SULIT
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
PEPERIKSAAN SEMESTER 2
SESI 2010/2011
FAKULTI KEJURUTERAAN PEMBUATAN
KOD MATA PELAJARAN
: BMFP 4513
MATA PELAJARAN
: PRODUCTION AND PLANNING CONTROL
(PERANCANGAN & KAWALAN PENGELUARAN)
PENYELARAS
: H HAERY IP
KURSUS
: BMFA/ BMFB/ BMFP/ BMFR/BMFU
MASA
: 9.00 PAGI – 12.00 PAGI ( 3 JAM)
TARIKH
: XX APRIL 2011
TEMPAT
: DEWAN UTeM
ARAHAN KEPADA CALON:
1. Kertas soalan ini mengandungi DUA (2) Bahagian iaitu Bahagian A dan B.
2. Sila jawab SEMUA soalan di Bahagian A.
3. Jawab SATU (1) soalan sahaja dari Bahagian B
4. Gunakan muka surat baru untuk setiap soalan yang dijawab.
KERTAS SOALAN INI TERDIRI DARIPADA EMPAT BELAS (14) MUKA SURAT
SAHAJA (TERMASUK MUKA SURAT HADAPAN)
SULIT
(BMFP 4513)
SULIT
PART A
ANSWER ALL QUESTIONS
QUESTION 1
What are the special requirements of supply chain systems in global environments?
[2 marks]
ANSWER
Supply chains in a global environment must be flexible, so that the firm can react to sudden
changes that might occur in parts availability or currency rates. They must be able to use
latest information technology for scheduling and managing shipments of parts and products.
And they must be staffed with specialists to handle duties, customs, and political issues in
other countries. (The strategic importance of the supply chain, moderate)
QUESTION 2
Differentiate between a push and a pull system.
[3 marks]
ANSWER
A push system pushes material into downstream workstations regardless of the resources
available. A pull system uses signals to request delivery from upstream stations to the
station that has production facilities available. In a pull system, materials or parts are pulled
where they are needed when they are needed. (Just-in-time and lean production, moderate)
QUESTION 3
Hitooth, Inc., produces short runs of custom airwave blower for the defense industry. You
have been asked by the owner, Mr. Otoho , to reduce inventory by introducing a kanban
system. After several hours of analysis, you develop the following data for airwave blower
used in the cvo.
Daily Demand
Lead Time
Safety Stock
Kanban Size
1,000 cvo
2 days
½ day
500 cvo
How many kanban do you need for this equipment?
[5 marks]
2
SULIT
(BMFP 4513)
SULIT
ANSWER
•
Demand during lead time-of 2 days: (1,000 x 2 ) = 2,000
•
Safety stock (1/2 day)
= 500
•
Maximum inventory level
= 2,500
Number of kanbans needed:
2,500 (Maximum inventory level)
5
500 (Kanban size)
QUESTION 4
Ezee Electronics Sdn Bhd is an electronics manufacturing company that produces a variety
of products for several applications. One of the main products is Robo Vacuum. Given
below are the production information for Robo Vacuum:
Week
1
2
3
4
5
6
7
8
9
10
Working days
(days)
2
2
4
1
2
2
4
2
4
5
Machine capacity
(products/hour)
5
4
2
3
1
4
2
2
5
2
Time Available
(hours/day)
2.2
4.25
4
4
4
5.5
6.75
4
3.8
3
The Robo Vacuums cost RM 650 each and the holding cost is 0.5% per week. The fixed
order cost is estimated to be RM 200.
a) Based on the table above, Generate the demand for Robo Vacuum for week 1 until week
10.
[5 marks]
b) Apply the Silver Meal heuristic to find the ordering policy.
[ 6 marks]
c) Apply the Least Unit Cost heuristic to find the ordering policy.
[ 6 marks]
3
SULIT
(BMFP 4513)
SULIT
d) By comparing the Silver Meal and least Unit Cost heuristic, which method results in the
lowest cost policy?
[ 3 marks]
ANSWER
a).
Week
1
2
3
4
5
6
7
8
9
10
Working days
(days)
2
2
4
1
2
2
4
2
4
5
Machine capacity
(products/hour)
5
4
2
3
1
4
2
2
5
2
Time Available
(hours/day)
2.2
4.25
4
4
4
5.5
6.75
4
3.8
3
DEMAND
(units)
22
34
32
12
8
44
54
16
76
30
b)
K = 200
Holding cost = 0.005 * 650 = 3.25
r = (22, 34, 32, 12, 8, 44, 54, 16, 76, 30)
a) Silver Meal Solution
Start in period 1:
C(1) = 200
C(2) = [200 + ((3.25)(34)]/2 = 155.25
C(3) = [(155.25)(2) + (3.25)(2)(32)]/3 = 172.83
Stop.
y1 = r1 + r2 = 56
Start in period 3:
C(1) = 200
C(2) = [200 + (3.25)(12)]/2 = 119.5
C(3) = [(2)(119.5) + (2)(3.25)(8)]/3 = 97
C(4) = [(3)(97) + (3)(3.25)(44)]/4 = 180
4
Stop.
