Production planning and Control-2

Assignment – A

Question 1. a) Explain the forecasting process? What are the techniques for monitoring forecasts?
(b) Explain various forecasting models.

Question 2. a) What is aggregate production plan? What are the pure strategies for APP?
(b) The demand and capacities for production of company is given below. Demand for January, February and March are 900, 300 and 700 respectively. The production capacities for each of the month are given below.

	January	February	March
Regular time	600	300	200
Over time	300	300	300
Sub contracted	500	500	500

The production cost per unit during regular time is Rs 60, during over time is Rs 70, and the sub contracted cost is Rs 72. The cost of carrying inventory is Rs 5 per unit per month. The cost of unused regular time capacity is Rs 15. Find the optimum production plan using transportation model.

Question 3 (a) What is Master Production Scheduling? Explain various types of Bill of Materials.
(b) What are the various disaggregation methods in use?

Question 4 (a) Explain Materials Requirement Planning. What are the inputs and outputs of MRP?
(b) Explain the various Lot sizing techniques.

Question 5 (a) Explain assembly line balancing clearly defining various terminologies like cycle time, precedence diagram, work stations, efficiency, utilization, balance delay, etc.
(b) Explain the key elements to successful JIT.

Assignment – B

Question 1. Explain, long-range, medium-range and short-term capacity planning methods?

Question 2. (a) What are various batch processing techniques?
(b) Explain the concept of theory of constraints and synchronous manufacturing.

Question 3. Write short notes
(a) Kanban
(b) Scheduling and sequencing
(c) System nervousness

Case Study

a) A company is setting up an assembly line to produce 192 units per eight-hour shift. The following table identifies the work elements, items, and immediate predecessors.

Work element	Time (seconds)	Immediate predecessor(s)
A	40	None
B	80	A
C	30	D, E, F
D	25	B
E	20	B
F	15	B
G	120	A
H	145	G
I	130	H
J	115	C,I
Total	720

Question    (a) What is the desired cycle time?

Question    (b) What is the theoretical minimum number of work stations?

Question    (c) Use the largest work element time rule to work out a solution.

Question    (d) What are the idle time, efficiency and balance delay for the solution?

(b) A laundry has three operations washing drying and ironing for the linen it receives from various customers. The laundry has 7 jobs at hand to be sequenced for the three activities. The activity times for the various jobs on hand is given in the following table.

Job	Washing	Drying	Ironing
A	1	7	8
B	3	3	10
C	7	8	9
D	9	2	11
E	4	8	9
F	5	6	14
G	2	1	12

Questions:

(a) Sequence these jobs using Johnson’s method and find the overall processing time.

(b) Find out the waiting time for the jobs.

(c) Find out the idling times for the machines.

(d) What are the conditions for using Johnson’s rule?

Assignment – C

1. Which of the following is not a characteristic of a production system
(a) It is a universally applicable model
(b) Varies from enterprise to enterprise
(c) It is a framework within which production activities take place
(d) Ensures coordination of various production operations

2. Which of the following is not a type of production system
(a) Continuous production
(b) Job or unit production
(c) Intermittent production
(d) Flexible manufacturing

3. All of the following are production functions except
(a) Aggregate planning
(b) Pricing of products
(c) Capacity assessment
(d) Scheduling of operations

4. Order winner means
(a) The sales person who gets the order
(b) The factor of the product that wins the order for the firm
(c) Order that results in high profits
(d) Repeat order

5. All of the following are functions of forecasting except
(a) An estimation tool
(b) A tool for predicting events related to operations planning and control
(c) An input for the JIT system
(d) A vital prerequisite for the planning process

6. Degree of uncertainty in short term forecasting is
(a) High
(b) Low
(c) Nil
(d) Significant

7. All of the following are key areas of forecasting except
(a) Better materials management
(b) Rationalized manpower decisions
(c) Basis for planning and scheduling
(d) Routine decisions

8. Which of the following is a dependent demand for an organization manufacturing refrigerators
(a) Compressor
(b) Requirement for a DG set
(c) Refrigerators
(d) Tea coffee vending machine

9. If a forecast repeatedly overestimates actual demand, bias will have
(a) Positive value
(b) Negative value
(c) Zero value
(d) Infinity

10. Which of the following is not a qualitative method of forecasting
(a) Delphi method
(b) Historical data
(c) Econometric models
(d) Nominal group technique

11. The most suitable method for forecasting the demand for a brand new product is
(a) Moving averages
(b) Historical data
(c) Exponential smoothening
(d) Delphi method

12. The planning that addresses the supply side of a firm’s ability to meet the demand is known as
(a) Business plan
(b) Aggregate production planning
(c) Aggregate capacity planning
(d) Master production scheduling

13. Which of the following is not a considerations in developing an aggregate production plan
(a) Concept of aggregation
(b) Goal for aggregate planning
(c) Forecast of aggregate demand
(d) Supplier lead time

