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47 Cards in this Set
- Front
- Back
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Component
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The raw material, part, or subassembly that goes into a higher level assembly, compound, or other item.
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Priority Planning
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The function of determining what material is needed and when, and maintaining proper due dates for required materials.
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Lead-time Offset
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A technique used in MRP where a planned order receipt in one time period will require the release of that order in an earlier time period based on the lead time for the item.
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MRP
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A set of techniques that uses BOM data, inventory data, and the MPS to calculate requirements for materials.
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Parent
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The item produced from one or more components.
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Planning BOM
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An artificial grouping of items or events in BOM format used to facilitate master scheduling and material planning.
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Scheduled Receipt
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Open order that has an assigned Due Date.
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Exploding
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Using the BOM to calculate component quantities.
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Gross Requirement
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The total of independent and dependent demand for a component before the netting of on-hand inventory and scheduled receipts.
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Pegging
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In MRP and MPS, the capability to identify for a given item the sources of its gross requirements or allocations.
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Net Requirements
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In MRP, _______ are derived as a result of applying gross requirements and allocations against inventory on hand, scheduled receipts, and safety stock.
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Planned Order Receipt
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The quantity planned to be received at a future date as a result of a planned order release.
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2. Which of the following is an objective of MRP?
A. Keep the factory busy B. Keep priorities current C. Determine the forecast D. Minimize inventory investment |
B. Keep priorities current
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3. What is the name of the set of priority planning techniques for planning component items below the end-item level?
A. Master Scheduling B. MRP C. Capacity Planning D. Production Control |
B. MRP
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4. Which of the following is a major input to an MRP system?
A. The production plan B. The capacity plan C. Shop floor activity planning and control D. The MPS |
D. The MPS
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5. What is the name of the document that shows the component parts and the number of parts needed to make one of an assembly or subassembly?
A. Route Sheet B. Material Requirements Planning C. BOM D. Material Requisition |
C. BOM
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6. Which of the following statements is true?
A. The same part number can be used to identify similar products. B. A part has one and only one part number. C. The same part on different BOM’s will have a different number. D. An item can be either a parent or a component, but not both. |
B. A part has one and only one part number.
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8. What is the term for the ability to relate the demand for an item shown on an MRP record back to the parent causing the demand?
A. Where-used B. Relating C. Pegging D. Item Planning |
C. Pegging
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10. Which statement is correct?
A. Planned order receipts show when the order is needed. B. When an order is released, it becomes a planned order. C. Scheduled receipts show when goods were put into inventory. D. Gross requirements come from the planned order receipt of the parent. |
A. Planned order receipts show when the order is needed.
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1. The feasibility of a master planning schedule may
be tested: a. By calculating ATP b. By the process of trial and error c. By the process of RCCP d. The cumulative with look-ahead method |
c. By the process of RCCP
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2. The practice of comparing graphic or tabular representations of manufacturing capacity with available hours for manufacture is called:
a. ATP b. MRP c. RCCP d. CRP |
d. CRP
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3. When a material planning supervisor speaks of maintaining the validity of the material plan, it means that:
a. The initial recommendations for scheduling production must be adhered to b. Orders are re-planned as necessary in response to external changes c. Production schedules must be approved by shop floor persons d. Only accurate materials planning schedules must be used |
b. Orders are re-planned as necessary in response to external changes
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4. A measure of the available quantities of finished product that can be used to fill current customer orders is termed:
a. ATP b. RCCP c. MPS d. MRP |
a. ATP
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5. In order to sustain an efficient system of MRP through IT software, it is recommended that data integrity be maintained at a %age-rate minimum of:
a. 99% b. 89% c. 79% d. 100% |
a. 99%
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6. MRP II systems were developed because:
a. A corporation may store its inventory in more than one factory location b. Electronic communications were not efficient in early MRP applications c. In original MRP versions, MRP did not include capacity planning d. Of all of the above |
c. In original MRP versions, MRP did not include capacity planning
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7. A manufacturing corporation relies on a PAC system in order to:
a. Release production orders to the manufacturing shop b. Establish priorities and production sequences with the data from daily dispatch lists and work release orders c. Monitor input/output and make corrections to the scheduling of material and work in the production sequences d. All of the above |
d. All of the above
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10. The MPS, or master production schedule, is based upon:
a. Demand forecast data, trends, and seasonality b. Market research figures c. Quantity, configuration, and completion dates d. Flow line configuration, available personnel, and materials |
c. Quantity, configuration, and completion dates
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11. Comparing the master schedule (MS) with the master production schedule (MPS), one might say that the:
a. MPS does not address quantities, product groups, or completed inventory, whereas the MS does b. MS is broader and more general and includes many of the planning elements that are absent from the MPS c. MPS includes demand forecasts and backlogged items for which customer orders have been received d. MS is essentially the output from the MPS |
b. MS is broader and more general and includes many of the planning elements that are absent from the MPS
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14. The minimum time for the MS planning horizon should be as long as the:
a. Master production schedule b. Engineering and procurement time c. Lead time required to fabricate the items on the master schedule d. Time required for production and delivery to the customer |
c. Lead time required to fabricate the items on the master schedule
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17. During the first MPS period of a product manufacture, the ATP quantity would be:
a. Zero b. The beginning inventory c. The sum of customer orders completed before the next MPS receipt d. The projected available balance |
b. The beginning inventory
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18. In its beginning stage, a production plan is:
a. A list of required capacity and vital resources needed for manufacture b. An authorization by operations-level management of a specific MPS c. A combined sales and operations plan stated in terms of product or product groups d. A projected level of customer demand |
c. A combined sales and operations plan stated in terms of product or product groups
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19. Why is the Japanese concept of kanban so important in lean manufacturing?
