PART B (70 MARKS)



[pic]

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

PEPERIKSAAN SEMESTER 2

SESI II - 2009/2010

FAKULTI KEJURUTERAAN PEMBUATAN

KOD MATA PELAJARAN : BMFP 4513

MATA PELAJARAN : PERANCANGAN & KAWALAN PENGELUARAN (PRODUCTION PLANNING & CONTROL)

PENYELARAS : H HAERY IP

KURSUS : BMFA/BMFB/BMFP/BMFR/BMFU/

MASA : 2.15 PETANG – 4.45 PETANG

(2 JAM 30 MINIT)

TARIKH : XX APRIL 2010

TEMPAT : DEWAN UTeM

ARAHAN KEPADA CALON:

1. Jawab SEMUA soalan di Bahagian A, B, dan C

2. Jawab SATU (1) soalan dari Bahagian D

3. Setiap soalan hendaklah dijawab pada muka surat yang baru

KERTAS SOALAN INI TERDIRI DARIPADA DELAPAN BELAS (18) MUKA SURAT SAHAJA (TERMASUK MUKA SURAT HADAPAN)

SECTION A

CHOOSE ONLY ONE RIGHT ANSWER

QUESTION 1

1. Which of the following is not one of the four things needed for aggregate planning?

a) a logical overall unit for measuring sales and output

b) a method for determining costs, such as hiring, firing, and inventory costs, associated with production schedules

c) a mathematical model that will minimize costs over the intermediate planning period

d) an aggregate demand forecast for an intermediate planning period

e) All of these are needed for aggregate planning

[1 Marks]

2. The ______ is the input to materials requirements planning which lists the assemblies, subassemblies, parts, and raw materials needed to produce one unit of finished product.

a) bill of materials

b) master production schedule

c) inventory records

d) assembly time chart

e) net requirements chart

[1 Marks]

3. An organization's process strategy

a) will have long-run impact on efficiency and flexibility of production

b) is the same as its transformation strategy

c) must meet various constraints, including cost

d) is concerned with how resources are transformed into goods and services

e) All of the above are true.

[1 Marks]

4. Which scheduling technique should be employed when due dates are important for a job order?

a) forward scheduling

b) loading

c) dispatching

d) backward scheduling

e) master scheduling

[1 Marks]

5. Scheduling is rather straightforward in product-focused facilities because

a) kanban automates the scheduling of the assembly line

b) demand is reasonably stable, and capacities, set-up times, and run times are generally known

c) assembly line balancing assures the highest possible production efficiency

d) finite capacity scheduling has made MRP much more realistic

e) All of the above are true.

[1 Marks]

QUESTION 2

1. The critical path for the network activities shown below is _____ with duration ______.

|Activity |Duration |Immediate |

| | |Predecessors |

|A |10 |--- |

|B |8 |--- |

|C |2 |A |

|D |4 |A |

|E |5 |B,C |

a. A-C; 12

b. A-D-E; 19

c. B-E; 13

d. A-B-C-D-E; 29

e. none of the above

[2 Marks]

2. Two activities are candidates for crashing on a CPM network. Activity details are in the table below. To cut one day from the project's duration, activity _____ should be crashed first, adding ______ to project cost.

|Activity |Normal Time |Normal Cost |Crash Duration |Crash Cost |

|One |8 days |$6,000 |6 days |$6,800 |

|Two |10 days |$4,000 |9 days |$5,000 |

a. One; $400

b. One; $6,800

c. Two; $1,000

d. Two; $5,000

e. One or two should be crashed; $1,400

[2 Marks]

3. Three jobs are to be assigned to three machines. Cost for each job-machine combination appears in the table below. Perform the first two steps of the assignment method (subtract the smallest number in each row and subtract the smallest number in each column; then cover with straight lines). At this point in the problem-solving process

| |Machine A |Machine B |Machine C |

|Job 1 |11 |14 |6 |

|Job 2 |8 |10 |11 |

|Job 3 |9 |12 |7 |

a. the row for Job 1 contains the values 5, 6, and 0

b. calculations are complete, and the problem is ready for an optimal set of assignments

c. the column for Machine B indicates that it should be retired

d. Job 1 should be performed on Machine B

e. Job 1 should be performed on Machine A

[2 Marks]

4. Given the following bill of materials

[pic]

If the demand for product A is 30 units, and there are 10 units of B on hand and none of C, how many units of part D will be needed?

a. 3

b. 40

c. 70

d. 90

e. 110

[2 Marks]

5. Five jobs are waiting to be processed. Their processing times and due dates are given below. Using the shortest processing time dispatching rule, in which order should the jobs be processed?

|Job |Processing Time (days) |Job due date (days) |

|A |4 |7 |

|B |7 |4 |

|C |8 |11 |

|D |3 |5 |

|E |5 |8 |

a. A, B, C, D, E

b. C, E, A, D, B

c. B, D, A, E, C

d. D, A, E, B, C

e. C, E, A, D, B

PART B

EXPLAIN BRIEFLY THE FOLLOWING:

QUESTION 3

Explain the fundamental difference between the "capacity options" and the "demand options" of aggregate planning strategies.

