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CPIM > CPIM Part 1, Module 3 - Plan Supply > Flashcards

CPIM Part 1, Module 3 - Plan Supply Flashcards

1
Q

What are the five things that master scheduling has to accomplish?

A
  • Produce what is agreed upon by sales and production
  • Maintain customer service at targeted level
  • Make most efficient use of resources
  • Keep inventories / backlogs at desired level
  • Enable valid order promises
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2
Q

How does the master schedule transform a general plan into a priority plan?

A

By assigning due dates and specific quantities of end items to be manufactured

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3
Q

What are the four steps of producing a master schedule?

A
  1. Disaggregate the production plan into preliminary master schedule end items
  2. Aggregate master schedules for all related end items
  3. Perform rough-cut-capacity planning
  4. Resolve the differences and publish the master production schedule
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4
Q

A workable preliminary master schedule satisfies five conditions, which are these?

A
  • Valid schedule
  • Valid capacity
  • Valid inventory or backlog
  • Valid changeovers
  • Valid batches and lots
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5
Q

What are the three ways of performing rough-cut-capacity planning?

A
  • Bill of labor
  • Capacity planning using overall factors
  • Resource profile approach
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6
Q

What is order entry?

A

The process of accepting and translating what a customer wants into terms used by the manufacturer or distributor

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7
Q

What is capable-to-promise?

A

The process of committing orders against available capacity as well as inventory

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8
Q

What are the two objectives of MRP?

A
  • MRP systems need to determine material requirements precisely in terms of what, how much and when
  • MRP systems are dynamic rather than static, have to adapt to changing priorities
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9
Q

What are the four inputs to MRP?

A
  • Master production schedule
  • Bills of materials
  • Inventory records
  • (Planning factors)
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10
Q

What is the outcome of MRP?

A

A time-phased priority plan. The plan proposes order release dates and corresponding order receipt dates for purchasing and production.

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11
Q

In what four departments / ways are BOMs used?

A
  • Engineering: To create or modify boms
  • Customer service and service department: To ensure right part is sent
  • Finance: helps determine product usage
  • MPC: uses BOMs to determine what to order or make
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12
Q

What is a planning bill of materials?

A

An artificial grouping of items or events in bill-of-material format used to facilitate master scheduling and material planning

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13
Q

What is capacity management?

A

The function of establishing, measuring and adjusted limits or levels of capacity in order to execute all manufacturing schedules

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14
Q

What is capacity planning?

A

The process of determining the amount of capacity required to produce in the future

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15
Q

What are the three steps of iterative capacity planning?

A
  1. Calculate capacity available
  2. Calculate the load per time bucket and determine differences between available and needed capacity
  3. Resolve differences
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16
Q

What are the five inputs to capacity requirements planning (CRP)?

A
  • Planned order releases
  • Open orders
  • Routings
  • Shop calendar
  • Work center files (info on capacity and lead time)
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17
Q

What is the difference between internal and external setup time?

A

Internal setup time is done while the process or machine is NOT running

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18
Q

What is productivity?

A

An overall measure of the ability to produce a good or service. It is the actual output of production compared to actual input of resources

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19
Q

What are the three steps of calculating load?

A
  1. Calculate the operation time per work order
  2. Simulate order scheduling to determine the start and finish dates for each operation on each work center
  3. Establish load profiles
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20
Q

What are the four inputs to back scheduling?

A
  • Quantity, due date, operation time per work order
  • Operations sequence from routing
  • Queue, wait and move times from work center file
  • Work center rated or demonstrated capacity from work center file
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21
Q

What is a load profile?

A

A display of future capacity requirements based on released and/or planned orders over a given span of time

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22
Q

What is the final assembly schedule?

A

A schedule of end items to finish the product for a specific customer’s order in a make-to-order or assemble-to-order environment.

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23
Q

A shop order packet includes the shop order (manufacturing order). What is a manufacturing order?

A

A document, group of documents or schedule conveying authority for the manufacture of specified parts or products in specific quantities

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24
Q

What four things does a shop packet include?

A
  • Manufacturing order
  • Bill of material
  • Routings
  • Engineering drawings / formulas
25
Q

What is a work order?

A

An order to the machine shop for tool maintenance or equipment maintenance

26
Q

What are the three iterations of MRP?

A
  1. the first one was open-loop
  2. the second one was closed-loop
  3. the third one is MRP-II. This one further integrated production, finance and marketing
27
Q

What are the three conventional procurement objectives?

A
  • Purchase the correct goods and services in the specified quantity
  • Purchase at lowest total cost to organization
  • Minimize delivery lead times and optimize other aspects of CS
28
Q

What is total cost of ownership in supply chain management?