SULIT
(BMFP 4513)
SULIT
y3 = r3 + r4 + r5 = 32 + 12 + 8 = 52
Start in period 6:
C(1) = 200
C(2) = [200 + (3.25)(54)]/2 = 187.75
C(3) = [(2)(187.75) + (2)(3.25)(16)]/3 = 159.83...
C(4) = [(3)(159.833..) + (3)(3.25)(76)]/4 = 305.125 Stop.
y6 = r6 + r7 + r8 = 44 + 54 + 16 = 114
Obtain y9 = r9 + r10 = 106
Silver Meal Solution = (56, 0, 52, 0, 0, 114, 0, 0, 106, 0)
Cost = (4)(200) + (3.25)(34 + 20 + 8 + 70 + 16 + 30)
= $1378.50
c)
Start in period 1:
C(1) = 200/22 = 9.09
C(2) = [200 + (3.25)(34)]/(22 + 34) = 5.54
C(3) = [200+(3.25)(34+(2)(32))]/(22+34+32) = 5.89 Stop.
y1 = r1 + r2 = 56
Start in period 3:
C(1) = (200)/(32) = 6.25
C(2) = [200 + (3.25)(12)]/(32 + 12) = 5.43
C(3) = [200 + (3.25)(12+(2)(8))]/(32+12 8) = 5.60 Stop.
y3 = r3 + r4 = 44
Start in period 5:
C(1) = 200/8 = 25
C(2) = [200+(3.25)(44)]/(8 + 44) = 6.60
C(3) = [200+(3.25)(44+(54)(2))]/(8+44+54) = 6.55
C(4) = [200+(3.25)(44+(54)(2)+(16)(3))]/(8+44+54+16) = 7.97
Stop.
y5 = r5 + r6 + r7 = 106
5
SULIT
(BMFP 4513)
SULIT
Start in period 8:
C(1) = 12.5
C(2) = 4.9
C(3) = 5.3 Stop
y8 = r8 + r9 = 92
y10 = r10 = 30
LUC solution: (56, 0, 44, 0, 106, 0, 0, 92, 0, 30)
Cost = (200)(5)+(3.25)(34 + 12 + 98 + 54 + 76) = $1,890.50.
d)
Summary of Results
Silver Meal = $1378.50
Least unit cost = $1890.50
From the results, we can say that the Silver Meal method results in the lowest cost policy.
QUESTION 5
Two engineering students, Belegug and Ontohod, are two brothers currently planning to
prepare for the Final Exam Test. Between of them requires the test preparation of course
subjects such as Mathematic, Statistic, English, PPC, and Engineering Economy. Based on
the experience, they estimate that they will need the time for self study in the following
amount of time (in hours) with each set of course materials such as follows:
Mathematic
Statistic
English
PPC
Engineering Economy
ONTOHOD
1.8
0.8
3.1
1.1
2.3
BELEGUG
1.2
2.2
0.7
0.5
1.5
They agree that Ontohod will get the opportunity to see each of course materilas before
Belegug.
Determine the exact times that each will begin and end studying each subject in order to
minimize the total time required for both to complete studying all five subjects if they start
the study at 8:00 P.M
.
[10 marks]
6
SULIT
(BMFP 4513)
SULIT
ANSWER
OTO (minute)
108
48
186
66
138
Mathematic
Statistic
English
PPC
Engineering Economy
Engineering
Economy
Statistic
Statistic
8:00 pm
8:48
Mathematic
English
Engineering
Economy
11:06
11:00
BELEGUG (minute)
72
132
42
30
90
PPC
Mathematic
12:54
12:36
English
4:00
2:06
PPC
5:06
4:42
 The optimal sequence is 2-5-1-3-4.
QUESTION 6
The MPS planner at Amburadul Sdn Bhd uses MPS time-phased records for planning enditem production. The planner is currently working on a schedule for the P24, one of
Ambradul’s top-selling products. The planner uses a production lot size of 70 and safety
stock of 5 for the P24 product.
Week
Forecast
Orders
Available
Available to Promise
MPS
1
30
13
2
30
8
3
30
4
7
4
40
5
40
6
40
7
45
8
45
SULIT
5:36
(BMFP 4513)
SULIT
a) Complete the MPS time-phased record for product P24
[5 marks]
b) Verify if Amburadul Sdb Bhd can accept the following order
[5 marks]
Order
1
2
3
4
c)
Amount
40
30
30
25
Desired Week
4
6
2
3
Update the MPS time-phased record for accepted orders.
