Production and Operations Planning
Textbook Exam Questions
Course Introduction
Production and Operations Planning focuses on the strategic and tactical processes involved in designing, managing, and optimizing the production and operations functions within manufacturing and service organizations. This course covers key concepts such as demand forecasting, capacity planning, inventory management, scheduling, lean operations, and supply chain coordination. Students will explore methods and tools for balancing supply with demand, allocating resources efficiently, and improving overall productivity and quality. Through case studies and practical exercises, the course develops analytical and decision-making skills essential for effective operations management in a competitive business environment.
Recommended Textbook
Supply Chain Focused Manufacturing Planning and Control 1st Edition by W. C. Benton
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12 Chapters
352 Verified Questions
352 Flashcards
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Chapter 1: Supply chain focused manufacturing planning and control
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30 Verified Questions
30 Flashcards
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Sample Questions
Q1) Choose the proper historical sequence of developments in manufacturing planning and control starting from the left.
A) Adaptive->Lean->Flexible->Push
B) Pull->Flexible->Push->Adaptive
C) Push->Pull->Flexible->Adaptive
D) Lean->Push->Flexible->Adaptive
Answer: C
Q2) In order to make products with a relative degree of high complexity, which manufacturing environment will be most effective?
A) Assemble to order (ATO)
B) Make to stock (MTS)
C) Assemble to Stock (ATS)
D) Make to Order (MTO)
Answer: A
Q3) Which of the following environments is best suited for Process Manufacturing?
A) Engineering to order (ETO)
B) Make to stock (MTS)
C) Engineering to Stock (ETS)
D) Make to Order (MTO)
Answer: B
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Chapter 2: Forecasting demand
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30 Flashcards
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Sample Questions
Q1) List the forecasting model that can forecast several periods ahead the available data with only a relatively small loss in accuracy.
Answer: Exponential smoothing model with trend and seasonality
Q2) The conceptual forecasting framework does not exclude human judgments.When does the framework suggest these judgments should be used?
A) Right after Mathematical Model is generated
B) Before historical data is gathered
C) Right after historical data is gathered
D) Before the selection of a forecasting technique
Answer: A
Q3) When generating the forecast for year 3 season 2 using an exponential smoothing model with seasonality, which seasonality index is subject to updating?
Answer: year 2 season 2
Q4) Define in one sentence what a time series is.
Answer: A time series is a sequence of data points collected or recorded at successive points in time, typically at uniform intervals.
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Chapter 3: S&OP/Aggregate planning
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Sample Questions
Q1) Currently the firm has 80 workers who produce 800 units per quarter each.The cost per unit is $35.00.The cost of holding 1 unit per quarter is $1.50.The cost of hiring a worker is $100.The cost of firing a worker is $500.When using the pure chase strategy, what is the total cost for the year? The quarterly demand information is provided below.
Q1:20,000 units, Q2:100,000 units, Q3:60,000 units, Q4:153,000 units
A) $11,694,000
B) $11,889,375
C) $8,570,500
D) $35,000,345
Answer: A
Q2) The typical planning horizon for the Sales and Operations Planning (S&OP)process covers _________ period.Fill in the blank space.
A) 6~18 months
B) 18~24 months
C) 30 days
D) 90~150 days
Answer: A
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Page 5
Chapter 4: Master production schedule
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Sample Questions
Q1) The __________________ manufacturing environment tries to supply a large variety of final product configurations from standard components and subassemblies within a relatively short lead time.Fill in the blanks.
A) Make to stock (MTS)
B) Assemble to order (ATO)
C) Make to order (MTO)
D) Assemble to stock (ATS)
Q2) According to the manufacturing framework, what is the immediate succeeding process to the MPS process?
