# BSOP 330 Complete Course/All Weeks Discussion Questions, Lab Assignments, Quiz Case Study

Product DescriptionBSOP330 Week 1 Lab Assignment Problems 4.1, 4.5, 4.9 and 4.11, pages 140-141

BSOP330 Week 2 Lab Assignments Chapter Four Problems 4.23, 4.27, 4.33, and 4.35

BSOP330 Week 2 Southwestern Case study

L. Houts Plastics is a large manufacturer of injection-molded plastics in North Carolina. An investigation of the company’s manufacturing facility in Charlotte yields the information presented in the table below. How would the plant classify these items according to an ABC classification system?

Chapter 12, problems 12.5

William Beville’s computer training school, in Richmond, stocks workbooks with the following characteristics:

Demand ,500 units/year

Ordering cost S = $25/order

Holding cost H = $4/unit/year

a) Calculate the EOQ for the workbooks.

b) What are the annual holding costs for the workbooks?

c) What are the annual ordering costs?

Chapter 12, problems 12.9

Southeastern Bell stocks a certain switch connector at its central warehouse for supplying field service offices. The yearly demand for these connectors is 15,000 units. Southeastern estimates its annual holding cost for this item to be $25 per unit. The cost to place and process an order from the supplier is $75. The company operates 300 days per year, and the lead time to receive an order from the supplier is 2 working days.

a) Find the economic order quantity.

b) Find the annual holding costs.

c) Find the annual ordering costs.

d) What is the reorder point?

Chapter 12, problems 12.15

M. Cotteleer Electronics supplies microcomputer circuitry to a company that incorporates microprocessors into refrigerators and other home appliances. One of the components has an annual demand of 250 units, and this is constant throughout the year. Carrying cost is estimated to be $1 per unit per year, and the ordering cost is $20 per order.

a) To minimize cost, how many units should be ordered each time an order is placed?

b) How many orders per year are needed with the optimal policy?

c) What is the average inventory if costs are minimized?

d) Suppose that the ordering cost is not $20, and Cotteleer has been ordering 150 units each time an order is placed. For this order policy (of ) to be optimal, determine what the ordering cost would have to be.

L. Houts Plastics is a large manufacturer of injection-molded plastics in North Carolina. An investigation of the company’s manufacturing facility in Charlotte yields the information presented in the table below. How would the plant classify these items according to an ABC classification system?

Chapter 12, problems 12.5

William Beville’s computer training school, in Richmond, stocks workbooks with the following characteristics:

Demand ,500 units/year

Ordering cost S = $25/order

Holding cost H = $4/unit/year

a) Calculate the EOQ for the workbooks.

b) What are the annual holding costs for the workbooks?

c) What are the annual ordering costs?

Chapter 12, problems 12.9

Southeastern Bell stocks a certain switch connector at its central warehouse for supplying field service offices. The yearly demand for these connectors is 15,000 units. Southeastern estimates its annual holding cost for this item to be $25 per unit. The cost to place and process an order from the supplier is $75. The company operates 300 days per year, and the lead time to receive an order from the supplier is 2 working days.

a) Find the economic order quantity.

b) Find the annual holding costs.

c) Find the annual ordering costs.

d) What is the reorder point?

Chapter 12, problems 12.15

M. Cotteleer Electronics supplies microcomputer circuitry to a company that incorporates microprocessors into refrigerators and other home appliances. One of the components has an annual demand of 250 units, and this is constant throughout the year. Carrying cost is estimated to be $1 per unit per year, and the ordering cost is $20 per order.

a) To minimize cost, how many units should be ordered each time an order is placed?

b) How many orders per year are needed with the optimal policy?

c) What is the average inventory if costs are minimized?

d) Suppose that the ordering cost is not $20, and Cotteleer has been ordering 150 units each time an order is placed. For this order policy (of ) to be optimal, determine what the ordering cost would have to be.

2. For the inserts, what are the EOQ’s for both printing companies? How many orders of each size will be needed?

3. Using the EOQ’s above and volume order information provided, what will be the cost of the programs and inserts if they are purchased from Quality Printing

4. Using the EOQ’s above and volume order information provided, what will be the cost of the programs and inserts if they are purchased from First Printing.

