Chapter 5 capacity management

Question 1

Capacity management

Answer 1

Supplying necessary resources

Question 2

capacity is not the quantity of work done it is…

Answer 2

a rate of doing work

Question 3

two kinds of capacity

Answer 3

capacity Available and capacity required

Question 4

Capacity available

Answer 4

the capacity of a system to produce a quantity of output in a given time; The rate at which work can be withdrawn from the system

Question 5

capacity required

Answer 5

the capacity of the system or resource needed to produce a desired outcome any given period of time

Question 6

load

Answer 6

The amount of released and planned work assigned to a facility for a particular time.; The sum of all required capacities; The amount of work in the system

Question 7

capacity is often pictured as…

Answer 7

A funnel

Question 8

Capacity management

Answer 8

determining that capacity needed to achieve priority plans and providing, monitoring, and controlling that capacity

Question 9

Capacity planning

Answer 9

The process of determining the resources required to meet the priority plan and methods needed to make capacity available

Question 10

Capacity control

Answer 10

the process of monitoring production output comparing it with capacity plans, and taking corrective action

Question 11

capacity planning

Answer 11

calculating the capacity needed to achieve the priority plan

Question 12

the process of capacity planning 3 steps

Answer 12

1. Determine available capacity at each work center
2. Determine the load at each workcenter
3. Resolve differences between the available capacity and required capacity. Adjust available capacity to match the load.

Question 13

Planning levels

Answer 13

Long-range capacity resource requirements, directly linked to production planning, Changes in staffing, capital equipment, product design, or other facilities that take a long time to acquire and implement

Question 14

rough-cut capacity planning

Answer 14

to check the feasibility of the master production schedule, provide warnings of any bottlenecks, ensure utilization of work centers, and advise vendors of capacity requirements

Question 15

capacity requirements planning

Answer 15

is concerned with individual orders at individual centers and calculates work centers bloats and labor requirements for each time. At each workcenter

Question 16

capacity requirements planning occurs at what level?

Answer 16

CRP occurs at the level of the material requirements plan MRP

Question 17

capacity requirements planning is…

Answer 17

the process of determining in detail the amount of labor and machine resources necessary to achieve production

Question 18

The most detailed, complete, and accurate of the capacity planning techniques

Answer 18

Capacity requirements planning

Question 19

Capacity requirements planning: inputs

Answer 19

Open shop orders, plan to order releases, routing, time the standards, lead times, and workcenter capacities

Question 20

Capacity requirements planning: inputs

4 major inputs?

Answer 20

1. Open order file 2. Material requirements plan 3. Routing file 4. Work center file

Question 21

Capacity requirements planning:

Inputs; open order file?

Answer 21

The open order file is a record of all active shop orders it can be maintained manually or as a computer file; appears as a scheduled receipt on the material requirements plan

Question 22

Capacity requirements planning: inputs; plan to order releases?

Answer 22

Planned order releases are inputs to the capacity requirements plan process in assessing the total capacity required in future time periods

Question 23

capacity requirements planning: inputs; Routing file?

Answer 23

A routing is the path that workflows from workcenter to workcenter as it is completed; specified on a route sheet; a routing file should exist for every component

Question 24

capacity requirements planning: inputs; routing file information?

Answer 24

1 operations to be performed

2. Sequence of operations
3. Work centers to be used
4. Possible alternate work centers
5. Tooling needed at each operation
6. Standard Times: set up times and run times per piece

Question 25

capacity requirements planning: inputs; work center files?

Answer 25

Workcenter is composed of a number of machines or workers capable of doing the same work; workcenter file contains information on capacity and move, wait, and queue times associated with the center

Question 26

capacity requirements planning: inputs; work center file; move time?

Answer 26

The move time is the time normally taken to move material from one workstation to another

Question 27

capacity requirements planning: inputs; work center file; wait time?

Answer 27

The wait time is the time a job is at a work center after completion and before being moved

Question 28

capacity requirements planning: inputs; work center file; Queue time?

Answer 28

The time a job waits at a workcenter before being handled

Question 29

capacity requirements planning: inputs; work center file; Lead time?

Answer 29

Lead time is the sum of the queue, set up, run, wait, and move times

Question 30

capacity requirements planning: inputs; Shop calendar?

Answer 30

Another piece of information needed is the number of working days available

Question 31

Capacity available?

Answer 31

Capacity of the system or resource to produce a quantity of output in a given time.

Question 32

Capacity Available: Factors affecting capacity available?

Answer 32

1. Product specifications
2. Product mix
3. Plant and equipment
4. Work effort

Question 33

Capacity Available: Factors affecting capacity available? Product specifications

Answer 33

if the product specifications changewere content will change affecting production

Question 34

Capacity Available: Factors affecting capacity available?