a. Because it reduces inventory costs b. Because it is a “pull” system c. Because it does not require computers d. Because it exposes otherwise hidden problems |
d. Because it exposes otherwise hidden problems
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20. The part of the master schedule that designates the work centers that will be utilized for manufacture is:
a. The operations schedule b. The job schedule c. The master production schedule d. The general plan |
b. The job schedule
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21. Operations scheduling is different from job scheduling in that:
a. Operations scheduling is a longer-term plan that assigns start and end dates to production orders b. Operations scheduling breaks the job down into separate tasks and work stations c. Operations scheduling determines the work centers to be used d. Job scheduling is a longer-term plan for assigning start and end dates to production orders |
a. Operations scheduling is a longer-term plan that assigns start and end dates to production orders
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22. Bottlenecks, excess inventory, and unresponsive manufacturing can be best addressed by:
a. Minimized material handling b. Matching capacity to demand c. More accurate production scheduling d. Synchronization of the production process |
d. Synchronization of the production process
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23. In the master planning process, planners have plenty of room to improve on the estimated 10%
of throughput efficiency. How can throughput efficiency be calculated? a. Value Added Time ÷ End to End Pipeline Time × 100 b. Value Added Time × End to End Pipeline Time ÷ 100 c. End to End Pipeline Time ÷ 100 × Value Added Time d. End to End Pipeline Time × 100 ÷ Value Added Time |
a. Value Added Time divided by End to End Pipeline Time times 100
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24. How are subassemblies handled on a computerized BOM?
a. Subassemblies are broken down into separate entry items b. Subassemblies are attached in separate BOMs c. Subassemblies are entered as single items on the BOM d. Subassemblies are not entered on the BOM |
c. Subassemblies are entered as single items on the BOM
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25. What are the two levels of MRP output?
a. Purchase orders and reschedule notices b. Data integration and FAS c. Recommended production schedule and recommended purchasing schedule d. Single layer and parent level output |
c. Recommended production schedule and recommended purchasing schedule
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26. Arrange the following manufacturing steps in the proper sequential order: production control; master production schedule; capacity requirements planning; and materials requirements planning using their appropriate abbreviations:
a. CRP, MPS, PC, and MRP b. MPS, MRP, CRP, and PC c. MRP, MPS, CRP, and PC d. PC, MPS, CRP, and MRP |
b. MPS, MRP, CRP, and PC
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27. ERP, or enterprise resource planning, is best described as:
a. A process developed in the 1970s that transformed manufacturing into a streamlined process b. A process developed in the 1960s that used a production planning and inventory management process to manage manufacturing c. The latest in a series of manufacturing innovations that integrates an entire company organization into a single central operations information module d. All of the above |
c. The latest in a series of manufacturing innovations that integrates an entire company organization into a single central operations information module
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37. At what stage of the MPC process would schedule and capacity requirements planning occur?
a. Scheduling and capacity requirements planning would occur at the OMP, or operations management planning, level b. Scheduling and capacity requirements planning would occur at the top management planning level c. Scheduling and capacity requirements planning would occur at the level of the operations management execution plan d. Scheduling and capacity requirement planning would occur at all levels of management operational levels |
a. Scheduling and capacity requirements planning would occur at the OMP, or operations management planning, level
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40. Among the ways in which productive capacity can be adjusted to meet different conditions and demand is by:
a. Adding more workers or decreasing the workforce b. Add.ng or removing of work centers c. Rescheduling of manufacturing orders d. All of the above |
d. All of the above
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41. In CRP applied to workers, currently available employee hours can be computed by:
a. Adding employee hours for released manufacturing orders to the total of all available employee hours b. Adding all available employee hours to the %age of employee capacity used for released manufacturing orders c. Subtracting employee hours used for released manufacturing orders from all available employee hours d. Subtracting employee hours used for released manufacturing orders from all available machine hours |
c. Subtracting employee hours used for released manufacturing orders from all available employee hours
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42. In planning production schedules, post-operation production time must be factored into planning. The best definition of post-operation time is:
a. The time required to set up a new manufacturing process b. The time required to move finished products to ATP inventory c. A required waiting time before unfinished products can move to the next stage of manufacturing d. A required waiting time before finished products can be logged into finished inventory |
c. A required waiting time before unfinished products can move to the next stage of manufacturing
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43. Define the term manufacturing instruction.
a. A manufacturing instruction contains the same information as a routing sheet. b. A manufacturing instruction is a planning diagram. c. A manufacturing instruction determines the direction of work flow. d. A manufacturing instruction contains more detailed information than can be found on the routing sheet. |
d. A manufacturing instruction contains more detailed information than can be found on the routing sheet.
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48. Operations management planning is the next step after top-level management has created a general plan for sales, operations, business, and resource requirements planning. Operations management planning consists of:
a. Capacity planning, material requirements planning, and production scheduling, but not distribution planning b. Capacity planning, materials requirements planning, production scheduling, and distribution planning c. Materials requirements planning, production scheduling, and distribution planning, but not capacity planning d. Production scheduling, capacity planning, and distribution planning, but not materials requirements planning |
c. Materials requirements planning, production scheduling, and distribution planning, but not capacity planning
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49. The master schedule horizon is divided by time fences. This means that:
a. The master schedule horizon is divided into separate time periods consisting of the final assembly stage, the manufacturing and purchasing stage, and the look-ahead period b. Time fences are used to prove the feasibility of the master production schedule c. The master schedule horizon is divided into separate time periods consisting of rough-cut capacity planning, distribution planning, and materials resource planning d. The master schedule horizon is separated into two time fences—a manufacturing and purchasing stage and a look-ahead period |
Aa. The master schedule horizon is divided into separate time periods consisting of the final assembly stage, the manufacturing and purchasing stage, and the look-ahead period
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