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ch12 Student: _ 1. MRP works best if the inventory items have dependent demand. True False 2. Low level coding represents items less than $18 per unit. True False 3. Independent demand tends to be more 'lumpy' than dependent demand meaning that we need large quantities followed by periods of no demand. True False 4. Lumpy demand for components results primarily from the periodic scheduling of batch production. True False 5. MRP is used within most MRP II and ERP systems. True False 6. The master production schedule states which end items are to be produced, in addition to when and how many. True False 7. Net requirements equal gross requirements minus safety stock. True False 8. The master schedule needs to be for a period long enough to cover the stacked or cumulative lead time necessary to produce the end items. True False 9. Initially, a master production schedule the output from MRP may not represent a feasible schedule. True False 10. MRP, considering inventory position, bills of material, open purchase orders and lead times guarantees a feasible production plan if the inputs to MRP are accurate. True False 11. The bill of materials indicates how much material will be needed to produce the quantities on a given master production schedule. True False 12. A bill of materials contains a listing of all the assemblies, parts, and materials needed to produce one unit of an end item. True False 13. The bill of materials contains information on lead times and current inventory position on every component required to produce the end item. True False 14. The inventory records contain information on the status of each item by time period. True False 15. An assemblytime chart indicates gross and net requirements taking into account the current available inventory. True False 16. MRP II did not replace or improve the basic MRP. True False 17. The gross requirements at one level of an MRP plan determine the gross requirements at the next lower level continuing on down to the lowest levels shown on the bill of material. True False 18. The gross requirements value for any given component is equal to the net requirements of that component's immediate parent multiplied by the quantity per parent. True False 19. The term pegging refers to identifying the parent items that have generated a given set of material requirements for a part or subassembly. True False 20. A netchange MRP system is one that is updated periodically but not less frequently than once a week. True False 21. One reason that accurate bills of material are important is that errors at one level become magnified at lower levels because of the multiplication process used by MRP. True False 22. A regenerative MRP system is one that is updated continuously every time there is a schedule change. True False 23. One of the primary output reports of MRP concerns changes to planned orders. True False 24. Safety time is sometimes used in MRP rather than safety stock quantities. True False 25. Lotforlot ordering in MRP provides coverage for some predetermined number of periods using forecasted demand to extend beyond the orders already received for those periods. True False 26. MRP output reports are divided into two main groups daily and weekly. True False 27. In MRP, EOQ models tend to be less useful for materials at the lowest levels than for upper level assemblies of the bill of materials since higherlevel assemblies have larger dollar investments. True False 28. Load reports show capacity requirements for departments or work centers which may be more or less than the capacity available in that work center. True False 29. ERP began in manufacturing organizations but has spread into service organizations. True False 30. MRP II is simply an improved version of MRP that processes faster and can plan for a larger number of end items. True False 31. Lotforlot ordering in MRP eliminates the holding costs for parts that are carried over to other periods. True False 32. Capacity requirements planning (CRP) is an important feature in MRP+. True False 33. Project Management approaches can help in a conversion to an ERP system. True False 34. As long as a forecast is plus or minus 10%, MRP works well. True False 35. ERP represents an expanded effort to integrate standardized recordkeeping that shares information among different areas of an organization. True False 36. Back flushing takes place after the production has been completed. True False 37. Before a schedule receipt can take place, and order must be placed with a vendor. True False 38. MRP really doesn't apply to services since raw material isn't required. True False 39. ERP implementation requires support and a direct mandate from the CEO because it impacts so many different functional areas. True False 40. ERP automates the tasks involved in performing a business process, such as order fulfillment and financial reporting. True False 41. Which of the following most closely describes dependent demand? A. demand generated by suppliers B. estimates of demand using regression analysis of independent variables C. derived demand D. demands placed on suppliers by their customers E. net material requirements 42. ERP implementation probably won't require: