Manufacturing Planning and Control
Exam Solutions
Course Introduction
Manufacturing Planning and Control focuses on the strategies, methods, and tools used to manage and optimize production processes in manufacturing environments. The course covers key topics such as demand forecasting, production planning, inventory management, material requirements planning (MRP), capacity planning, and scheduling. Emphasis is placed on the integration of these activities to ensure efficient use of resources, timely delivery of products, and alignment with organizational goals. Students will explore both traditional and modern approaches, including lean manufacturing and just-in-time (JIT) techniques, and learn how advances in information technology support real-time decision-making and process improvement in manufacturing systems.
Recommended Textbook
Supply Chain Focused Manufacturing Planning and Control 1st Edition by
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12 Chapters
352 Verified Questions
352 Flashcards
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W. C. Benton
Chapter 1: Supply chain focused manufacturing planning and
control
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30 Verified Questions
30 Flashcards
Source URL: https://quizplus.com/quiz/10777
Sample Questions
Q1) Describe in your own words what a healthy customer-supplier relationship looks like.
Answer: A healthy customer-supplier relationship is one where both parties communicate openly and honestly, have mutual respect for each other, and work together to achieve common goals. The customer provides clear expectations and feedback, while the supplier delivers high-quality products or services that meet those expectations. Both parties are committed to resolving any issues or conflicts in a constructive manner, and they continuously strive to improve and innovate together. Trust, transparency, and collaboration are the key elements that define a healthy customer-supplier relationship.
Q2) The Assemble to order (ATO)environment is characterized by __________ and
A) Standard products/Stable forecasts
B) High customization/inaccurate forecasts
C) Tailored unique products/Stable forecasts
D) Customization/Modular product architecture
Answer: D
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3
Chapter 2: Forecasting demand
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30 Flashcards
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Sample Questions
Q1) The exponential smoothing model with trends uses 3 steps to generate forecasts.Among these steps, __________ can be described as updating the ________________.Fill in the blanks correctly.
A) Step 1/Trend estimate
B) Step 1/Base value
C) Step 2/Seasonality Index
D) Step 3/Trend estimate
Answer: B
Q2) Build a forecast model using a simple exponential smoothing model with 2009 demand provided below.The exponential smoothing constant is 0.3.What is the bias for this model when the Forecast for January is set at 24?
\[\begin{array} { c c c c c c c c c c c c c }
\text { Month } & 1 & 2 & 3 & 4 & 5 & 6 & 7 & 8 & 9 & 10 & 11 & 12 \\
\hline \text { Demand } & 17 & 20.4 & 23.8 & 27.2 & 21.6 & 27.6 & 31.2 & 26.35 & 22.95 & 15.3 & 16 & 14
\end{array}\]
Answer: -1.35
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Page 4
Chapter 3: S&OP/Aggregate planning
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30 Verified Questions
30 Flashcards
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Sample Questions
Q1) ABC Inc.custom makes furniture.It has 20 workers who produce 135 units per quarter each.The cost per unit is $2500.00.If a pure chase strategy is used, how many workers are fired or hired during quarter 2? Be as close as possible.The quarterly demand information is provided below.
Q1:3,000 units, Q2:500 units, Q3:4,500 units, Q4:6,000 units
A) Hired 20 workers
B) Hired 5 workers
C) Fired 19 workers
D) No one is hired
Answer: C
Q2) The Sales and Operations Planning (S&OP)operate at the product level of ______________.Complete the sentence.
A) Product Lines and Families
B) Components
C) Manufacturing Operations
D) Individual Products
Answer: A
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Page 5
Chapter 4: Master production schedule
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Sample Questions
Q1) Fill in the MPS record when the MPS can only be ordered in 100 unit intervals.
\[\begin{array} { | c | c | c | c | c | l | }
\hline \text { Periods } & 1 & 2 & 3 & 4 & 5 \\
\hline \text { Forecast } & 50 & 25 & 120 & 20 & 100 \\
\hline \text { Orders } & 76 & 12 & & 25 & \\
\hline \text { Available } & & & & & \\
\hline \begin{array} { c }
\text { Available to } \\
\text { promise }
\end{array} & & & & & \\
\hline \text { MPS } & & & & & \\
\hline \text { On hand } & 10 & & & & \\
\hline
\end{array}\]
Q2) The initial factors for generating a MPS Record include ____________ and ______________.Fill in the blanks.
A) Forecast Demand / On hand Inventory
B) MPS Quantity / Forecast Demand
C) Safety Stock (SS) / On hand Inventory
D) Bill of materials (BOM) / MPS Quantity
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Page 6
Chapter 5: Supply chain focused inventory management
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27 Flashcards
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Sample Questions
Q1) Select, among the following statements regarding Decoupling stocks, the correct statements.
1)inventories at major stocking points throughout the system
2)allows for each work center to begin at the same starting time
3)Used to absorb random demand uncertainties
A) (1)
B) (3)
C) (1) and (2)
D) None of the above
Q2) Choose, among the inventory systems, the system that has the least relations to the following description?
An order is placed whenever the inventory levels fall below reorder point
A) Fixed-order quantity order point system
B) EOQ model
C) Reorder point system
D) Periodic review system
Q3) In a Q-system, the daily demand is 850 units with a standard deviation of 12 units.The Cycle service level is 97.5%.What is the reorder point?
Q4) In one sentence, define what demand is during lead time.
