FINAL EVALUATION: PRODUCTION PLANNING MODULE

TOPICS: FORECASTING, MRP, CAPACITY PLANNING AND PLANNING

AGREGATED.
FECHA: nov 30 de 2013.
MAXIMUM DURATION: 120 MINUTES
GENERAL CONTENT
FIRST PART: conceptual development of the production planning Module
FIRST POINT: GENERAL THEORY (Value 40 points) MANDATORY

Questionnaire form, in which the student must respond by indicating the answer that
consider correct.

1. The objective of forecasting techniques is:

a. Prepare the maintenance budget of a Company.

b. Project the production rates for each machine.
c. Infer the market share of a product.
d. Project the future value of economic, technological, and demand variables.
among others.
e. None of the above.
f. All of the above.

2. The validity of a forecastdepends on:

The quality of the available data from historical periods.

b. The characteristic of historical demand.
c. The number of periods to forecast.
d. From the variability of the conditions that occurred in the past
e. None of the above
[Link] of the above.

3. Within the production planning environment, the external factors that most
they affect the same one:

a) The variability of demand, the availability of raw materials, the installed capacity
actual, la variabilidad del producto
b) The current labor capacity, the current production capacity, the level of investment
current in advertising
c) The variability of the sales points, the availability of raw materials, the competition,
the economic conditions, the current inventories.
d) None of the above.
e) All of the above

4. To achieve production planning, it is essential and necessary to know

previously:

a) The demand projection, strategic planning, development, and design of

product.
b) The demand projection, the plant capacity, the development and design of
product and process, the layout of the plant
c) Demand projection, product design, and plant layout.
d) None of the above.
e) All of the above

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5. The level of confidence in the future of the forecasts properly approved
dependent on:

a) The value of absolute mean deviation.

b) The value of the tracking signal
c) The value of the mean squared error.
d) The value of the estimated standard error.
e) All of the above
f) None of the above.

6. The seasonal variations are basically:

a. Fluctuations of the variable under study that repeat over time.

b. Fluctuations of the variable under study that repeat almost identically within a
period
c. Fluctuations of the variable under study that are reproduced almost identically year after year.
year.
d. Fluctuations that show the evolution of the variable under study over a period.
[Link] of the above
f. None of the above.

7. The correct application of the 5P strategies (advertising, product, promotion,

price and product) has the purpose of:

a) Exercise a force capable of maintaining future sales levels from the past.
b) Exercise a force capable of positively or negatively influencing future sales.
c) To exert a force capable of increasing the sustainability of future sales.
d) Exercise a force capable of increasing future sales and market share.
market.
e) All of the above
f) None of the above

8 The aggregate planning technique aims to establish:

a) How to manage resources balancedly to meet demand.

b) How to optimize the use of resources to meet demand
c) How to provide the availability of resources to face future variability
of the demand.
d) All of the above
e) None of the above

9. Production losses are focused on:

a) The failure to achieve 100% of the design capacity of the plants.

b) Achieving 100% efficiency in the use of available resources.
c) The achievement of 100% resource availability.
d) All of the above
e) None of the above

10. The essential information requirements to establish the MRP are:

a) The list of materials from the warehouse.
b) The purchase and/or production times of the parts.
c) The demand for the final product.
d) The inventories of the system components
e) All of the above
f) None of the above

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11. The demand and the type of items handled by the MRP are:

a) Projected demand and product components.

b) Random demand and product components.
c) Known demand and spare parts.
d) Dependent demand and product components.
e) None of the above.
f) All of the above

12. The design capacity of a production system is given by:

b) The efficiency and availability achieved of the machines, the labor, and the material
first.
c) The quality obtained from the machines, the labor, and the raw materials.
d) The reliability of the production process
e) The physical and mental integrity of the workers.
f) All of the above.
g) None of the above.

The maximum capacity of a production system is given by:

a) The maximum speed at which the system can perform work.

b) The maximum speed at which the system can safely perform work.
c) The maximum speed at which the system can perform quality work.
d) La velocidad máxima a la que el sistema puede realizar un trabajo confiable.
e) None of the above.
f) All of the above.

14. Aggregate production planning could be defined as:

a) The strategy to be followed by the company to address the projection of demand.

b) How to optimally plan resources to meet demand.
c) The selection of the most cost-effective strategy for planning resources to address the
demand.
d) All of the above
e) none of the above.

15. What is the main challenge for the production manager?

a) Make efficient use of all production resources.

b) Integrate all production resources optimally to meet demand and
comply with the indicators of your management
c) Synchronize the production lines to meet demand, their clients, and comply with
the rules that govern it.
d) All of the above
e) None of the above.

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SECOND PART: PRACTICAL DEVELOPMENT OF THE PLANNING MODULE OF THE
PRODUCTION

Below is an exercise for each topic discussed. The student has the option to
select only two of them and develop it to its conclusion.

2. SECOND POINT: Application of the time series model. (Value 30 points)

Company ABC sold the quantities of product indicated in the years 2010, 2011, and 2012.
in the table by quarters.
.
QUARTERS SALES QUARTERS VENTAS QUARTERS SALES

( AÑO 2011) (UNITS) (YEAR 2012) (UNITS (YEAR 2013) (UNITS)

1 70000 1 60000 1 50000
2 40000 2 30000 2 20000

3 60000 3 50000 3 40000

4 20000 4 15000 4 10000

QUESTIONS.
1. What should be the expected or projected sales per quarter in the year 2013?
making use of some of the time series forecasting techniques?
2. Once known the results, what would you recommend to the company.

