BSOP 429 Production Activity Control and Just-in-time Complete Course
Week 1
Week 1 DQ 1 (How Other Levels of OPC Affect PAC (Graded)
Select one of the five areas of OPC noted in this week’s lecture, and discuss how activities in this area will or could affect PAC. Why do you feel this way? Does any one area of OPC affect PAC more than another? which specific area of PAC is impacted the most by the areas you selected? How does the textbook describe PAC? What are the sections of PAC? And based on the description of PAC from the lecture and textbook, which specific area of PAC is impacted the most by the master production schedule? which specific area of PAC is impacted the most by the master production schedule? are there any other areas of OPC that have a similar impact on OPC?
Week 1 DQ 2 (Compare and Contrast JIT and MRP )
Discuss how or if MRP and JIT affect PAC differently. Do you view these impacts as positive or negative? Why? Do you view the impacts that MRP & JIT has on PAC as positive or negative? And why do you say so? What does the textbook describe as the optimum scenario or manufacturing environment to use MRP? Also, what would be the optimum scenario or manufacturing environment to use JIT?
Week 1 Assignments:
BSOP 429 Week 1 Manufacturing Planning and Control – Production Activity Control
BSOP 429 Week 1 Written Assignment
Week 2
Week 2 DQ 1 (Lead Times (Graded)
Which of the four lead time elements discussed on page 279 might cause the most difficulty? Why? Why might other lead time elements be less important? What does the textbook say about queue time that may not make it the most difficult to manage? And since it may not be the most difficult, which of the remaining three elements is the most difficult to manage? And why?
Week 2 DQ 2 (Lab 1 Discussion (Graded)
What should the first step be in our Week 2 Lab Assignment? Why? What would the next step be? What are the remaining steps to calculating earliest due date (EDD) as outlined by the lecture? And what pitfalls should we avoid in our calculations for this week’s lab?
Week 2 Assignments:
BSOP 429 Week 2 PAC Framework – Assignment
BSOP 429 Week 2 The Scheduling Lab
Week 3
Week 3 DQ 1 (Types of Constraints )
As far as PAC is concerned, what is a constraint? Why is it important to be able to identify a constraint in the first place? What are the specific steps to managing constraints as outlined in the textbook and lecture?
Week 3 DQ 2 (Lab 2 Discussion)
What should the first step be in our Week 3 Lab Assignment? Why? What would the next step be? the very first statement of the lab states that Maruchek’s orders average 100 pieces per order. What does that mean for your lab?
Week 3 Assignments:
BSOP 429 Week 3 Lab 2 of 6; Lab Scheduling
BSOP 429 Week 3 Written Assignment
Week 4
Week 4 DQ 1 (PAC Feedback )
Select one of the types of feedback that should be provided by PAC and discuss why it is important to have. Are other types of feedback less important? Why would you think so? Of the two types of feedback from PAC, do you think one is more important than the other? And why do you say so?
Week 4 DQ 2 (Lab 3 Discussion )
What should the first step be in our Week 4 Lab Assignment? Why? What should be the next step? are there any pitfalls we should avoid when calculating our front load schedule lab? So, are there any pitfalls that we should avoid when we’re building this week’s front load schedule?
Week 4 Assignments:
BSOP 429 Week 4 Lab 3 of 6; Scheduling, Reporting and Feedback
BSOP 429 Week 4 Written Assignment
Week 4 Midterm Exam Set 1
Page 1
- (TCO 12) _____ is the objective under JIT and time-based competition. (Points : 5)
- (TCO 2) Which of the following lead-time elements can be compressed into one well-designed PAC system? (Points : 5)
- (TCO 3) What happens to inventory as the number of kanban cards increases? (Points : 5)
- (TCO 1) In managing supplier relations, which of the following is a beneficial setup? (Points : 5)
- (TCO 6) When linking marketing requirements and manufacturing strategy, what design approaches for shop floor system should be considered? (Points : 5)
- (TCO 9) Which of the following is true? (Points : 5)
- (TCO 4) According to Elyahu Goldratt, the TOC system uses a scheduling approach called _____. (Points : 5)
- (TCO 5) The amount of time covered by the basic MRP record is called the _____. (Points : 5)
Page 2
- (TCO 1) Please explain PAC. (Points : 20)
- (TCO 2) How does input from other areas into PAC and the feedback PAC provides impact PAC? Explain. (Points : 20)
- (TCO 6) Discuss the differences between MRP and JIT. (Points : 20)
Set 2
Multiple Choice
- (TCO 12) Formal systems for shop floor control under JIT are _____.