A

The sum of all costs associated with every activity of the supply stream

29
Q

What is supplier relationship management (SRM)?

A

A comprehensive approach to managing an enterprise’s interactions with the organizations that supply the goods and services the enterprise uses. Goal is to streamline and make more effective processes

30
Q

What are the five steps of the purchasing process?

A

Planning:
1. Establish specifications

  1. Select suppliers
  2. Negotiate contracts

Execution :
4. Manage purchasing cycle / manage contract buying

Monitoring and controlling:
5. Monitor supplier performance

31
Q

Customer requirements will be translated in three different types. Which three?

A
  • Functional
  • Quantity
  • Price
32
Q

How is quality defined by customer?

A

As fitness for use

33
Q

How is quality define by manufacturing?

A

Conformance to requirements

34
Q

How is quality called when it is a combined of good price and good quality?

A

Value-based

35
Q

What four categories are part of a contract negotiation?

A
  • Price
  • Terms and conditions
  • Delivery (responsibility) and quantity
  • Quality
36
Q

What is supplier scheduling?

A

This is when MRP data on required due dates are directly used in the supplier’s master scheduling process

37
Q

What is the purchasing cycle and what are its five steps?

A

It is a purchasing method used for low-volume or one-time purchasing.

  1. Generate requisition
  2. Issue purchase order
  3. Follow-up
  4. Receive goods
  5. Approve payment
38
Q

What is a purchase requisition?

A

An authorization to the purchasing department to purchase specified materials in specified quantities within a specified time

39
Q

What is purchase order?

A

The purchasers authorization used to formalize a purchase transaction with a supplier

40
Q

What is contract buying? And for what item is it used?

A

Contract buying is the authorization of material releases against a long-term contract. It is used for high-volume / or high-frequency purchases as for MRP.

41
Q

What are the steps organizations have to cycle through with regards to responding to disruptions

A
  1. Mobilizing: Enacting initial response plan and establish rules for how to respond
  2. Sensing: Reprioritization of risks and responses depending on newly arising challenges
  3. Analyzing: Walking through what-if scenarios and protocols
  4. Configuration: set-up existing supply chain network according to protocols developed in previous step
  5. Operation: executing plans and protocols and track results
42
Q

What is production activity control?

A

The function of routing and dispatching the work to be accomplished through the production facility and of performing supplier control

43
Q

What are the five objectives of PAC?

A
  • Execute the orders authorization from the MPS and MRP
  • Optimize the use of resources
  • Provide availability information
  • Provide information on work-in-process inventories
  • Maintain customer service at targeted level
44
Q

What are the six inputs to PAC?

A
  • Material requirements plan
  • Item master files
  • Bills of material
  • Routing files
  • Work center files
  • Shop order files
45
Q

What is flow rate?

A

The inverse of cycle time

46
Q

What is a production schedule?

A

A plan that authorizes the factory to manufacture a certain quantity of a specific item

47
Q

What is priority control?

A

The process of communicating start and completion dates to manufacturing departments in order to execute a plan

48
Q

What is operations scheduling?

A

A technique for short-term planning of actual jobs to be run in each work center based upon capacity and priorities

49
Q

What is dispatching?

A

The selecting and sequencing of available jobs to be run at individual workstations and the assignment of those jobs to workers. Basically controlling the priority of orders

50
Q

What is critical ratio (CR)?

A

It is a dispatch rule where actual processing time is divided by lead time remaining. This results in a ratio that shows the relative priority of the order compared to other orders.

51
Q

What is capacity cushion?

A

Extra capacity that is added to a system after capacity for expected demand is calculated

52
Q

What is exception management?

A

The practice of only responding to issues or events that fall outside a predetermined threshold

53
Q

What is input/output control? And what is the goal?

A

A technique for capacity control where planned and actual inputs and planned and actual outputs are monitored. Goal is to keep work in process and queue times under control

54
Q

What is a VATI analysis?

A

In the theory of constraints, a procedure for determining the general flow of parts and products from raw materials to finished products

55
Q

What is the theory of constraints?

A

A holistic management philosophy based on the principle that complex systems exhibit inherent simplicity

56
Q

What is throughput?

A

The rate at which a system generates “Goal units”

57
Q

What drum-buffer-rope?

A

The theory of constraints method for scheduling and managing operations that have an integral constraint or capacity-constrain resource

58
Q

What is the drum?

A

It is the master production schedule in a drum-buffer-rope scheduling system. It determines the rate of production.

59
Q

When the market is the constraint in a theory of constraints environment there are certain things that differ from instances of internal constrains. What three are these?

A
  • The drum is at shipping and is based on market needs
  • The rope connects the drum to the material release point
  • The time buffer is only at shipping

CPIM (11 decks)

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