MASTER PRODUCTION SCHEDULE

MAKE-TO-STOCK

Beginning PAB prior to week number one is 500.

If the forecast is larger than the book orders, complete the MPS using the forecast demand. If the booked orders is larger than the forecast complete the MPS using the booked orders

Lead-time for MPS releases is one week.

All MPS releases must be in lot sizes of 250 units.

Period order coverage is one period.

1. Complete the MPS due line and the MPS released line.

2. Complete the PAB line.

3. Complete the ATP line.

BSOP Master Planning, Week 5 Assignment, Problem Two

Make-to-Stock MPS

GIVENS FOR THE MPS PROBLEM:

1. Beginning on-hand inventory prior to week one is 200 units.

2. If the forecast is larger than the book orders, complete the MPS using the forecast demand. If the booked orders is larger than the forecast complete the MPS using the booked orders

3. Lead-time for MPS planned orders is one week.

4. All MPS releases must be in lot sizes of 200 or multiples of 200.

REQUIRED:

Complete the MPS due and MPS planned lines.

Calculate the new projected on-hand inventory line.

Calculate the ATP line for the entire MPS.

BSOP330 Master Planning, Week 5, Problem 3

Forecast Disaggregation

Product Family Blenders

Model Number

Percent of the Annual Forecast

B-100

10.00%

B-200

7.00%

B-300

25.00%

B-400

30.00&

B-500

12.00%

B-600

16.00%

Total

100.00%

Note: the total percentage must equal exactly 100%.

If the aggregate forecast for the family of blenders for the month of September is 5,000 units, complete the chart below.

Question :

(TCO 9, 10, & 12) The MPS

Student Answer:

must sum up to the total in the production plan.

can have any quantity necessary to meet customer demand.

is only used in make-to-stock manufacturing.

does not have to be tested for capacity limits.

2.

Question :

(TCO 12) In an assemble-to-order MPS, the items stocked in inventory are

Student Answer:

finished goods.

component parts.

raw materials.

sub-assemblies.

3.

Question :

(TCOs 9, 11, & 12) Which one of the following pieces of information would be more useful to the order entry department in a make-to-stock company?

Student Answer:

The planned order receipt file

The planned MPS released quantity file

The available to promise file

The balance of the forecast quantity

4.

Question :

(TCO 12) A forecast

Student Answer:

is always 100 percent correct.

will get better and better the more time and money you spend.

is a time prediction of the future based on the past.

is a monthly project that marketing loves to do.

5.

Question :

(TCO 10 & 12) In job shop (make-to-order) operations, the master production schedule is usually expressed in

Student Answer:

end items.

modules.

kits.

customer orders.

warehouse orders.

You have developed the following simple product structure of items needed for your gift bag for a rush party for prospective pledges in your organization. You forecast 200 attendees. Assume that there is no inventory on hand of any of the items. Explode the bill of material. (Subscripts indicate the number of units required.)

Chapter 14, problems 14.3

The demand for subassembly S is 100 units in week 7. Each unit of S requires 1 unit of T and 2 units of U. Each unit of T requires 1 unit of V, 2 units of W, and 1 unit of X. Finally, each unit of U requires 2 units of Y and 3 units of Z. One firm manufactures all items. It takes 2 weeks to make S, 1 week to make T, 2 weeks to make U, 2 weeks to make V, 3 weeks to make W, 1 week to make X, 2 weeks to make Y, and 1 week to make Z.

a) Construct a product structure. Identify all levels, parents, and components.

b) b) Prepare a time-phased product structure.

Chapter 14, problems 14.9

As the production planner for Gerry Cook Products, Inc., you have been given a bill of material for a bracket that is made up of a base, two springs, and four clamps. The base is assembled from one clamp and two housings. Each clamp has one handle and one casting. Each housing has two bearings and one shaft. There is no inventory on hand.

Your boss at Gerry Cook Products, Inc., has just provided you with the schedule and lead times for the bracket in Problem 14.8. The unit is to be prepared in week 10. The lead times for the components are bracket (1 week), base (1 week), spring (1 week), clamp (1 week), housing (2 weeks), handle (1 week), casting (3 weeks), bearing (1 week), and shaft (1 week). a) Prepare the time-phased product structure for the bracket. b) In what week do you need to start the castings?