- (TCO 2) An operation setback chart _____.
- (TCO 3) In order to minimize the number of orders waiting in the queue and maximize the number of orders processed in a center, which of the following rules should be used?
- (TCO 1) Which of the following is true?
- (TCO 6) When linking marketing requirements and manufacturing strategy, what design approaches for shop floor system should be considered?
- (TCO 9) Which of the following is true?
- (TCO 4) How much of total lead time is accounted for by queue time?
- (TCO 5) Gross requirements in an MRP record are _____ because they are stated as unique items for a given period.
Essay Type
- (TCO 1) List and briefly discuss the five main parts of the operations planning control (OPC) system.
- (TCO 2) What information should be provided into PAC as feedback and why they are important?
- (TCO 6) Compare and contrast JIT and MRP.
Week 5
Week 5 DQ 1 (Using cellular manufacturing)
What are they referring to when they suggest we use “cellular manufacturing”, and why would we use this methodology? What do you think will be the biggest challenge to implementing cellular manufacturing? What insights do the textbook offer?
Week 5 DQ 2 (Lab 4 Assignment )
What should the first step be in our Week 5 Lab Assignment? Why? What should be the next step? are there any other pitfalls to avoid with the kanban formula? What else about your post on the daily usage is an extremely important point to consider for your
Week 5 Assignments:
BSOP 429 Week 5 Lab 4 of 6; JIT and PAC
BSOP 429 Week 5 Written Assignment (Manuf Planning and Control)
Week 6
Week 6 DQ 1 (Supply Chain for JIT Operations)
JIT places certain new demands on the supply chain. At the same time, it provides much more simplified procedures and transactions. Discuss both the new demands and simplifications in the supply chain for JIT operations.
Week 6 DQ 2 (Lab 5 Assignment )
What should the first step be in our Week 6 Lab Assignment (5 of 6 labs)? Why? What should be the next step? Are there any other pitfalls to avoid? How do these points about operating bottlenecks impact WIP reporting?
Week 6 Assignments:
BSOP 429 Week 6 Lab JIT and Supply Chain Management
BSOP 429 Week 6 Lab WIP Report
Week 7
Week 7 DQ 1 (Implementation)
Is the implementation of JIT different than the implementation of other supply chain management systems discussed in Chapter 10A of our text? What cautions should be taken when introducing a JIT system for the first time? What should be avoided?
Week 7 DQ 2 (Lab 6 Assignment)
What should the first step be in our Week 7 Lab Assignment (6 of 6 Labs)? Why? What should be the next step? what specific pitfalls should be avoided when calculating this week’s lab on CPM? what suggestions can you give your classmates to avoid these pitfalls?
Week 7 Assignments:
BSOP 429 Week 7 Lab 6 of 6; Critical Path Method
BSOP 429 Week 7 Assignment
Week 8 Final Exam
Page 1
- (TCO 4) The priority rule, which will sequence jobs in the order they are received, is _____. (Points : 5)
- (TCO 2) In an assignment method problem, if it takes Abe 3 hours to build a birdhouse and 4 hours for a doghouse, and Betty takes 4 hours for a birdhouse and 3 hours for a doghouse, what is the reduced cost (in hours) of assigning Betty to build the doghouse? (Points : 5)
- (TCO 2) A major difference between manufacturing and service systems in terms of scheduling is (Points : 5)
- (TCO 3) Scheduling in service systems may involve scheduling which of the following?