Answer:

Capacity options do not try to change the demand but attempt to absorb the demand fluctuations; capacity options deal with supply, not demand. Demand options try to smooth the demand pattern, but do not impact supply or capacity.

[5 Marks]

QUESTION 4

Discuss what are the advantages and disadvantages of ERP System

Answer:

|Advantages |Disadvantages |

|ERP provides integration of the supply chain, production, and |ERP is very expensive to purchase, and even more costly to |

|administrative processes; creates commonality of databases; |customize; requires major changes in the company and processes |

|incorporates improved, redesigned, or "best" practices; |to implement; is such a complex program that many companies |

|increases communication and collaboration worldwide; helps |cannot adjust to it; involves an ongoing process for |

|integrate multiple sites and business units; comes with software|implementation, often never completed; and expertise in ERP is |

|core that is off-the-shelf coding; and provides a strategic |limited, with staffing an ongoing problem. |

|advantage over competitors. | |

|Essential attributes of ERP systems are the following: (1) multifunctional in scope, (2) integrated in that when a transaction |

|or piece of data representing an activity of the business is entered by one of the function, data regarding the other related |

|function is changed as well, (3) the software is modular in structure, and (4) the software much facilitate manufacturing |

|planning and control activities including forecasting, production planning, and inventory management. |

[5 Marks]

QUESTION 5

Discuss the relationship between stability and firm planned orders

Answer:

Firm planned orders do not get changed by the computer, so changes are in the hands of the master production scheduler. The master production scheduler can, therefore, look at other ways of solving problems than moving orders around. This can provide a great deal of stability and predictability on the shop floor, thereby building increased confidence that, when changes are made, they are needed.

[5 Marks]

QUESTION 6

Discuss the reason for a firm to outsource and what must they do to get their customers to outsource.

Answer:

Outsourcing essentially allows the firm to focus its activities where it can best add value. This also implies its position in the value chain. As a supplier, one needs to take on the problems of the customer – doing them better and more efficiently – allowing the customer to reposition itself in the value chain – offering a superior bundle of goods and services to its customers.

[5 Marks]

QUESTION 7

There is considerable evidence that getting correct operating conditions is more important than the choice between MRP, kanban, or reorder point methods in the material planning and control system. Justify your answer

Answer:

The point of this question is to get the students to think of what is not measured in the research described in this chapter. MRP still has a lot of hidden factory costs associated with the transaction reporting required. Kanban and reorder point methods are closely related, simple approaches that don't have the overhead associated with MRP. When there is little uncertainty, level schedules and short lead times, any of the approaches works well, but the MRP costs are still there and processing transactions may be the limiting factor in the shop.

[5 Marks]

QUESTION 8

Describe the major differences between lean manufacturing, lean organization, and lean enterprise.

[5 Marks]

Answer:

Lean manufacturing has its focus for improvement on the factory, while lean organization focuses on the business unit (integrations of all functions) , and lean enterprise focuses on all business units ( including joint purchasing and joint sales to large customers.

SECTION C

ANSWER ALL QUESTIONS

QUESTION 9

The following Table 1 were obtained from a recent quarterly report for Abal-Abal Computer (in millions)

Table 1. Quarterly Report

|Net Revenue |8,028 |

|Cost of Revenue |6,580 |

|Inventories | |

|Production Materials |126 |

|Work-in-process and finished goods |224 |

|Accounts Receivable |2,689 |

|Accounts payable |4,326 |

Calculate the cash-to-cash cycle time for Abal-Abal Computer.

[10 Marks]

Answer:

|SD |=8028 / (13*7) |=88.22 M |

|ARd |=2689 / 88.22 |=30.48 days |

|CD |= 88.22 * (6580 / 8028) |=72.31M |

|Id |=(126+224)/72.31 |=4.84 days |

|APd |=4326/72.31 |=59.83 days |

Cash to Cash Cycle Time = 30.48 + 4.84 – 59.83 = -24.51 days

QUESTION 10

Top management told Mr. Naoto that the new building is to be opened as soon as possible. Based on the data collected as shown in as in Table 2, he has to present this information include all the calculation needed.