THIRD POINT: Application of MRP. (Value 30 points)

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 The demand for 'TOYOTA' for its car A in the world is 8000 units per quarter.
According to the production structure indicated below and the schedule table of
delivery and initial inventory of some parts, please provide answers to the following questions:

QUESTIONS

1. PREPARE THE MRP (value 35 points)

1S A1

2S B1 (4) 1S C1 (3)
2S
1S 5S
4S 6S 3S
1S E1 (3) D2(4) N1(4)
D1 (4) K1 (5) L1 (2) F1 (6)
2S
2S 3S
2S 3S G2 (2) D3 (4) 1S
G3 (1) F3 (2)
G1 (1) F2 (2)

4S 6S 2S 5S 4S 3S 2S
K 2(1) L2 (2) M1(3 N2 (1) H1 (6) I1(3) E2 (1)
)

DELIVERY TIMES FOR THE MANUFACTURE OF PRODUCT A

COMPONENT INITIAL INVENTORY DELIVERY TIME

A 200 1 WEEK
B 500 2 WEEKS
C 0 1 WEEK
D 50 1 WEEK
E 0 2 WEEKS
F 0 3 WEEKS
G 100 2 WEEKS
H 200 4 WEEKS
I 100 3 WEEKS
K 200 4 WEEKS
L 50 6 WEEKS
M 30 2 WEEKS
N 100 5 WEEKS

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FOURTH POINT: CALCULATION OF CAPACITIES (VALUE 30 points)

Good company, produces a component that is then used in the aerospace industry.
the component consists of 4 parts (A, B, C, D, E, F) that are purchased externally and cost
40, 50, 30, 20, 80, 50 dollars per piece, respectively. Parts A and B are assembled first in
the assembly line N1, which produces 600 parts per hour. Part C is subjected to a
drilling operation, before being finally assembled with part D in a line of
assemblyN2. In total, there are 10 mechanical drills, currently all are in good condition.
to be operable. Each drill drills part C at a rate of 100 parts per hour and a
90% availability. And they can only be operable for a maximum of two shifts. The speed of
assembly of line N2 is 400 parts per hour. Part E is subjected to an operation of
milled before finally being assembled with the part F, there are a total of 4 milling machines,
yields of 400 units per hour and are 100% available. The assembly speed of the line
N3es of 800 units/hour In the final assembly, the product that comes out of the assembly line
No1 is assembled with the resulting part of assembly N2, and in turn with the resulting product.
of assembly N3. The final assembly line N4 produces at a rate of 100 components per
hour.

Initially, there is an OEE for each line, as follows:

LINES AVAILABILITY EFFICIENCY QUALITY OEE

N1 90% 85% 95% 73%
N2 80% 85% 90% 61%
N3 85% 70% 85% 51%
N4 90% 90% 95% 77%

Currently, the final components and the resulting part of lines N1 and N2, N3 and N4,
They are produced based on 8 hours of daily work, 6 days a week.

MANAGERIAL CONSIDERATIONS
Management considers that if necessary, it is possible to work up to 3 shifts of 8.
hours in a maximum of two assembly lines and increase the current capacity of each drill in
a 30%.

QUESTIONS TO SOLVE

1.
3. What is the capacity under the current design conditions of the production line?
week and its economic cost?
--- 5 points
2. What is the efficiency of each assembly line under the current design conditions?
capacidad producción? ---5 puntos

3. What would be the production at maximum efficiency that could be achieved under the conditions
What management proposes. ---20 points

FIFTH POINT: Aggregate planning (value 30 points)

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COMPANY XYZ IS MANUFACTURING INTERCOMS FOR THE COMMUNITY BUILDINGS MARKET AND
YOU NEED TO DEVELOP A TOTAL PRODUCTION PLAN FOR THE MONTHS OF JANUARY TO JUNE. HOW
STUDENT OF THE PRODUCTION MANAGEMENT SPECIALIZATION BASED ON INFORMATION
GIVEN IN THE TABLE BELOW, DEFINE: QUESTIONS 1) WHICH OF THE FOLLOWING STRATEGIES IS THE
MORE ECONOMIC AND WHY?: A) PRODUCE CONSTANTLY TO SATISFY DEMAND AT THE COST OF
VARY THE WORKFORCE. B) MAINTAIN A CONSTANT WORKFORCE AND WITHSTAND THE
FLUCTUATION OF DEMAND WITH INVENTORY VARIABILITY C) MAINTAIN A
LOW LABOR FORCE AND SUPPORTING DEMAND FLUCTUATION WITH SUBCONTRACTING
FROM PRODUCTION D) MAINTAIN A CONSTANT AVERAGE LABOR FORCE AND TURN TO OVER
TIME

PRODUCTION ITEMS ENERO FEBRERO MARZO APRIL MAY JUNE JULIO

DEMAND PROJECTION 1000 1500 1400 1600 1200 1800 2000

In business days 20 19 22 20 22 19 25

COSTS AND OTHERS

MATERIALS US$100/UNIT.
MAINTENANCE OF
US$50/UNIT / MONTH
INVENTORY
DEPLETION OF
US$20/UNIT / MONTH
EXISTENCES
SUBCONTRACTING OF US$100/UNIT /
PRODUCTS. MES
HIRING AND US$500/WORKED
TRAINING R
US$1000/WORKED
dismissal OR
WORKING HOURS BY
4 HOURS / UNIT
UNIT
NORMAL HOUR COST
US$ 30/ HOUR
(LINEAR)
OVERTIME COST US$20/ HOUR

NORMAL DAILY JOURNEY 8 HOURS

DAILY EFFECTIVE JOURNEY 5.5 HOURS
NUMBER OF WORKERS THE REQUIRED ONES INITIALLY
INITIAL INVENTORY
400

Successes
GONZALO CARDOZO CORREA
Industrial Engineer - instructor