheckPoint includes:
1. (TCO 10) The ultimate goal of lean operations is to have
2. (TCO 10) Which of the following does not contribute to reduced setup time and cost?
3. (TCO 10) A basic requirement for operating with the low inventories present in lean systems is
4. (TCO 15) Organizations with fixed, perishable capacity can benefit from _____.
5. (TCO 15) The matrix below shows relative costs for various job-machine combinations. Which set of pairs constitutes the minimum cost solution using the assignment method?
6. (TCO 16) Input/output (I/O) control refers to
BSOP 334 Week 7 Homework includes:
Chapter 14: Discussion and Review Questions: 2, 3, 4, 5, 8 (pp. 650-651)
2. What is the ultimate goal of a lean system? What are the supporting goals? What are the building blocks?
3.Describe the philosophy that underlies JIT (i.e., what is JIT intended to accomplish?).
Chapter 16: Discussion and Review Questions: 1, 5, 7, 8 (p. 732)
4. What are some of the main obstacles that must be overcome in converting from a traditional system to lean?
1.Why is scheduling fairly simple for repetitive systems but fairly complex for job shops?
5. Briefly describe each of these priority rules:
7. What problems not generally found in manufacturing systems do service systems present in terms of scheduling the use of resources?
8. Explain forward and backward scheduling and each one’s advantage.
BSOP 334 Week 8 Final Exam
1. (TCO 1) Which of the following functions involves budgeting, analysis of investment proposals, and provision of funds? (Points : 5)
Question 2. 2. (TCO 1) Transformation includes all of the following, except (Points : 5)
Question 3. 3. (TCO 1) Which of the following is providing new opportunities for productivity improvements? (Points : 5)
Question 4. 4. (TCOs 3 & 6) In an effort to reduce inventory, which of the following interactions with vendors would potentially be helpful? (Points : 5)
Question 5. 5. (TCOs 3 & 6) Which of the following costs related to order size is nonlinear? (Points : 5)
Question 6. 6. (TCO 2) Which of the following is a computer-based information system designed to handle ordering and scheduling of dependent-demand inventories? (Points : 5)
Question 7. 7. (TCO 2) Net material requirements can be described as (Points : 5)
Question 8. 8. (TCO 2) When an MRP system is periodically updated to account for all changes that have occurred within a given time interval, the process is called (Points : 5)
Question 9. 9. (TCOs 4, 5, & 6) How does a net-change system work? (Points : 5)
Question 10. 10. (TCOs 4, 5, & 6) The MRP approach that is used for components or subassemblies to compensate for variations in lead times is called (Points : 5)
Question 11. 11. (TCOs 4, 5, & 6) A lead time service level of 90 percent implies which of the following? (Points : 5)
Question 12. 12. (TCOs 5, 7, & 9) The dynamic store of information on the status of each item by time period (e.g., scheduled receipts, lead time, lot size), which is an input to the MRP, is the (Points : 5)
Question 13. 13. (TCOs 5, 7, & 9) What will be the quantity of the first planned receipt if net requirements for component J are as follows: 60 units in Week 2, 40 units in Week 3, and 60 units in Week 5? A fixed-period, two-period lot-sizing method is used. (Points : 5)
Question 14. 14. (TCO 11, 12, 13, & 14) Given a product mix, scheduling difficulties, quality factors, and so on, the maximum expected output is (Points : 5)
Question 15. 15. (TCOs 11, 12, 13, & 14) Given the following information, calculate the efficiency.
Effective capacity = 50 units per day
Design capacity = 100 units per day
Actual output = 30 units per day (Points : 5)
Question 16. 16. (TCOs 10, 15, & 16) In an assignment method problem, it takes Abe 3 hours to build a birdhouse and 4 hours for a doghouse, while Betty takes 4 hours for a birdhouse and 3 hours for a doghouse. What is the reduced cost (in hours) of assigning Abe to build the doghouse? (Points : 5)
Question 17. 17. (TCOs 10, 15, & 16) The matrix below shows relative costs for various job-machine combinations. Which set of pairs constitutes the minimum cost solution using the assignment method?
1. (TCO 1) A company has found that introducing one additional worker enables a process improvement that reduces processing time for each unit so that output is increased by 25% with less material. Under the old process, five workers could produce 60 units per hour. Labor costs are $12/hour, and material input was previously $16/unit. For the new process, material is now $10/unit. Overhead is charged at 1.6 times direct labor cost. Finished units sell for $31 each. What increase in productivity is associated with the process improvement? (Points : 30)
2. (TCOs 3 & 6) If instantaneous replenishment is assumed when given the same demand, setup/ordering costs, and carrying costs, then the EOQ calculated using incremental replenishment will be _____.
Illustrate using a numeric example. (Points : 30)
4. (TCOs 4, 5, & 6) Given the tree below, develop a material requirements plan for end-item P and its components. Assume that all lead times are one week and that lot-for-lot ordering is used, except for Item F, which is ordered in multiples of 400 units.
6. (TCOs 11, 12, 13, & 14) A small business owner is contemplating the addition of another product line. Capacity increases, and equipment will result in an increase in annual fixed costs of $50,000. Variable costs will be $25 per unit. What unit selling price must the owner obtain to break even on a volume of 2,500 units a year?
5. (TCOs 5, 7, & 9) Explain the advantages and disadvantages of frequent deliveries of small shipments. (Points : 25)
7. (TCOs 10, 15,& 16) Compare and contrast kanban and CONWIP. (Points : 20)
Ans)
8. (TCOs 8 & 9) MPS planners use what is referred to as time fences? What are they, and why are they used? (Points : 20)
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