Chapter 14, problems 14.13

Electro Fans has just received an order for one thousand 20-inch fans due week 7. Each fan consists of a housing assembly, two grills, a fan assembly, and an electrical unit. The housing assembly consists of a frame, two supports, and a handle. The fan assembly consists of a hub and five blades. The electrical unit consists of a motor, a switch, and a knob. The following table gives lead times, on-hand inventory, and scheduled receipts.

Question 2. Evaluate the current staffing plan. What does it cost? Are 26 officers sufficient to handle the normal workload?

Question 3: Determine the cost of the Chiefs plan. Do you need to implement the Chief’s plan or can the current staff handle the load? Explain your thinking

Question 4: From the data in the case, determine the schools current cost to provide police services during football games.

Question 5: There isn’t any one right answer for this question. This a critical thinking question. Based on what you have read and the scheduling and costs you put together, what do you see as alternatives for the manning the schedule.

16.1 Leblanc Electronics, Inc., in Nashville, produces short runs of custom airwave scanners for the defense industry. You have been asked by the owner, Larry Leblanc, to reduce inventory by introducing a kanban system. After several hours of analysis, you develop the following data for scanner connectors used in one work cell. How many kanbans do you need for this connector?

Daily demand 1,000 connectors

Lead time 2 days

Safety stock day

Kanban size 500 connectors

16.3

Chris Millikan Manufacturing, Inc., is moving to kan-bans to support its telephone switching-board assembly lines. Determine the size of the kanban for subassemblies and the number of kanbans needed.

16.5

Discount-Mart, a major East Coast retailer, wants to determine the economic order quantity (see Chapter 12 for EOQ formulas) for its halogen lamps. It currently buys all halogen lamps from Specialty Lighting Manufacturers, in Atlanta. Annual demand is 2,000 lamps, ordering cost per order is $30, annual carrying cost per lamp is $12.

a) What is the EOQ?

b) What are the total annual costs of holding and ordering (managing) this inventory?

c) How many orders should Discount-Mart place with Specialty Lighting per year?

16.9

a) Given the following information about a product, at Phyllis Simon’s firm, what is the appropriate setup time?

length of the work shift, expressed in minutes per day.

time it takes a unit to move from one workstation to the next.

time between the start of one unit and the start of the next unit.

sum of all the task times to make one unit of a product.

time from raw materials receipt to finished product exit.

2. (TCOs 5 & 12) The implementation of JIT offers several advantages, including (Points : 4)

reduced throughput.

increase in variability to better respond to variable demand.

decreased profit margins.

support for lean production.

increased work in process inventory.

3. (TCOs 5 & 12) Which of the following statements regarding JIT in services is true? (Points : 4)

Restaurants do not use JIT layouts because they interfere with the creation of a good servicescape.

Excess customer demand in services such as air travel is met by dipping into safety stocks.

All of the JIT techniques for dealing with suppliers, layout, inventory, and scheduling are used in services.

Scheduling is not relevant to the effective use of JIT in services.

All of the above are false.

4. (TCO 12) Which of the following is the author of the phrase, “Inventory is evil”? (Points : 4)

Poka Yoke

Pat “Keiretsu” Morita

Kanban Polka

Shigeo Shingo

None of the above

5. (TCO 12) Great Lakes Barge and Baggage Company makes, among other things, battery-operated bilge pumps. Which of the following activities isnot part of JIT? (Points : 4)

They communicate their schedules to suppliers.

They produce in long production runs to reduce the impact of setup costs.

They use a pull system to move inventory.

They continuously work on reducing setup time.

They produce in small lots.

BSOP330 Week 2 Lab Assignments Chapter Four Problems 4.23, 4.27, 4.33, and 4.35

BSOP330 Week 2 Southwestern Case study

**BSOP330 Week 3 Lab Assignments Chapter 13 problems 13.3, 13.5, 13.9, 13.21**Chapter 12, problems 12.1L. Houts Plastics is a large manufacturer of injection-molded plastics in North Carolina. An investigation of the company’s manufacturing facility in Charlotte yields the information presented in the table below. How would the plant classify these items according to an ABC classification system?