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Chapter 6: MRP production system
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Sample Questions
Q1) Fill out the following MRP record and calculate the inventory holding cost using end inventory values.The lot size is a multiple of 500 units and the holding cost is $20 per unit per period.
\[\begin{array} { | c | c | c | c | l | }
\hline \text { Periods } & 1 & 2 & 3 & 4 \\
\hline \text { Demands } & 1000 & 350 & 500 & 800 \\
\hline \begin{array} { c }
\text { Projected } \\
\text { Availability }
\end{array} & & & & \\
\hline \begin{array} { c }
\text { Net } \\
\text { Requirements }
\end{array} & & & & \\
\hline \end{array}\]
Q2) What is the difference between using average inventory values and end inventory values when it comes to calculating inventory costs?
Q3) Explain what differentiates MRP from a reorder point system.
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Page 8
Chapter 7: JIT/Lean production
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Sample Questions
Q1) According to the conceptual framework of JIT, there are 8 practices considered essential for a comprehensive JIT implementation.At the same time, there are two additional practices which constitute the foundation of all 8 activities.List these two additional practices.
Q2) Practices such as ____________ are associated with Just in time (JIT)philosophy.However, practices such as ________________ are contradictive to JIT.Fill in the blanks with the correct answers.
A) Small lots/Uniform production
B) Uniform production/Preventive maintenance
C) Inspections at arrival / Preventive maintenance
D) Small lots / Inspections at arrival
Q3) Briefly discuss the role of culture in regard to JIT using the US and Japan as examples.
Q4) Provide a reason for why a JIT organization would end up with a smaller supplier base than other non-JIT ones.
Q5) According to the conceptual framework of JIT, there are 8 practices considered essential for a comprehensive JIT implementation.List at least 4 of them.
Q6) Describe value steam mapping (VSM)and its relationship with lean
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Chapter 8: Push and pull production systems
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Sample Questions
Q1) Mom &Pop Inc.uses 6 kanban cards for a system with a container size of 500 units.Using the demand information bellow, find the safety stock level.The estimated lead time is 1 day.
\[\begin{array} { c | c c c c c c }
\text { Daily } & 1 & 2 & 3 & 4 & 5 & 6 \\
\hline \text { Demand } & 1,000 & 500 & 3,000 & 4,000 & 3,000 & 500
\end{array}\]
A) 1,000 units
B) 1,200 units
C) 250 units
D) 800 units
Q2) Describe the difference between a push and pull system in on paragraph.
Q3) Among the following relative disadvantage claims for a pull manufacturing, which one is most likely to be true?
A) The machine utilization will increase
B) People may be idle at times
C) Asset utilization may increase
D) The worker turnover is higher than push manufacturing
Q4) Describe in one paragraph, what a Hybrid production System is.
Q5) How is the Kanban system similar to fixed-order inventory systems?
Page 10
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Chapter 9: Capacity management
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Sample Questions
Q1) Describe the activities and scope of Long-Range Capacity Planning.
Q2) Of the following solutions for overloaded work centers, which is the least effective solution?
A) Backordering
B) Subcontracting
C) Increasing the efficiency of the operation
D) Rerouting work to another work center
Q3) Choose the statements that differentiate the Resource Profile Method (RPM)from other alternative RCCP approaches.
1)It is easier to perform
2)It has longer time buckets
3)It includes a timing dimension
4)It only requires partial information
A) (1)
B) (2) and (3)
C) (3)
D) (2) and (4)
Q4) Write the equation for Rated capacity.
Q5) Define, in your words, capacity planning and control.
Q6) What is the planning horizon of the Capacity requirements planning (CRP)?
Page 11
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Chapter 10: Production planning and control for remanufacturing
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Sample Questions
Q1) Describe remanufacturing is one sentence.
Q2) Which of the following product categories are not well suited for remanufacturing?
A) Musical instruments
B) Construction equipment
C) Furniture
D) Industrial machinery and machine tools
Q3) Which of the following statements are not findings of the Core Acquisition Study of Automobile Parts Industry?
1)The quality of the cores acquired is extremely poor in general
2)Arm's length supplier-buyer relationships are popular in the industry
3)The remanufactures are dependent on the core suppliers
4)Product trade-ins are the main source for cores
A) (1)
B) (2) and (4)
C) (1), (2), and (4)
D) (4)
Q4) In your own words, what does differentiate remanufacturing from recondition or recycled products?
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Q5) What is the response of the remanufacturing managers to the shortage of cores?
Chapter 11: Supply chain focused outsourcing
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Sample Questions
Q1) Within an outsourcing relationship, is has been shown that suppliers some time do not behave in the manner expected.Creating a comprehensive contract can prevent some of these behaviors.Which of the following contract specifications could prevent opportunistic behaviors on the part of the outsource service provide?
A) Clearly outline a dispute resolution process
B) Specify the length of the contract to be a long term contract
C) Include clauses to protect transferred equipment
D) Do not specify which party is responsibility for an external disruption of the supply chain
Q2) What is the buyer's risk when the probability of outsourced function being disrupted is 2% and the cost of a disruption is $4,000,000?
A) $500,500
B) $250,000
C) $80,000
D) $100,000
Q3) In your own words, provide reasons for the reduction in internal coordination costs from outsourcing being less than expected.
Q4) Describe the nature of Core Competencies in the context of outsourcing.
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Page 13
Chapter 12: Manufacturing focused supply chain integration
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Sample Questions
Q1) Choose the aspects of information not directly associated with information sharing in the context of supply chain integration.
1)Directedness
2)Support IT technology
3)Content
4)Usefulness
A) (1) and (2)
B) (2)
C) (1) and (4)
D) None of the above
Q2) JIT Production includes five practices.Choose the correct practice and its effect match.
A) Cycle time reduction (smaller batches)
B) Agile manufacturing strategy (balances resources)
C) Bottleneck removal (reduce throughput time)
D) Cellular manufacturing (maximizes production output)
Q3) Which information aspect is concerned with the degree to which the information shared meets the needs of the organizations?
Q4) How many levels are in the SCOR model?
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