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ASSIGNMENTS
ADL-65: PRODUCTION PLANNING AND CONTROL
INSTRUCTIONS
a) Students are required to submit three assignments
ASSIGNMENT
Assignment A
Assignment B
Assignment C
DETAILS
Five subjective questions
Three subjective questions + Case Study
Forty objective questions
MARKS
10
10
10
b)
c)
d)
e)
:
:
_________________________
_________________________
Assignment 'A'
Assignment 'B'
Assignment 'C'
45
57
60
Using 50 as the exponential smoothing forecast for November, and using 0.3 as the exponential
smoothing coefficient, forecast February sales.
2. ACE Computers has the following expected production capacity and demand for minicomputers:
Quarter
1
2
3
4
Capacity
300
400
450
550
Demand
300
600
300
500
The company does not accept any backorders and wishes to fulfill demand by letting inventories
absorb all fluctuations. How many minicomputers must they have on hand on January 1 to
meet the forecast demand throughout the year?
3. The Vice President of Koza Company has estimated the following demand requirements for the
forthcoming periods.
Periods
1
2
3
4
Forecast
1400
1600
1800
1800
Period
5
6
7
8
Forecast
2200
2200
1800
1400
inventory before period 1 at no additional cost. The inventory cost per period is $20 per unit.
Answer the following:
1. Analyse the above plans. Use graph and tables for presentation of your analysis.
2. Discuss the merits and disadvantages of these plans.
3. Which plan will you recommend and why?
4. Using the data in Table 1 below, compute weekly requirement for the following schedule:
Period
5
Product 1
100
150
Product 2
10
200
200
200
Product 3
150
300
300
Table 1
Item
Finished Product
1
2
3
Subassembly(SA)
4
5
6
7
Part(P)
8
9
10
11
Subassembly(SA)
4
5
6
7
2
1
Part(P)
9
10
11
Raw Materials(RM)
12
13
14
15
1
2
3
1
1
2
2
1
2
1
2
1
1
2
5. With reference to Problem 4, calculate the capacity requirements for the final assembly
department, ignoring lead times.
Average assembly time:
Average subassembly time:
Average fabrication time:
1.2 hours
0.8 hours
0.2 hours
The subassembly lead times are included in the assembly lead times.
MPS
8
GR-A
10
100
GR-H
11
50
150
100
Item
A
B
C
D
E
F
G
H
J
K
12
OH
0
100
50
50
75
75
75
0
100
100
50
LT
1
2
2
1
2
2
1
1
2
2
GR
1
30
3
40
5
30
6
70
7
20
9
10
10
80
11
12
50
Equipment
Job A
Setup hours
Run hours
0.750
0.040
Job B
Job C
Punch
0.600
0.060
Grind
Setup hours
Run hours
0.750
0.020
Screw
Setup hours
Run hours
0.400
0.030
0.520
0.050
1500
2000
1000
300
500
250
How many of each of the machines will be needed if the plant works a 40 hour week?
Case Study
Notes: Read the case study and answer the questions given at the end.
CASE I
In 1990, Jain began to make custom furniture full time in his garage. Jain's work had been
admired by friends and neighbours, who often asked him to make special pieces for them. In
1995, he expanded his operations by leasing a used facility and hiring two additional skilled
workers: a woodworker and a leather specialist. By 1998, Jain formed a company called Good
Wood P Ltd, and had 11 employees.
Today, Good Wood serves a custom furniture market covering Delhi and surrounding regions.
Jain, the CEO, has a staff of 37 employees. Custom made furniture is the sole product line, and
the company has prided itself on high quality and timely delivery services.
Organisationally, Good Wood has Production, Sales, Purchasing, Shipping, and Design
departments. Production department includes wood framing, wood preparation, wood finishing,
metal finishing, leather, glass, plastics, and cloth fabrics.
This past year, 250 to 300 jobs were processed in the facility on any given day. Although
product quality remains high, on time deliveries have deteriorated. The average job seems to be
four to seven weeks late. Suresh, an employee since 1995, and a special assistant to the shop
manager does the shop loading. His job also includes coordinating the overall shop efforts with
those of the sales and design departments. He recently compiled data on waiting job orders for a
typical day.