A. cross functional teams B. just a few weeks to install C. intensive training D. high funding for both initial cost and maintenance E. frequent upgrades after installation 43. A computerbased information system designed to handle ordering and scheduling of dependentdemand inventories is: A. computer aided manufacturing (CAM) B. computer integrated manufacturing (CIM) C. economic order quantity (EOQ) D. material requirements planning (MRP) E. economic run size (ERS) 44. The development and application of MRP depended upon two developments: (1) the recognition of the difference between independent and dependent demand, and (2): A. computers B. development of the EOQ model C. inventory control systems D. blanket purchase orders E. the internet 45. The output of MRP is: A. gross requirements B. net requirements C. a schedule of requirements for all parts and end items D. inventory reorder points E. economic order quantities and reorder points 46. Which one of the following is not an input in an MRP system? A. plannedorder schedules B. bill of materials C. master production schedule D. inventory records E. All are inputs 47. The MRP input stating which end items are to be produced, when they are needed, and what quantities are needed, is the: A. master schedule B. billofmaterials C. inventoryrecords D. assemblytime chart E. netrequirements chart 48. In an MRP master schedule, the planning horizon is often separated into a series of times periods called: A. pegging B. lead times C. stacked lead times D. time buckets E. firm, fixed and frozen 49. The MRP input listing the assemblies, subassemblies, parts, and raw materials needed to produce one unit of finished product is the: A. master production schedule B. billofmaterials C. inventoryrecords D. assemblytime chart E. netrequirements chart 50. A visual depiction of the subassemblies and components that are needed to produce and/or assemble a product is called a(n): A. assembly time chart B. product structure tree C. MRP II D. pegging E. Gantt chart 51. The MRP input storing information on the status of each item by time period (e.g., scheduled receipts, lead time, lot size) is the: A. master production schedule B. billofmaterials C. inventoryrecords D. assemblytime chart E. netrequirements chart 52. Which one of the following most closely describes net material requirements? A. gross requirements amount onhand scheduled receipts B. gross requirements planned receipts C. gross requirements order releases + amount onhand D. gross requirements planned order releases E. gross requirements amount onhand + planned order releases 53. In MRP, "scheduled receipts" are: A. identical to "plannedorder receipts" B. identical to "plannedorder releases" C. open orders (that is, ordered before the first time bucket, but not delivered yet) D. "net requirements" E. available to promise inventory 54. In MRP, under lotforlot ordering, "plannedorder receipts" are: A. identical to "scheduled receipts" B. identical to "plannedorder releases" C. open orders (that is, ordered before the first time bucket, but not delivered yet) D. "gross requirements" E. available to promise inventory 55. Under lotforlot, order sizes for component parts are essentially determined directly from which one of the following? A. gross requirements B. net requirements C. economic order quantity D. gross requirements net requirements E. net requirements amount onhand 56. In MRP, the gross requirements of a given component part are calculated from: A. net requirements + amount onhand B. gross requirements of the immediate parent C. planned orders of the end item D. net requirements of end item E. planned orders of the immediate parent 57. The identification of parent items is called: A. Paternity B. Pegging C. Requirement I.D D. Relationship tracking E. Master Scheduling 58. Periodic updating of an MRP system to account for all changes which have occurred within a given time interval is called: A. pegging B. planned order release C. net change D. regenerative E. exception report 59. An MRP system whose records are updated continuously is referred to as a(n): A. regenerative system B. batchtype system C. PlosslWright system D. netchange system E. grosschange system 60. Which is true of a netchange system? A. It is a batchtype system which is updated periodically B. It is usually run at the beginning of each month C. The basic production plan is modified to reflect changes as they occur D. It is used to authorize the execution of planned orders E. It indicates the amount and timing of future changes 61. Which one of the following most closely describes the MRP approach that is used for components or subassemblies to compensate for variations in lead time? A. pegging B. safety stock C. increased order sizes D. safety time E. lowlevel coding 62. Which of the following lot sizing methods does not attempt to balance ordering (or setup) and holding costs? A. economic order quantity B. economic run size C. lotforlot D. partperiod E. all of the above 63. When MRP II systems include feedback, they are known as: A. MRPIII B. Enterprise resource planning C. Circular MRP D. Feasible MRP E. Closed Loop MRP 64. The multiplication process used by MRP to determine lower level requirements is called: A. timephasing B. pegging