Chapter 12, problems 12.5

William Beville’s computer training school, in Richmond, stocks workbooks with the following characteristics:

Demand ,500 units/year

Ordering cost S = $25/order

Holding cost H = $4/unit/year

a) Calculate the EOQ for the workbooks.

b) What are the annual holding costs for the workbooks?

c) What are the annual ordering costs?

Chapter 12, problems 12.9

Southeastern Bell stocks a certain switch connector at its central warehouse for supplying field service offices. The yearly demand for these connectors is 15,000 units. Southeastern estimates its annual holding cost for this item to be $25 per unit. The cost to place and process an order from the supplier is $75. The company operates 300 days per year, and the lead time to receive an order from the supplier is 2 working days.

a) Find the economic order quantity.

b) Find the annual holding costs.

c) Find the annual ordering costs.

d) What is the reorder point?

Chapter 12, problems 12.15

M. Cotteleer Electronics supplies microcomputer circuitry to a company that incorporates microprocessors into refrigerators and other home appliances. One of the components has an annual demand of 250 units, and this is constant throughout the year. Carrying cost is estimated to be $1 per unit per year, and the ordering cost is $20 per order.

a) To minimize cost, how many units should be ordered each time an order is placed?

b) How many orders per year are needed with the optimal policy?

c) What is the average inventory if costs are minimized?

d) Suppose that the ordering cost is not $20, and Cotteleer has been ordering 150 units each time an order is placed. For this order policy (of ) to be optimal, determine what the ordering cost would have to be.

**BSOP330 Week 4 Lab Assignments Chapter 12, problems 12.1, 12.5, 12.9, 12.15**Chapter 12, problems 12.1L. Houts Plastics is a large manufacturer of injection-molded plastics in North Carolina. An investigation of the company’s manufacturing facility in Charlotte yields the information presented in the table below. How would the plant classify these items according to an ABC classification system?

Chapter 12, problems 12.5

William Beville’s computer training school, in Richmond, stocks workbooks with the following characteristics:

Demand ,500 units/year

Ordering cost S = $25/order

Holding cost H = $4/unit/year

a) Calculate the EOQ for the workbooks.

b) What are the annual holding costs for the workbooks?

c) What are the annual ordering costs?

Chapter 12, problems 12.9

Southeastern Bell stocks a certain switch connector at its central warehouse for supplying field service offices. The yearly demand for these connectors is 15,000 units. Southeastern estimates its annual holding cost for this item to be $25 per unit. The cost to place and process an order from the supplier is $75. The company operates 300 days per year, and the lead time to receive an order from the supplier is 2 working days.

a) Find the economic order quantity.

b) Find the annual holding costs.

c) Find the annual ordering costs.

d) What is the reorder point?

Chapter 12, problems 12.15

M. Cotteleer Electronics supplies microcomputer circuitry to a company that incorporates microprocessors into refrigerators and other home appliances. One of the components has an annual demand of 250 units, and this is constant throughout the year. Carrying cost is estimated to be $1 per unit per year, and the ordering cost is $20 per order.

a) To minimize cost, how many units should be ordered each time an order is placed?

b) How many orders per year are needed with the optimal policy?

c) What is the average inventory if costs are minimized?

d) Suppose that the ordering cost is not $20, and Cotteleer has been ordering 150 units each time an order is placed. For this order policy (of ) to be optimal, determine what the ordering cost would have to be.

**BSOP330 Week 4 Quiz****BSOP330 Week 4 Southwestern Case study Printing companies Programs and Inserts**Southwestern University Case Study1. For the programs, what are the EOQ’s for both printing companies? How many orders of each size will be needed?2. For the inserts, what are the EOQ’s for both printing companies? How many orders of each size will be needed?

3. Using the EOQ’s above and volume order information provided, what will be the cost of the programs and inserts if they are purchased from Quality Printing

4. Using the EOQ’s above and volume order information provided, what will be the cost of the programs and inserts if they are purchased from First Printing.

**BSOP330 Week 5 Homework Problems Mater Production Schedule Problem 1, 2 and 3**BSOP330 Master Planning, Week 5, Problem 1MASTER PRODUCTION SCHEDULE

MAKE-TO-STOCK

Beginning PAB prior to week number one is 500.

