POM Exam 2

Arrival rate

the expected number of customers that arrive during each period

What is MPS?

the master production schedule is a plan that specifies what will be made by a production system in the future

Queuing theory

the mathematical analysis of the waiting line Contains 3 parts: 1. Customer arriving into the system 2. servicing the customer 3. how customers exit the system

Workstation cycle time

the time between successive units coming off the end of an assembly line

Which of the following is a characteristic that can be used to guide the design of service systems? 1. Services cannot be inventoried 2. Even service businesses have internal services 3. Quality work means quality service 4. Services businesses are inherently entrepreneurial 5. Services are all similar

1. Services cannot be inventoried

Which of the following is a basic type of process structure ? 1. Workcenter 2. Process flow diagram 3. Process matrix 4. Manual assembly 5. Product matrix

1. Workcenter

Which of the following is the net requirement using an MRP program if the gross requirement is 1000 and the inventory is 500? 1. 400 2. 500 3. 1,000 4. 950 5. 350

2. 500

Which of the following is an input to the master production schedule? 1. Inventory records files 2. None of these 3. Planned-order schedules 4. Exception reports 5. Bill of Materials (BOM)

2. None of these

Which of the following is not considered a major work flow structure? 1. Continuous flow 2. Assembly line 3. Fabrication 4. Project 5. Work Center

3, Fabrication

Assemble-to-order

A production environment where pre-assembled components, subassemblies, and modules are put together in response to a specific customer order

Make-to-order

A production environment where the product is built directly from raw materials and components in response to a specific customer order

Calculate cycle time

C= production time per day/ required output per day (in units)

Engineer-to-order

Here the firm works with the customer to design a product, which is then made from purchased material, parts, and components

Model 3

Like model 1, but two or more servers are available (ex. a bank lobby with multiple tellers)

What is MRP?

Material requirements planning (MRP) is the logic that calculates the number of parts, components, and other materials needed to produce a product

Poka- yokes

Procedures that prevent mistakes in the execution of processes, thus reducing defects

Model 2

Similar to model one with the difference being that it takes exactly the same time to serve each customer, there is no service variability (ex. robot making the same part over and over again)

How to calculate efficiency

Sum of task times (T)/ (Actual number of workstations (Na)x Workstation cycle time (C))

How to calculate the number of workstations needed

Sum of task times (T)/ Cycle Time (C)

Bill-of-materials (BOM)

The complete product description, listing the materials, parts and components, and also the sequence in which the product is created

How to calculate inventory?

Throughput rate X flow time

service blueprint

a flowchart of a process emphasizing in the execution of processes, thus reducing defects

Product- process matrix

a frame work depicting when the different production process types are typically used, depending on product volume and how standardized the product is

days-of-supply

a measure of the number of days of supply of an item

Workcenter

a process with great flexibility to produce a variety of products, typically at lower volume levels

Make-to-stock

a production environment where the customer is served "on-demand" from finished good inventory

inventory turn

an efficiency measure where costs of goods sold is divided by the total average value of inventory

Manufacturing cells

dedicated area where a group of similar products are produced

Process Mapping

drawing of a diagram that depicts the material flow and inventory in a process

Little's Law

mathematical relationship between units in inventory over time

Model 1

useful for simple situations where there is a single line of customers who arrive according to Poisson distribution, and who are processed by a single server that servers each customer in the order they came (ex. Automated teller machine)

Which of the following is considered a primary report in an MRP system? 1. Performance reports 2. Planned order schedules 3. Cycle counting reports 4. Exception reports 5. Planning reports

2. Planned order schedules

Which of the following is a suggestion for managing queues that is mentioned in the textbook? 1. Use humor to defuse a potentially irritating situation 2. Segment the customers 3. Tell people in the queue that each will be served as soon as possible 4. Assure customers that the wait is fair and inform them of the queue discipline 5. Put up a serpentine lane to keep people from jumping ahead in line

2. Segment the customers

When balancing an assembly line, which of the following is not a way to reduce the longest task time below the required workstation cycle time> 1. Split the task between two work stations 2. Speed up the assembly line transfer mechanism 3. Upgrade the equipment 4. Use a more skilled worker 5. Assign a roaming helper to support the line

2. Speed up the assembly line transfer mechanism

There are many applications of poka-yokes in service organizations. Which of the following is one of the three-T's used to classify poka-yokes? 1. Time 2. Task 3. Talent 4. Trust 5. Teamwork

2. Task

Which of the following is an input to the master production schedule (MPS)? 1. Planned order schedules 2. The aggregate plan 3. The bill of materials 4. inventory records file 5. the exception report

2. The aggregate plan

According to Little's Law, which of the following can be used to estimate work-in-process inventory? 1. Set up time/ Throughput rate 2. Throughput rate times flow time 3. Process time/ Cycle time 4. Process velocity/ flow time 5. value added time/ process velocity