C. netting D. projecting E. exploding 65. _ is choosing how many to order or make. A. Quantity determination B. Package sizing C. Lot sizing D. Grouping E. Aggregation 66. Which of the following is not usually necessary in order to have an effective MRP system? A. a computer and software B. an accurate bill of materials C. lotforlot ordering D. an uptodate master schedule E. integrity of file data 67. The _ of ERP makes it valuable as a strategic planning tool. A. Internet base B. Rapid Batch capability C. Employee focus D. Realtime aspect E. Database structure 65. _ is choosing how many to order or make. A. Quantity determination B. Package sizing C. Lot sizing D. Grouping E. Aggregation Lot sizing sets the order or batch quantity AACSB: Reflective Thinking Blooms: Remember Difficulty: Medium Learning Objective: 1202 Describe the inputs; outputs; and nature of MRP processing Stevenson Chapter 12 #65 Topic Area: Other Considerations 66. Which of the following is not usually necessary in order to have an effective MRP system? A. a computer and software B. an accurate bill of materials C. lotforlot ordering D. an uptodate master schedule E. integrity of file data MRP does not depend on lotforlot ordering AACSB: Reflective Thinking Blooms: Remember Difficulty: Medium Learning Objective: 1204 Discuss the benefits and requirements of MRP Stevenson Chapter 12 #66 Topic Area: Benefits and Requirements of MRP 67. The _ of ERP makes it valuable as a strategic planning tool. A. Internet base B. Rapid Batch capability C. Employee focus D. Realtime aspect E. Database structure ERP provides realtime, consistent guidance to decisionmaking AACSB: Reflective Thinking Blooms: Remember Difficulty: Hard Learning Objective: 1208 Describe ERP; what it provides; and its hidden costs Stevenson Chapter 12 #67 Topic Area: ERP 68. A recent effort to expand the scope of production resource planning by involving other functional areas in the planning process has been: A. material requirements planning B. capacity requirements planning C. manufacturing resources planning D. JustInTime planning E. multifunctional relationships planning MRP II brings other functional areas into the planning process AACSB: Reflective Thinking Blooms: Remember Difficulty: Easy Learning Objective: 1207 Describe MRP II and its benefits Stevenson Chapter 12 #68 Topic Area: MRP II 69. Which statement concerning MRP II is false? A. It is basically a computerized system B. It can handle complex planning and scheduling quickly C. It involves other functional areas in the production planning process D. It involves capacity planning E. It produces a production plan which includes all resources required MRP II doesn't necessarily consider all production resources AACSB: Reflective Thinking Blooms: Remember Difficulty: Medium Learning Objective: 1207 Describe MRP II and its benefits Stevenson Chapter 12 #69 Topic Area: MRP II 70. Which of these items would be most likely to have dependent demand? A. Xbox batteries B. toy trains C. flowers D. chocolate chip cookies E. wrist watches Xbox batteries would only be needed if Xbox consoles were being produced AACSB: Reflective Thinking Blooms: Remember Difficulty: Medium Learning Objective: 1201 Describe the conditions under which MRP is most appropriate Stevenson Chapter 12 #70 Topic Area: Introduction 71. Which of these products would be most likely to have dependent demand? A. refrigerators B. automobile engines C. televisions D. brownies E. automobiles Engines would only be necessary when automobiles were being produced AACSB: Reflective Thinking Blooms: Remember Difficulty: Medium Learning Objective: 1201 Describe the conditions under which MRP is most appropriate Stevenson Chapter 12 #71 Topic Area: Introduction 72. Using the product tree shown, determine the following: (A) the quantity of component K that will be needed to assemble 80 units of P, assuming no onhand inventory of any components exists (B) the quantity of component K needed to assemble 80 units of P, given onhand inventory of 30 A's, 50 B's and 20 C's A) [3 Ks per C x 2 Cs per A x 2 As per P] + [2 Ks per B x 5 Bs per P] + [3 Ks per C x 3 Cs per P] = 31 Ks per P. For 80 Ps, a total of 2,480 Ks will be needed B) With 30 As, 50 Bs and 20 Cs onhand, K requirements are: [3 Ks per C x 2 Cs per A x (2 As per P 30 As)] + [2 Ks per B x (5 Bs per P 50 Bs)] + [3 Ks per C x (3 Cs per P 20 Cs)]; for 80 Ps, a total of 2,140 Ks will be needed Feedback: Explode the bill of material AACSB: Analytic Blooms: Apply Difficulty: Medium Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #72 Topic Area: MRP Processing 73. The following is a list of components required to produce one unit of end item P: P: 2 A's, 3 B's, 3 C's A: 5 M's, 2 R's B: 1 D, 3 N's C: 1 T, 4 N's M: 1 N Determine the number of N's that will be needed to make 60 P's in each of these cases: (A) There are currently 10 P's on hand (B) Onhand inventory consists of 15 P's, 10A's, 20 B's, 10 C's, 100 N's, 300 T's, and 200 M's. The productstructure tree: A) [1 N per M x 5 M per A x 2 A per P] + [3 N per B x 3 B per P] + [4 N per C x 3 C per P] = 31 N per P. For 60 P, N requirements are: [31 N per P x (60 P 10 OH)] = 1,500 N B) A total of 945 Ns will be needed Feedback: Explode the bill of material