Detailed scheduling of orders has always been the responsibility of the three shop foremen. Joshi
is foreman of the wood preparation, framing, and finishing departments. Srivastava is the
foreman for the leather and cloth fabrics departments. Chatterjee is the foreman of the metal,
glass and plastics departments.
Jain is concerned about job lateness. He feels deteriorating customer service might well affect
future sales. He has requested George, whose primary experience has been co-ordinating a new
physical distribution system, to analyse the current situation and recommend changes. George is
uncertain which factors he should consider and how to proceed with the problem.
Discuss
1. What is the main problem and what could be the causes of the problem?
2. Propose a production planning and control system to George which would minimise the
above problems
ADL- 65: Production Planning and Control
Assignment 'C'
Given below are 40 multiple choice question.
(Marks: 10)
1. If the order winner is delivery speed to customer, then the production planning and control
system must focus on:
a)
b)
c)
d)
Cost
Lead time
Quality
Coordination with Marketing
2. A firm uses simple exponential smoothing to forecast demand with = 0.2. The forecast for the
month of March was 500 units whereas the actual demand turned out to be 460 units. What is
the forecast for the month of April?
a)
b)
c)
d)
489.6
492
480
490
4. Aggregate output planning generally consists of planning a desired output over a period of:
a)
b)
c)
d)
one week
five years
daily
three months to 1 year
a)
b)
c)
d)
the planning of resources in the manufacturing environment using the closed loop system
another term for rough cut capacity planning
is also known as MRP I or little
is a quicker way to MRP
10. A classification system has been devised to determine how well an MRP system has been
implemented. Class C company is:
a) one which has MRP II in full use and the closed loop is working
b) one in which MRP system is working only in the computing department
c) one which may have MRP, capacity planning and shop floor controls working
d) one which uses MRP for inventory ordering but not for scheduling
11. MRP logic uses the following relationships:
a) Net requirements = total requirements - available inventory
b) Net requirements = scheduled receipts + inventory on hand
13. The simulation studies on many of the lot sizing rules show:
a)
b)
c)
d)
18. A good strategy to meet short term overload for a month can be:
a)
b)
c)
d)
assigning jobs to work centers without considering the work center's capacity
using Gantt chart for loading
using visual load profile for showing load
considering loading of planned orders only
when
when
when
when
21. An aluminium extruder forecasted the demand for pipe extrusions to be 500 units per month
for each of three months. The actual demands turned out to be 400, 560 and 700. The forecast
error in terms of MAD(Mean Absolute Deviation) is:
a)
b)
c)
d)
-50 units
125 units
120 units
53 units
22. Frigerware has experienced demand for ice coolers at 400 units for April, 500 units for May and
600 units for June. The forecast of demand for July using a three period model with the most
recent period's demand weighted twice as heavily as each of the previous two period's demand
is:
a)
b)
c)
d)
425
525
625
400
23. In the regression model for forecasting, the forecast of the period's demand F is expressed as
F = a + bX, where:
a)
b)
c)
d)
25. For short term periods of up to one year, fundamental capacity is fixed. However, short term
adjustments of capacity are possible by:
a)
b)
c)
d)
30. For scheduling N jobs through two machine centers in series, you will use:
a)
b)
c)
d)
Johnson rule to decide the sequence and then schedule on a Gantt chart
McLaren's Order Moment
Groff's Algorithm
None of the above
Copyright 2004. Amity.
31. If a machining center has a machine utilisation of 95% and operator efficiency of 80%, what is
the effective work centre capacity in July assuming 26 working days and 3 shifts running each
day:
a)
b)
c)
d)
472.24 hours
472 hours
158.08 hours
59.28 hours
4 stations
4.22 stations
5 stations
4.2 stations
3162
316
31623
3000
40. If D is the demand per unit of time, L is the lead time, A is the container capacity and S the
safety stock factor,the number of Kanbans N will be :
a)
b)
c)
d)
DL(1+S)/A
A(1+S)/D
LAS(1+D)/24
(D/A)+L+S