2. Throughput rate times flow time

In an MRP program, the program accesses the status segment of an inventory record according to specific periods called which of the following? 1. Time modules 2. Time buckets 3. BOM units 4. Time lines 5. Cubed time units

2. Time buckets

One of the main purposes of a MRP system is which of the following? 1. Track inventory levels 2. develop schedules specifying when each component should be ordered or produced 3. upgrade manufacturing's professionalism 4. create productive capacity 5. Decrease layers of management

2. develop schedules specifying when each component should be ordered or produced

Using the assembly-line balancing procedure, which of the following is the required cycle time if the production time in minutes per day is 1440 and the required output per day in units is 2000? 1. 250 2. Cannot be determined 3. 0.72 4. 1.388 5. 500

3. 0.72

Using the assembly-line balancing procedure, which of the following is the theoretical minimum number of workstations if the task times for the six tasks that make up the job are 4, 6, 7, 2, 6, and 5 minutes, and the cycle time is 10 minutes? 1. None of these 2. 5 3. 3 4. 6 5. 8

3. 3

Using the assembly-line balancing procedure, which of the following is the required cycle time in minutes per unit if the daily production time is 480 minutes and the required daily output is 50 units? 1. Cannot be determined 2. 50 3. 9.6 4. 480 5. 0.104

3. 9.6

Which of the following basic types of process structures is one which equipment or work processes are arranged according to the progressive steps by which the product is made? 1. Manufacturing cell 2. Workcenter 3. Assembly Line 4. Project 5. Continuous process

3. Assembly line

MRP systems seek to achieve which of the following? 1. Relieve capacity bottlenecks 2. Minimize lot sizes 3. Determine the number of dependent demand items needed 4. Provide a yardstick for future improvements 5. Improve on JIT methods

3. Determine the number of dependent demand items needed

The placement of which of the following is not determined by production process organization decisions? 1. Workstations 2. Departments 3. Emergency exits 4. Machines 5. Workgroups

3. Emergency exits

Which of the following is not a queue discipline discussed in the textbook? 1. Shortest processing time 2. Best customer first 3. Last in, first out 4. First come, first served 5. Limited needs

3. Last in, first out

In the service-system design matrix, a face-to-face total customization service encounter is expected to have which of the following? 1. None of these 2. Low sales opportunity 3. Low production efficiency 4. Low degree of customer/ server contact 5. High production efficiency

3. Low production efficiency

Which of the following is considered a primary report in an MRP system? 1. Aggregate production plan report 2. Planning report 3. Planned order schedule 4. Inventory accuracy report 5. Peg Report

3. Planned order schedule

For an infinite queuing situation, if the arrival rate for loading trucks is 5 trucks per hour, what is the mean time between arrivals? 1. None of these 2. 5 hours 3. 0.1 hours 4. 0.2 hours 5. 2.5 hours

4. 0.2 Hours

Which of the following is an input file necessary to run an MRP system? 1. Planned order schedule 2. personnel files 3. Exception report 4. Inventory records file 5. Computer-aided- design files

4. Inventory records file

Standing in line to buy a ticket for a movie where there are multiple windows to buy tickets is which type of queuing system line structure? 1. Multichannel, multiphase 2. None of these 3. Single channel, single phase 4. Multichannel, signle phase 5. Single channel, single phase

4. Multichannel, single phase

Which of the following is a suggestion for managing queues presented in the textbook? 1. Use humor to defuse a potentially irritating situation 2. Periodically close the service channel to temporarily disperse the line 3. Tell customers that the line should encourage them to come back during slack periods 4. Train your servers to be friendly 5. Give each customer a number

4. Train your servers to be friendly

You have just determined the actual number of workstations that will be used on an assembly line to be 6 using the assembly-line balancing procedure. The cycle time of the line is 5 minutes and the sum of all that tasks required on the line is 25 minutes. Which of the following is the correct value for the resulting line's efficiency? 1. 0.973 2. None of these 3. 0.990 4. 0.500 5. 0.833

5. 0.833

Buying a ticket for a college football game where there are multiple windows to buy the ticket at features which type of queuing system line structure? 1. Single channel, multiphase 2. Multichannel, multiphase 3. None of these 4. Single channel, single phase 5. Multichannel, single phase

5. Multichannel, single phase

We would expect to see which of the following in a MRP system's inventory status file? 1. Computer errors 2. End items produced 3. Labor Efficiency 4. Late/ Early delivery records 5. Scrap parts

5. Scrap parts

What is an ERP system and what does it do?

An enterprise resource planning system integrates application programs in accounting, sales, manufacturing, and the other functions in a firm.

Throughput

The average rate that items flow through a process

flow time

the time it takes one unite to completely flow through a process

lead time

the time needed to respond to a customer

Total average value of inventory

the total investment in inventory at the firm, which includes raw materials, work-in-process, and finished goods

Lean manufacturing

to achieve high customer service with minimum levels of inventory investment