AACSB: Analytic Blooms: Apply Difficulty: Medium Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #73 Topic Area: MRP Processing 74. Given the following information, construct a product tree diagram and develop a material requirements plan that will lead to 400 units of product P being available at the start of week 7 Feedback: Items C and D must be planned last AACSB: Analytic Blooms: Apply Difficulty: Medium Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #74 Topic Area: MRP Processing 75. Develop a material requirements plan for end item P and its components, given the tree below. Assume that all lead times are one week, and that lotforlot ordering is used except for item F, which is ordered in multiples of 400 units One hundred units of P should be available at the start of week 4 and at the start of week 8. Beginning inventories are: 20 P, 100 A, and 200 F Scheduled receipts are: 800 F at the start of week 1 All items have zero balances except F, which carries 240 units forward from period 5 Feedback: Item F must be planned last AACSB: Analytic Blooms: Apply Difficulty: Hard Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #75 Topic Area: MRP Processing 76. Given the following data, construct a material requirements plan which will result in 100 units of Parent #1 (P1) at the beginning of week 6, and 200 units of Parent #2 (P2) at the beginning of week 8: Item A has an onhand balance of 70 units after week 7, Item B has an onhand balance of 150 units after week 7, and Item C has an onhand balance of 1,500 units after week 4 Feedback: C's gross requirements come from planned releases for A and B AACSB: Analytic Blooms: Apply Difficulty: Hard Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #76 Topic Area: MRP Processing 77. End item Alpha's product structure tree and inventory information are as follows: (A) If 50 units of Alpha are to be assembled, how many additional units of S will be needed? All parts can be ordered using lotforlot ordering, except M, which must be ordered in multiples of 40 units. [Hint: You don't need to do an MRP plan.] (B) An order for 100 units of Alpha is scheduled to be shipped at the start of week 9. When is the earliest that any particular component must be started so that the order for Alpha will be ready to ship? [Hint: You don't need to do an MRP plan.] A) Gross requirements for S are 200 units, leading to net requirements for S of 100 units B) Additional units of W will have to be started at the beginning of week 1 Feedback: If 50 units of Alpha are to be assembled, then gross requirements for K will be 50 and gross requirements for M will be 100. Net requirements for K will be 20 and net requirements for M will be 70. K is ordered lotforlot, so its net requirements lead to gross requirements for S of 40 units. M is ordered in multiples of 40, so its order quantity of 80 units will lead to gross requirements for S of 160 units The longest sum of lead times is 8 (Alpha's 2 weeks + H's 4 weeks + W's 2 weeks). This means that additional units of W will have to be started at the beginning of week 1 AACSB: Analytic Blooms: Apply Difficulty: Medium Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #77 Topic Area: MRP Processing Refer to this producttree: Stevenson Chapter 12 78. If 17 Ps are needed, and no onhand inventory exists for any items, how many Cs will be needed? A. 8 B. 16 C. 136 D. 204 E. 272 Explode these product structure trees AACSB: Analytic Blooms: Apply Difficulty: Medium Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #78 Topic Area: MRP Processing 79. If 17 Ps are needed, and onhand inventory consists of 10 As, 15 Bs, 20 Cs, 12 Ms, and 5 Ns, how many Cs are needed? A. 48 B. 144 C. 192 D. 212 E. 272 Fewer C's are needed as a result of these other items being present in these quantities AACSB: Analytic Blooms: Apply Difficulty: Hard Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #79 Topic Area: MRP Processing 80. If 40 Ps are needed, and onhand inventory consists of 15 Ps and 10 each of all other components and subassemblies, how many Cs are needed? A. 340 B. 350 C. 380 D. 400 E. 590 Net requirements for C reflects these other items being present in these quantities AACSB: Analytic Blooms: Apply Difficulty: Hard Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #80 Topic Area: MRP Processing Bunny Helpers, Inc. has just received an order for 100 Deluxe Easter Baskets, which must be ready for delivery at the start of week six. An MRP planner has prepared the following table showing product structure, lead times (orders are lotforlot), and quantities on hand: Each Deluxe Basket contains two dark chocolate truffles and four carved chocolate eggs; additionally one bottle of AlkaSelzer is included for those who overindulge Stevenson Chapter 12 81. What is the net requirement for Dark Chocolate Truffles to fill this order? A. 100 B. 140 C. 150 D. 180 E. 200 Explode the bill of materials and use MRP processing AACSB: Analytic Blooms: Apply Difficulty: Medium Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #81 Topic Area: MRP Processing 82. When should an order for Carved Chocolate Eggs be released? A. at the start of week 2 B. at the start of week 3 C. at the start of week 4 D. at the start of week 5 E. at the start of week 6 