Q3) Fill out the following MPS record.There are 500 units on hand and the MPS policy is to order in 500 unit intervals.
\[\begin{array} { | c | c | c | c | c | }
\hline \text { Periods } & 1 & 2 & 3 & 4 \\
\hline \text { Forecast } & 1200 & 1600 & 500 & 450 \\
\hline \text { Available } & & & & \\
\hline \text { MPS } & & & & \\
\hline
\end{array}\]
Q4) Describe what a superbill is in one sentence.
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Chapter 5: Supply chain focused inventory management
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27 Verified Questions
27 Flashcards
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Sample Questions
Q1) The company is using a lot size of 700 units per order.Calculate the safety stock required for a cycle service level of 97.5%.In addition, what is the cost difference between the current policy and using the EOQ lot size? (safety stock/cost)
The expected annual demand is 123,670 units.The standard deviation for a week is 345 units.The ordering cost is $200 and the carrying cost is $3.00 per unit per year.In addition, the lead time is 3 weeks and there are 52 weeks per year.
A) 1171 units/$24,202
B) 8306 units/$36,384
C) 1171 units/$24,202.
D) 4060 units/$12,182.
Q2) ABC Classification uses dollar usage to classify inventory items into categories of importance.There have been attempts to extend the concept of ABC Classification to other more sophisticated measures.Explain why this mostly does not work and why ABC Classification in its simplest form does work.
Q3) Explain is a paragraph how Economic Order Size (EOQ)Model works.Go into detail and do not just include the equation.
Q4) In one sentence, define what demand is during lead time.
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Chapter 6: MRP production system
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25 Flashcards
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Sample Questions
Q1) Fill out the following MRP record.The lot size is 100 units and the units on hand are 100 units.The lead time between order placement and receipt is 2 periods.Multiple lots per order are possible.
\[\begin{array} { | c | c | c | c | c | c | c | c | l | }
\hline \begin{array} { c }
\text { Lot } \\
\text { size: } \\
100 \mathrm { x }
\end{array} & { \text { Period } } \\
\hline & 1 & 2 & 3 & 4 & 5 & 6 & 7 & 8 \\
\hline \text { GR } & 160 & 90 & 125 & 280 & 150 & 150 & 150 & 30 \\
\hline \text { SR } & 60 & 150 & & & & & & \\
\hline \text { POH } & & & & & & & & \\
\hline \text { NR } & & & & & & & & \\
\hline \text { POR } & & & & & & & & \\
\hline
\end{array}\]
Q2) Explain what differentiates MRP from a reorder point system.
Q3) Describe how MRP II is differentiated from the MRP system in the context of manufacturing control and planning.
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Chapter 7: JIT/Lean production
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Sample Questions
Q1) In your own words, briefly describe the concept of Multifaceted Work Force utilized by JIT.
Q2) Provide a reason for why a JIT organization would end up with a smaller supplier base than other non-JIT ones.
Q3) Explain the reasons for JIT originating from Japan in a paragraph.
Q4) In one sentence, describe the basic underlining concept of Just in time (JIT)manufacturing.
Q5) The implementation of JIT moves beyond an adoption of a tool set.It is a organization wide philosophical change.One method of managing change is the Kotter's 8 Steps.Which of the following is not included in Kotter's 8 Steps as a step?
A) Create a sense of urgency
B) Communicate for understanding and buy-in
C) Put together the guiding team
D) Produce long-term wins
Q6) Which of the following is a correct paper kaizen guidelines?
A) Do not include automation as a factor for the work elements
B) Do not include any breaks for operators as work elements
C) Do not include any cycle work for operators as work elements
D) Do not include any walking as a work element.
Page 9
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Chapter 8: Push and pull production systems
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Sample Questions
Q1) For Panama.Inc., there have been having problems with deciding on the number of Kanban cards in the system.There were several material shortages during the last period.In order to prevent shortages while maintaining an efficient Kanban system, how many Kanban cards should be released in the system?