- (Points : 5)
- (TCO 5) The owner and operator of the local franchise of Handyman, Inc., has four jobs to do today, shown in the order they were received:
- (TCO 6) Building up an inventory of standard parts or modules instead of immediately producing the finished end items is the essence of (Points : 5)
- (TCO 7) With regard to suppliers, JIT systems typically require (Points : 5)
- (TCO 10) Which of the following is characteristic of the JIT philosophy? (Points : 5)
- (TCO 1) In make-to-stock systems, fluctuations in sales volume are managed through which of the following? (Points : 5)
- (TCO 5) In an MRP master schedule, the planning horizon is often separated into a series of times periods called (Points : 5)
Page 2
- (TCO 8) Explain how cellular manufacturing represents a flexible manufacturing system. (Points : 25)
- (TCO 11) State the four building blocks of lean operations, and explain how fast and simple are the two common threads that run through them. (Points : 25)
- (TCO 9) Elaborate on the statement: “The output of the system cannot exceed the output of the bottleneck operation(s).” (Points : 25)
- (TCO 4) Differentiate between infinite loading and finite loading as two major approaches used to load work centers. (Points : 25)
- (TCO 12) The theory of constraints has a goal of maximizing flow through the entire system. (Points : 25)
- (TCO 2) Refer to the following data for jobs waiting to be processed at a single work center (jobs are shown in order of arrival):
- (TCO 10) Respond to the question: “Which is better, MRP or JIT?” (Points : 25)
- (TCO 1) The design of the MPC system is influenced by some key features of market demand and product design. Name the key features that will lead to an assemble-to-order system and explain the rationale. (Points : 25)
- (TCO 6) Market requirements drive the choice of the shop floor system approach. Describe and explain the type of market requirements that would be suitable for an MRP-based system, along the lines of product design, product variety, product volume per period, product mix changes, and delivery schedule changes. (Points : 25)
- (TCO 10) Manufacturing strategy also drives the choice of shop floor system. Describe and explain the strategies that lend themselves to a JIT-based system, from the perspective of WIP, changeover cost, and process choice. (Points : 25)
Set 2
Page 1
- (TCO 4) The two different approaches to load work centers in job-shop scheduling are (Points : 5)
- (TCO 2) The priority rule where jobs are processed according to the smallest ratio of due date to processing time is (Points : 5)
- (TCO 2) A scheduling rule used for sequencing jobs through two work centers is (Points : 5)
- (TCO 3) The owner and operator of the local franchise of Handyman, Inc., has four jobs to do today, shown in the order they were received:………………….If he uses the first-come, first-served (FCFS) priority rule to schedule these jobs, what will be the average completion time? (Points : 5)
- (TCO 5) The ultimate goal of JIT operations is to have (Points : 5)
- (TCO 6) Building up an inventory of standard parts or modules instead of immediately producing the finished end items is the essence of (Points : 5)
- (TCO 7) A kanban card is used to signal that (Points : 5)
- (TCO 10) The type of processing system that is used for highly standardized products is (Points : 5)
Page 2
- (TCO 8) Does cellular manufacturing apply best to repetitive, high-volume product or nonrepetitive, low-volume product? Explain and give an example. (Points : 25)
- (TCO 11) Validate or invalidate the statement that although inventories are maintained, the goal of lean operations is to maintain a minimum of safety stock. (Points : 25)
- (TCO 9) Elaborate on the statement: “The output of the system cannot exceed the output of the bottleneck operation(s).” (Points : 25)
- (TCO 4) Differentiate between infinite loading and finite loading as two major approaches used to load work centers. (Points : 25)
- (TCO 12) Explain why batch process helps maximize worker efficiency. (Points : 25)
- (TCO 2) Refer to the following data for jobs waiting to be processed at a single work center (jobs are shown in order of arrival):………………………… Batch job requires specialized operations carried out by different workers or group of workers and so there is a need for more specialization and standardization. What is the schedule sequence using the first-come, first-served (FCFS) priority rule? (Points : 25)
- (TCO 10) Respond to the question: “Which is better, MRP or JIT?” (Points : 25)
- (TCO 1) The design of the MPC system is influenced by some key features of market demand and product design. Name the key features that will lead to a make-to-stock system and explain the rationale.(Points: 25)
- (TCO 6) Market requirements drive the choice of the shop floor system approach. Describe and explain the type of market requirements that would be suitable for an MRP-based system, along the lines of product design, product variety, and product volume per period, product mix changes, and delivery schedule changes. (Points : 25)
- (TCO 10) Manufacturing strategy also drives the choice of shop floor system. Describe and explain the strategies that lend themselves to a JIT-based system, from the perspective of WIP, changeover cost, and process choice. (Points : 25)