This is one week before the first receipt of Carved Chocolate Eggs is required AACSB: Analytic Blooms: Apply Difficulty: Medium Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #82 Topic Area: MRP Processing 83. How many Dark Chocolate Eggs should be ordered? A. 310 B. 450 C. 500 D. 550 E. 600 These are the net requirements for Dark Chocolate Eggs AACSB: Analytic Blooms: Apply Difficulty: Medium Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #83 Topic Area: MRP Processing 84. If the firm is using a fixed period lot size of two periods, what is the order size for the first order? A. 120 B. 200 C. 280 D. 160 E. 150 This represents two weeks of net requirements AACSB: Analytic Blooms: Apply Difficulty: Medium Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #84 Topic Area: MRP Processing 85. Which of the following represents an attempt to balance the benefits of stability against the benefits of responding to new information? A. safety stock B. safety time C. bills of material D. time fences E. fixedperiod lot sizing Time fences attempt to balance these two factors AACSB: Reflective Thinking Blooms: Remember Difficulty: Easy Learning Objective: 1206 Outline the potential benefits and some of the difficulties users have encountered with MRP Stevenson Chapter 12 #85 Topic Area: Capacity Requirements Planning 86. Comparing known and expected capacity requirements with projected capacity availability is the job of _. A. planned releases B. load reports C. lot sizing D. work loading E. time fencing Load reports convey this comparison AACSB: Reflective Thinking Blooms: Remember Difficulty: Medium Learning Objective: 1206 Outline the potential benefits and some of the difficulties users have encountered with MRP Stevenson Chapter 12 #86 Topic Area: Capacity Requirements Planning 87. ERP's primary value comes from applications . A. deployment B. development C. interfaces D. integration E. networking Integration is where ERP truly adds value AACSB: Reflective Thinking Blooms: Understand Difficulty: Easy Learning Objective: 1206 Outline the potential benefits and some of the difficulties users have encountered with MRP Stevenson Chapter 12 #87 Topic Area: ERP 88. Net requirements for component J are as follows: 60 units in week 2, 40 units in week 3, and 60 units in week 5. If a fixedperiod, twoperiod lotsizing method is used, what will be the quantity of the first planned receipt? A. 60 units B. 120 units C. 180 units D. Cannot be determined E. None of the above The first planned receipt will be for 100 units AACSB: Analytic Blooms: Apply Difficulty: Medium Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #88 Topic Area: Other Considerations 89. Net requirements for component J are as follows: 60 units in week 2, 40 units in week 3, and 60 units in week 5. If a fixedperiod, threeperiod lotsizing method is used, what will be the quantity of the first planned receipt? A. 60 B. 100 C. 160 D. Cannot be determined E. None of the above The first planned receipt will be for periods 2, 3 and 4 AACSB: Analytic Blooms: Apply Difficulty: Medium Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #89 Topic Area: Other Considerations ch12 Summary Category # of Questio ns AACSB: Analytic 15 AACSB: Reflective Thinking 74 Blooms: Apply 15 Blooms: Remember 71 Blooms: Understand Difficulty: Easy 26 Difficulty: Hard 21 Difficulty: Medium 42 Learning Objective: 1201 Describe the conditions under which MRP is most appropriate Learning Objective: 1202 Describe the inputs; outputs; and nature of MRP processing 24 Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for l owerlevel items 31 Learning Objective: 1204 Discuss the benefits and requirements of MRP Learning Objective: 1205 Explain how an MRP system is useful in capacity requirements planning Learning Objective: 1206 Outline the potential benefits and some of the difficulties users have encountered with MRP Learning Objective: 1207 Describe MRP II and its benefits 10 Learning Objective: 1208 Describe ERP; what it provides; and its hidden costs Stevenson Chapter 12 91 Topic Area: An Overview of MRP Topic Area: Benefits and Requirements of MRP Topic Area: Capacity Requirements Planning Topic Area: ERP Topic Area: Introduction Topic Area: MRP II 10 Topic Area: MRP in Services Topic Area: MRP Inputs 14 Topic Area: MRP Outputs Topic Area: MRP Processing 27 Topic Area: Other Considerations 11 ... Learning Objective: 1203 Explain how requirements in a master production schedule are translated into material requirements for lowerlevel items Stevenson Chapter 12 #8 Topic Area: MRP Inputs 9. Initially, a master production schedule the output from MRP may not represent a feasible schedule. TRUE Management must make more detailed capacity requirements planning to determine whether these more ... Difficulty: Medium Learning Objective: 1207 Describe MRP II and its benefits Stevenson Chapter 12 #32 Topic Area: MRP Processing 33. Project Management approaches can help in a conversion to an ERP system. ... ERP extends beyond purchasing and materials management AACSB: Reflective Thinking Blooms: Remember Difficulty: Medium Learning Objective: 1208 Describe ERP; what it provides; and its hidden costs Stevenson Chapter 12 #40
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