The lead time is 2 day and the safety stock level is set to 15% of the average demand during the day.The container size is 10 units per container.The following is the demands over the last 10 days.
\[\begin{array} { c | r r r r r r r r r r }
\text { Days } & 1 & 2 & 3 & 4 & 5 & 6 & 7 & 8 & 9 & 10 \\
\hline \begin{array} { c }
\text { Daily } \\
\text { demands }
\end{array} & 100 & 98 & 97 & 120 & 123 & 125 & 121 & 100 & 110 & 105
\end{array}\]
A) 10 cards
B) 5 cards
C) 30 cards
D) 25 cards
Q2) Describe the concept of a pull system in one sentence.
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Page 10
Chapter 9: Capacity management
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Sample Questions
Q1) Capacity planning is the creation of a series of interrelated hierarchical plans.The levels of these plans correlate with the levels of the manufacturing framework.Which of the following capacity plan and manufacturing process matches are at the same level?
1)Sales and Operations Planning <-->Rough-Cut Capacity Planning
2)Shop-Floor Control (SFC)<-->Rough-Cut Capacity Planning
3)Material Requirements Planning (MRP)<-->Capacity Requirements Planning
4)Master Production Scheduling (MPS)<-->Input/Output Analysis
A) (1)
B) (2) and (4)
C) (3)
D) (1), (2), and (4)
Q2) The movie theater has scheduled 6 showings a day.The movie theater can play a maximum of 8 trailers for every movie showing.However, because of the time needed to clean the theater after each showing, only 32 trailers are played every day.What is the Effective capacity utilization?
A) 52.95%
B) 66.70%
C) 72.50%
D) 60.20%
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Chapter 10: Production planning and control for remanufacturing
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Sample Questions
Q1) What happens to the cores that do not pass the initial quality inspections in a remanufacturing process?
Q2) Which of the following are recommendations given by the Core Acquisition Study of Automobile Parts Industry?
1)Forecast product return rates
2)Do not depend on statistical or mathematical techniques for planning and control
3)Improve long-term forecast accuracy
4)Focus on developing Arm's length supplier relationships
A) (1)
B) (2) and (4)
C) (1), (3), and (4)
D) None of the above
Q3) What is the response of the remanufacturing managers to the shortage of cores?
Q4) Provide a brief description of the remanufacturing process called Shop-floor systems
Q5) The remanufacturing process can be described as the flow of cores.Please elaborate about this but do not go over a paragraph.
Q6) Describe remanufacturing is one sentence.
Page 12
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Chapter 11: Supply chain focused outsourcing
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Sample Questions
Q1) Which of the following is not considered a quality cost category when discussing outsourcing?
A) Appraisal cost
B) Internal failure cost
C) Return cost
D) Preventative cost
Q2) Domestic Industries.Inc.is relocating its manufacturing facilities from Ohio to Mexico.What term could we use for this decision?
A) Outsourcing
B) Off-shoring
C) Domestic Outsourcing
D) In-sourcing
Q3) The ____________ complexity can be described as being related to the scale and breadth of the outsourcing service.Fill in the bank space with the correct answer.
A) Location-Specific
B) Task-Specific
C) Resource-Specific
D) Industry-Specific
Q4) List at least 3 costs of switching sources in the context of outsourcing.
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Chapter 12: Manufacturing focused supply chain integration
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Sample Questions
Q1) The SCOR model provides a selection of good practices for each process type.What process type is associated with the practice of reduce the supplier base?
A) Make
B) Plan
C) Source
D) Maintenance
Q2) In its development, the SCOR model incorporated four groups of practices for the Make process.Among the following possible choices, find the correct groups of which there could be more than two.
1)S&OP process
2)Lean manufacturing
3)Human resource management (HRM)
4)SPC
A) (3)
B) (3) and (4)
C) (1) and (2)
D) (1), (2) and (3)
Q3) List at least 2 good practices of the source process type of the SCOR Model.
Q4) Explain the requirements of supply chain integration.
Page 14
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