Sec 5- Capacity Management and Production Activity Control

Question 1

Define Capacity Requirements Planning (CRP)

Answer 1

The process of determining in detail the amount of labor and machine resources required to accomplish the tasks of production. Provides a validity check of the priority plan.

Question 2

Define Capacity Management

Answer 2

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

Question 3

What is capacity management called at each of these levels?

1) S&OP
2) master scheduling
3) MRP
4) PAC

Answer 3

1) resource planning
2) RCCP
3) CRP
4) input/output control and operations sequencing

Question 4

List the 4 steps of the Capacity Planning Process

Answer 4

1) determine available capacity
2) use priority plan to determine amount of capacity required for each time period
3) Sum up the capacities for each time period required for each resource and compare to available capacity for that resource
4) Resolve differences between available and required capacities.

Question 5

Define Capacity Available

Answer 5

the capability of a system or resource to produce a quantity of output in a particular time period. Can be “rated” or “demonstrated”

Question 6

How is demonstrated capacity determined?

Answer 6

From historical data

Question 7

How is rated capacity calculated?

Answer 7

available time X utilization X efficiency

Question 8

How is available time calculated?

Answer 8

number of machines X hours a day X days a week

Question 9

How is utilization calculated?

Answer 9

hours actually worked / available hours X 100

Question 10

How is efficiency calculated?

Answer 10

standard hours of work / hours actually worked X 100

Question 11

What are the 5 key inputs into the Capacity Requirements Plan (CRP)

Answer 11

Available capacity
load
data requirements
shop calendar
lead-time elements

Question 12

Define Load

Answer 12

the amount of planned work scheduled for and actual work released to a facility, work center, or operation for a specific span of tie. Usually expressed in standard hours of work

Question 13

How is operation times calculated?

Answer 13

number of pieces x run time per piece + setup time

Question 14

What sort of data is required to do the Capacity Requirements Plan (CRP)?

Answer 14

open shop orders
planned order releases
where work is done
time needed (standard hours)
lead times
work center capacity

Question 15

What is the Manufacturing Calendar?

Answer 15

provides information on the actual number of working days available in each week or month

Question 16

What are the 5 components of Manufacturing Lead Time?

Answer 16

1) Queue- time spent waiting before an operation begins
2) Setup - time spent getting ready for an operation
3) Run - time spent performing an operation
4) Wait- time spend waiting after operation ends
5) Move - time spent physically moving materials between operations

Question 17

Define Load Profile

Answer 17

a graphical comparison of each work center’s available capacity and the load established by the planned and released orders for each time period of the plan

Question 18

What are the 4 objective of the Production Activity Control (PAC)?

Answer 18

1) Execute the MPS and MRP
2) Optimize use of resources
3) Minimize WIP
4) Maintain customer service

Question 19

What are the 3 functions of the PAC?

Answer 19

1) Plan/Replan - ensure resources are available, schedule start and completion dates, replan if necessary
2) Implement- release shop orders to manufacturing and prepare “shop packet”
3) Control - establish/maintain priority list, monitor control WIP/lead times/queues, track and report production status, report work center performance data

Question 20

What are the 4 basic scheduling and loading techniques?

Answer 20

Forward scheduling
Backward scheduling
Infinite loading
Finite loading

Question 21

Define Forward Scheduling

Answer 21

Activities are scheduled form a known start date through a finished date

Question 22

Define Backward Scheduling

Answer 22

Activities are schedule back from the due date

Question 23

Define Infinite Loading

Answer 23

Assumes that capacity is infinite at any work center

Question 24

Define Finite Loading

Answer 24

Assumes there is a definite limit to capacity at any work center

Question 25

Define Priority Control

Answer 25

Communicating start and completion dates for orders that are to be run at each workstation

Question 26

Define Critical Ratio (CR)

Answer 26

A dispatching rule that calculates a priority index number by dividing the time to due date remaining by the expected elapsed time to finish the job

Question 27

Define Input/output Control (I/O)

Answer 27

Technique for capacity control. Monitors both planned/actual inputs and planned/actual outputs.

Question 28

Define Flow Control

Answer 28

Used in a continuous manufacturing system where materials flow through production at a established rate using fixed routing and dedicated machinery.