If the forecast is larger than the book orders, complete the MPS using the forecast demand. If the booked orders is larger than the forecast complete the MPS using the booked orders

Lead-time for MPS releases is one week.

All MPS releases must be in lot sizes of 250 units.

Period order coverage is one period.

1. Complete the MPS due line and the MPS released line.

2. Complete the PAB line.

3. Complete the ATP line.

BSOP Master Planning, Week 5 Assignment, Problem Two

Make-to-Stock MPS

GIVENS FOR THE MPS PROBLEM:

1. Beginning on-hand inventory prior to week one is 200 units.

2. If the forecast is larger than the book orders, complete the MPS using the forecast demand. If the booked orders is larger than the forecast complete the MPS using the booked orders

3. Lead-time for MPS planned orders is one week.

4. All MPS releases must be in lot sizes of 200 or multiples of 200.

REQUIRED:

Complete the MPS due and MPS planned lines.

Calculate the new projected on-hand inventory line.

Calculate the ATP line for the entire MPS.

BSOP330 Master Planning, Week 5, Problem 3

Forecast Disaggregation

Product Family Blenders

Model Number

Percent of the Annual Forecast

B-100

10.00%

B-200

7.00%

B-300

25.00%

B-400

30.00&

B-500

12.00%

B-600

16.00%

Total

100.00%

Note: the total percentage must equal exactly 100%.

If the aggregate forecast for the family of blenders for the month of September is 5,000 units, complete the chart below.

**BSOP330 Week 5 Quiz**BSOP 330 Week 5 Quiz1.Question :

(TCO 9, 10, & 12) The MPS

Student Answer:

must sum up to the total in the production plan.

can have any quantity necessary to meet customer demand.

is only used in make-to-stock manufacturing.

does not have to be tested for capacity limits.

2.

Question :

(TCO 12) In an assemble-to-order MPS, the items stocked in inventory are

Student Answer:

finished goods.

component parts.

raw materials.

sub-assemblies.

3.

Question :

(TCOs 9, 11, & 12) Which one of the following pieces of information would be more useful to the order entry department in a make-to-stock company?

Student Answer:

The planned order receipt file

The planned MPS released quantity file

The available to promise file

The balance of the forecast quantity

4.

Question :

(TCO 12) A forecast

Student Answer:

is always 100 percent correct.

will get better and better the more time and money you spend.

is a time prediction of the future based on the past.

is a monthly project that marketing loves to do.

5.

Question :

(TCO 10 & 12) In job shop (make-to-order) operations, the master production schedule is usually expressed in

Student Answer:

end items.

modules.

kits.

customer orders.

warehouse orders.

**BSOP330 Week 6 Lab Assignments Chapter 14, problems 14.1, 14.3, 14.9, 14.13**Chapter 14, problems 14.1You have developed the following simple product structure of items needed for your gift bag for a rush party for prospective pledges in your organization. You forecast 200 attendees. Assume that there is no inventory on hand of any of the items. Explode the bill of material. (Subscripts indicate the number of units required.)

Chapter 14, problems 14.3

The demand for subassembly S is 100 units in week 7. Each unit of S requires 1 unit of T and 2 units of U. Each unit of T requires 1 unit of V, 2 units of W, and 1 unit of X. Finally, each unit of U requires 2 units of Y and 3 units of Z. One firm manufactures all items. It takes 2 weeks to make S, 1 week to make T, 2 weeks to make U, 2 weeks to make V, 3 weeks to make W, 1 week to make X, 2 weeks to make Y, and 1 week to make Z.

a) Construct a product structure. Identify all levels, parents, and components.

b) b) Prepare a time-phased product structure.

Chapter 14, problems 14.9

As the production planner for Gerry Cook Products, Inc., you have been given a bill of material for a bracket that is made up of a base, two springs, and four clamps. The base is assembled from one clamp and two housings. Each clamp has one handle and one casting. Each housing has two bearings and one shaft. There is no inventory on hand.

Your boss at Gerry Cook Products, Inc., has just provided you with the schedule and lead times for the bracket in Problem 14.8. The unit is to be prepared in week 10. The lead times for the components are bracket (1 week), base (1 week), spring (1 week), clamp (1 week), housing (2 weeks), handle (1 week), casting (3 weeks), bearing (1 week), and shaft (1 week). a) Prepare the time-phased product structure for the bracket. b) In what week do you need to start the castings?