Product mix

Answer 34

Each product has its own work content, the time it takes to make the product, if the mix of products being produced changes the total work content will change

Question 35

Capacity Available: Factors affecting capacity available?

Plant and equipment

Answer 35

If the methods he used to make the product Change, the output will change

Question 36

Capacity Available: Factors affecting capacity available?

Work effort

Answer 36

If the workforce changes pace The capacity will be altered

Question 37

Capacity Available: measuring capacity; units of output?

Answer 37

Measuring output is done in different ways time is a unit common to all products

Question 38

Capacity Available: measuring capacity;Standard time

Answer 38

the time it would take a qualified operator working at a normal pace to do the job

Question 39

Capacity Available: measuring capacity; levels of capacity?

Answer 39

Capacity needs to be measured on at least three levels

Question 40

Capacity Available: measuring capacity; levels of capacity?

Answer 40

1 machine or individual worker

2. Workcenter
3. Plant: Considered as a group of different work centers

Question 41

Capacity Available: measuring capacity; Determining capacity available; Two ways of determining capacity available?

Answer 41

1. measurement

2. Calculation

Question 42

Capacity Available: measuring capacity; Determining capacity available; Measured capacity “demonstrated”

Answer 42

Measured capacity is figured from historical data

Question 43

Capacity Available: measuring capacity; Determining capacity available; Calculation capacity

Answer 43

Calculation capacity also called rated capacity is based on available time, utilization, and efficiency

Question 44

Capacity Available: measuring capacity; Determining capacity available; Rated capacity

Answer 44

Rated capacity is the product of the available time, utilization, and efficiency

Question 45

Capacity Available: measuring capacity; Determining capacity available; available time?

Answer 45

The available time is the number of hours a workcenter can be used a workcenter working one eight hour shift five days a week is available 40 hours per week

Question 46

Capacity Available: measuring capacity; Determining capacity available; Utilization?

Answer 46

Available time is the maximum hours we can expect from the workcenter. The percentage of time that the workcenter is active compared to the available time is called the workcenter utilization

Question 47

Capacity Available: measuring capacity; Determining capacity available; formula utilization?

Answer 47

Utilization equals (the hours actually worked / Available hours) X 100

Question 48

Capacity Available: measuring capacity; Determining capacity available; Efficiency Formula?

Answer 48

Efficiency equals( standard hours produced/hours actually worked) X 100

Question 49

Capacity Available: measuring capacity; Determining capacity available; rated capacity

Answer 49

Rated capacity is calculated by taking into account the work center utilization and efficiency
rated capacity equals( available time X utilization X Efficiency)

Question 50

Capacity Available: measuring capacity; Determining capacity available; demonstrated capacity

Answer 50

To determine the capacity of the workcenter examine the previous production records and use this information as available capacity; just find the numerical average

Question 51

capacity required (load): Capacity required is a two-step process…

Answer 51

1. Determine the time needed for each order at each workcenter
2. Some the capacity required for individual orders to obtain the load

Question 52

capacity required (load): Formula …Time needed for each order;

Answer 52

The time needed for each order is the sum of the setup time and though run time; the runtime per piece multiplied by the number of pieces in the order

Question 53

capacity required (load); What is the load on a workcenter?

Answer 53

The load on a workcenter is the sum of the required times for all the planned and actual orders to be run on the workcenter in a specified period

Question 54

capacity required (load); The steps in calculating load?

Answer 54

1. Determine the standard hours of operation time for each planned and released order for each workcenter by time.
   2 add all the standard hours together for each workcenter in each period.

Question 55

capacity required (load); work center load report?

Answer 55

Comparing the load to the available capacity; The workcenter load report shows future capacity requirements based on released and planned orders for each time period of the plan

Question 56

capacity required (load); Work center and load reports

Answer 56

The workcenter mode report did show overcapacity are under capacity situations

Question 57

scheduling orders: scheduling?

Answer 57

A timetable for planned occurrences

Question 58

scheduling orders: Back scheduling?

Answer 58

Start with the due date and using the lead times, to work back to find the start date for each operation

Question 59

scheduling orders: Information necessary to schedule?

Answer 59

1. Quantity and due date
2. Sequence of operations and work centers required
3. Set up and run times for each operation
4. Queue, weight, and move times
5. Work center capacity available

Question 60

making the plan: Balancing capacity available and load

Answer 60

Altering the load being shifting orders ahead or back so the load is leveled; Adjust the capacity

Question 61

The result of the capacity requirements plan

Answer 61

A detailed the workable plan that meets the priority objectives and provides the capacity to meet these objectives

Utilization of the workforce, machinery, and equipment