14. The aggregate production planning strategy that cannot be employed in a strong union environment is
(a) Changing inventory levels
(b) Changing workforce levels
(c) Subcontracting
(d) Influencing demand

15. Which of the following is not an alternative for managing supply
(a) Inventory based alternatives
(b) Promotional schemes
(c) Capacity adjustment
(d) Capacity augmentation

16. All of the following are capacity adjustment alternatives except
(a) Hiring/ Firing of workers
(b) Varying shifts
(c) Varying working hours
(d) Subcontracting

17. Which of the following is not an aggregate production planning method
(a) Trial-and-error method
(b) Transportation method
(c) Linear programming method
(d) Assignment method

18. All of the following are characteristics of Master Production Scheduling except
(a) MPS makes use of actual customer orders
(b) Product varieties are taken care of in MPS
(c) MPS is a critical linkage between planning and execution of operations
(d) It is same as rough cut capacity planning

19. Which is not a characteristic of a Bill Of Materials
(a) List all parts required for one unit of a product
(b) Shows dependency relationships
(c) Gives total number of a part used in a product
(d) Indicates multi levels of a product

20. All of the following are time phasing requirement of an MRP logic except
(a) Gross requirement will occur at the middle of a period
(b) On hand inventory will be measured at the end of a period
(c) Planned order release will occur at the beginning of a period
(d) Lead time considerations are not taken for time phasing

21. Which of the following is not an input to the MRP system
(a) The Master Production Schedule
(b) Bill of materials
(c) Engineering drawing
(d) Inventory status file

22. Which of the following is not a Lot sizing technique
(a) The lot-for lot technique
(b) The EOQ approach
(c) Mini-Max approach
(d) Period order quantity approach

23. The process of tracing the effect of one component in another is called
(a) Pegging
(b) Cycle counting
(c) Lot sizing
(d) Time fencing

24. Stability in an MRP is achieved by
(a) Updating
(b) Cycle counting
(c) Lot Sizing
(d) Time fencing

25. Time fence means
(a) The shortest lead-time from raw material to finished production of an item
(b) Ensuring accuracy of inventory records
(c) Method used to update MRP at regular intervals
(d) Calculating net requirements of components

26. All of the following are characteristics of capacity except
(a) It is the maximum rate at which a system can accomplish work
(b) Capacity depends on the bottleneck
(c) Capacity is the productive capability of a facility
(d) Capacity is measured in monetary terms

27. Operations managers are concerned with capacity for several reasons. Which of the following is not a concern
(a) Enough capacity to meet customer demands
(b) Capacity affects cost efficiency of operations
(c) Investment required in capacity
(d) Machine locations in a facility

28. Which of the following is not a short term strategy for modifying capacity
(a) Inventories
(b) Employment levels
(c) Subcontracting
(d) Expansion

29. All of the following are steps in capacity control except
(a) Monitoring of output
(b) Comparing with capacity plan
(c) Assessing demand
(d) Taking corrective actions

30. Multi-skilling of work force doesn’t results in
(a) Increasing capacity
(b) Increasing flexibility
(c) Improving productivity
(d) Waste elimination

31. Activity not associated with Dispatching is
(a) Issue of instructions concerning movement of materials between work centers
(b) Issue of instructions to operators
(c) Loading work centers with jobs
(d) Issue instructions concerning the issue and return of special tools

32. Routing doesn’t include
(a) Sequence of processes, operations for a product
(b) Machines, tools, work stations used in producing the product
(c) Standard time applicable for each operation
(d) Detailed skills of the operator for each operation

33. Three planning premises are used in production management. Which of the following is not one among them
(a) Make to stock
(b) Make to order
(c) Assemble to order
(d) Make subassemblies

34. A strategy that is not used for altering lead time is
(a) Overlapping
(b) Lot sizing
(c) Operations splitting
(d) Lot splitting

35. Backlogs can be reduced by all of the following except
(a) Increasing work center capacity
(b) Reducing order release rate
(c) Increasing lead time
(d) Subcontracting

36. Priority index in scheduling is also known as
(a) Critical ratio
(b) Critical Path
(c) Random number
(d) Earliest due date

37. All of the following are characteristics of flow shop production except
(a) Special purpose equipment
(b) Many number of end items
(c) Low skilled workers
(d) Low in process inventories

38. Which of the following is not a characteristic of job shop production
(a) Multipurpose equipment
(b) Highly skilled workers
(c) High investment
(d) Low raw material inventory

39. Bottleneck operation in line balancing means
(a) Having high operation time
(b) Having high cycle time
(c) Having low operation time
(d) Having more no. of follower operations

40. Which of the following is not associated with line balancing
(a) Precedence diagrams
(b) Cycle time
(c) Closeness matrix
(d) Minimum number of workstations