Table 2. Project Activity

|Activity |Duration |Earliest Start|Latest Start|Slack |Optimistic |Most Likely |Pessimistic |

| | | | | |(a) |(m) |(b) |

|C |10 |5 |5 |0 |9 |11 |13 |

|G |35 |15 |15 |0 |30 |35 |40 |

|J |15 |50 |50 |0 |9 |14 |15 |

|K |10 |65 |65 |0 |8 |11 |14 |

|D |5 |0 |20 |20 |3 |5 |10 |

|H |40 |5 |25 |20 |38 |40 |48 |

|E |5 |0 |0 |0 |5 |6 |9 |

|I |15 |15 |30 |15 |15 |17 |19 |

|F |10 |0 |5 |5 |9 |10 |12 |

|L |20 |30 |45 |15 |19 |21 |25 |

a. Calculate the EF, LF, and Slack times for each activity.

[5 Marks]

b. Draw the network diagram and identify what the immediate predecessor of network diagram?

[5 Marks]

c. Determine the total completion time and the critical path for the project

[5 Marks]

Answer:

a.

|Activity |Slack |Earliest Finish |Latest |Immediate |Expected Time [pic] |Variance |

| | | |Finish |Predecessor | |[pic] |

|C |0 |15 |15 |E |11.00 |0.44 |

|G |0 |50 |50 |F,C |35.00 |2.78 |

|J |0 |65 |65 |G,I |13.33 |1.00 |

|K |0 |75 |75 |H,L,J |11.00 |1.00 |

|D |20 |5 |25 |- |5.50 |1.36 |

|H |20 |45 |65 |D,E |41.00 |2.78 |

|E |0 |5 |5 |- |6.33 |0.44 |

|I |15 |30 |45 |C |17.00 |0.44 |

|F |5 |10 |15 |- |10.17 |0.25 |

|L |15 |50 |65 |E,I |21.33 |1.00 |

b.

[pic]

c. Critical Path is : E –C –G – J – K.

Total completion date is 5 + 10 + 35 + 15 + 10 = 75 days. (see table and figure above)

QUESTION 11

Bolehbongkar Repair is under contract to repair, recondition, and/or refurbish commercial and industrial icemakers from restaurants, seafood processors, and similar organizations. Bolehbongkar currently has five jobs to be scheduled as shown in Table 3 based on the order in which they arrived.

Table 3. Project Activity

|Job |Processing Time (hours) |Due (hours) |

|V |20 |50 |

|W |10 |35 |

|X |50 |90 |

|Y |15 |35 |

|Z |55 |75 |

a. Calculate by SPT, FCFS, EDD, and CR

[10 Marks]

b. Which dispatching rule has the best score for flow time?

[5 Marks]

Answer:

a.

|SPT |Machine1 |Due Date |Flow Time |Late |

|W |10 |35 |10 |0 |

|Y |15 |35 |25 |0 |

|V |20 |50 |45 |0 |

|X |50 |90 |95 |5 |

|Z |55 |75 |150 |75 |

|Total | | |325 |80 |

|Average | | |65 |16 |

SPT Average # jobs in system = 2.17

|FCFS |Machine1 |Due Date |Flow Time |Late |

|V |20 |50 |20 |0 |

|W |10 |35 |30 |0 |

|X |50 |90 |80 |0 |

|Y |15 |35 |95 |60 |

|Z |55 |75 |150 |75 |

|Total | | |375 |135 |

|Average | | |75 |27 |

FCFS Average # jobs in system = 2.5

|EDD |Machine1 |Due Date |Flow Time |Late |

|W |10 |35 |10 |0 |

|Y |15 |35 |25 |0 |

|V |20 |50 |45 |0 |

|Z |55 |75 |100 |25 |

|X |50 |90 |150 |60 |

|Total | | |330 |85 |

|Average | | |66 |17 |

EDD Average # jobs in system = 2.23

|Job |Processing |Due |Critical | | | |

|  |Time |  |Ratio | | | |

|V |20 |50 |50/20 |2.38 | | |

|W |10 |35 |35/10 |3.18 | | |

|X |50 |90 |90/50 |1.76 | | |

|Y |15 |35 |35/15 |2.19 | | |

|Z |

| | | | | | | |

|Job |Processing |Due - Current Time |Critical | | | |

|  |Time | |Ratio | | | |

|V |20 |-5 |-0.25 | ................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download