Chapter 14, problems 14.13

Electro Fans has just received an order for one thousand 20-inch fans due week 7. Each fan consists of a housing assembly, two grills, a fan assembly, and an electrical unit. The housing assembly consists of a frame, two supports, and a handle. The fan assembly consists of a hub and five blades. The electrical unit consists of a motor, a switch, and a knob. The following table gives lead times, on-hand inventory, and scheduled receipts.

**BSOP330 Week 7 Case Study Final**Question 1. Which variations in demand for police services should be considered in an aggregate plan for resources? Which variations can be accomplished with short-term scheduling adjustments?Question 2. Evaluate the current staffing plan. What does it cost? Are 26 officers sufficient to handle the normal workload?

Question 3: Determine the cost of the Chiefs plan. Do you need to implement the Chief’s plan or can the current staff handle the load? Explain your thinking

Question 4: From the data in the case, determine the schools current cost to provide police services during football games.

Question 5: There isn’t any one right answer for this question. This a critical thinking question. Based on what you have read and the scheduling and costs you put together, what do you see as alternatives for the manning the schedule.

**BSOP330 Week 7 Lab Assignments Chapter 16, problems 16.1, 16.3, 16.5, and 16.9 (pages 640-641)**Chapter 16, problems 16.1, 16.3, 16.5, and 16.9 (pages 640-641)16.1 Leblanc Electronics, Inc., in Nashville, produces short runs of custom airwave scanners for the defense industry. You have been asked by the owner, Larry Leblanc, to reduce inventory by introducing a kanban system. After several hours of analysis, you develop the following data for scanner connectors used in one work cell. How many kanbans do you need for this connector?

Daily demand 1,000 connectors

Lead time 2 days

Safety stock day

Kanban size 500 connectors

16.3

Chris Millikan Manufacturing, Inc., is moving to kan-bans to support its telephone switching-board assembly lines. Determine the size of the kanban for subassemblies and the number of kanbans needed.

16.5

Discount-Mart, a major East Coast retailer, wants to determine the economic order quantity (see Chapter 12 for EOQ formulas) for its halogen lamps. It currently buys all halogen lamps from Specialty Lighting Manufacturers, in Atlanta. Annual demand is 2,000 lamps, ordering cost per order is $30, annual carrying cost per lamp is $12.

a) What is the EOQ?

b) What are the total annual costs of holding and ordering (managing) this inventory?

c) How many orders should Discount-Mart place with Specialty Lighting per year?

16.9

a) Given the following information about a product, at Phyllis Simon’s firm, what is the appropriate setup time?

**BSOP330 Week 7 Quiz**1. (TCOs 5 & 12) Manufacturing cycle time is best defined as the (Points : 4)length of the work shift, expressed in minutes per day.

time it takes a unit to move from one workstation to the next.

time between the start of one unit and the start of the next unit.

sum of all the task times to make one unit of a product.

time from raw materials receipt to finished product exit.

2. (TCOs 5 & 12) The implementation of JIT offers several advantages, including (Points : 4)

reduced throughput.

increase in variability to better respond to variable demand.

decreased profit margins.

support for lean production.

increased work in process inventory.

3. (TCOs 5 & 12) Which of the following statements regarding JIT in services is true? (Points : 4)

Restaurants do not use JIT layouts because they interfere with the creation of a good servicescape.

Excess customer demand in services such as air travel is met by dipping into safety stocks.

All of the JIT techniques for dealing with suppliers, layout, inventory, and scheduling are used in services.

Scheduling is not relevant to the effective use of JIT in services.

All of the above are false.

4. (TCO 12) Which of the following is the author of the phrase, “Inventory is evil”? (Points : 4)

Poka Yoke

Pat “Keiretsu” Morita

Kanban Polka

Shigeo Shingo

None of the above

5. (TCO 12) Great Lakes Barge and Baggage Company makes, among other things, battery-operated bilge pumps. Which of the following activities isnot part of JIT? (Points : 4)

They communicate their schedules to suppliers.

They produce in long production runs to reduce the impact of setup costs.

They use a pull system to move inventory.

They continuously work on reducing setup time.

They produce in small lots.

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