[5 marks]
ANSWER
a.
Item: P24
Week
1
2
3
4
5
6
7
8
Forecast
30
30
Orders
13
8
Available
60
30
Available to Promise
69
MPS
70
If On-hand = 20, MPS lot size = 70
30
4
70
66
70
40
40
40
45
45
30
60
70
70
20
45
70
70
70
70
70
2
3
4
5
6
7
8
Forecast
30
30
Orders
13
8
Available (on hand =0)
40
10
Available to Promise
49
0
MPS
70
0
If On-hand = 0, MPS lot size = 70
30
4
50
66
70
40
0
10
0
0
40
0
40
70
70
40
0
0
0
0
45
0
25
70
70
45
0
50
70
70
Or
Week
1
8
SULIT
(BMFP 4513)
SULIT
b.
Order
1
2
3
4
Amount
40
30
30
25
Desired Week
4
6
2
3
Accept (Y or N)
Y
Y
Y
Y
c.
Item: P24
Week
1
2
3
4
5
6
7
8
Forecast
30
30
Orders
13
38
Available
60
22
Available to Promise
39
MPS
70
If On-hand = 20, MPS lot size = 70
30
29
62
1
70
40
40
22
40
40
30
12
45
45
37
70
70
62
70
70
Week
2
3
4
5
6
7
8
Forecast
30
30
Orders
0
30
Available (on hand =0)
40
10
Available to Promise
40
0
MPS
70
0
If On-hand = 0, MPS lot size = 70
30
25
50
5
70
40
40
10
0
0
40
0
40
40
70
40
30
0
0
0
45
0
25
70
70
45
0
50
70
70
1
QUESTION 7
Consider the following MRP record:
Week
Gross Requirements
Scheduled Receipts
Projected Available Balance
Planned Order Release
52
40
70

1
25
35
10
9
2
30
50
30
3
5
4
15
25
10
5
5
15
20
6
10
10
SULIT
(BMFP 4513)
SULIT
Suppose 15 units of the scheduled receipt for 40 units due on Week 2 are scrapped during
week 1, and no scrap ticket is issued. Furthermore, assume this lot isn’t counted before it’s
put away in the stockroom on Week 2, but is recorded as receipt of 50 units.
What will be the impact of these actions on factory operations?
[10 marks]
ANSWER
Without recording the scrap, the MRP record will appear as it does in the problem. If the
scrap had been reported, it would be:
Week
Gross Requirements
Scheduled Receipts
Projected Available Balance
Planned Order Release
1
25
35
2
30
35
15
10
3
5
4
15
10
-5
5
5
15
5
6
10
-5
Q = LFL, LT = 5, SS = 0
The 5 unit shortage may not be discovered until week 4. At that time, it will be necessary to
expedite the scheduled receipt of 15 from week 5 into week 4, and cover the deficiency in
week 6.
QUESTION 8
A Manufacturing site is supplied by 3 suppliers: A,B, and C. They ship to the site using a
trucking company that has a depot in the vicinity. The distances between these entities is as
follows:
To
From
A
B
C
Depot
Site
A
10
20
5
25
B
10
15
6
20
10
C
20
15
30
10
Depot
5
6
30
Site
25
20
10
20
20
SULIT
(BMFP 4513)
SULIT
a) Assume that when A wishes to ship to the site, a truck comes from the depot. Then after
loading, they go to the site and returns to the depot. The same pattern is repeated from
shipment from B to C.
Find the total traveled to bring lots from all three suppliers to the site?
[5 marks]
b) Determine the percentage saving in travel time if the truck picks up all lots in one pass,
travelling from Depot to A , then to B, then to C, then to Site, and back to Depot?
[5 marks]
ANSWER
a.
Depot-A-site-return =
Depot-B-site-return =
Depot-C-site-return =
Total = 156
5+25+20
6+20+20
10+30+20
=50
=46
=60
b.
Depot-A-B-C-site-return = 5+10+15+30+20 =60
Savings =[156 - (156-60)]/156=38.46%
QUESTION 9
There are options for shipping $ 100,000 of machine parts from Tanjung Perak to Klang
port in Malaysia as follows:
 By using a ship that will take 30 days at a cost of $ 3,800
 By using truck from Banjarnegara to Tanjung Periuk and then ship to Klang at a total
cost of $ 4,800. This option will take only 20 days.
You are paid via a letter of credit the days parts arrive. Your holding cost is estimated at
30% of the value per year. {Note: 1 year = 365 days}
a) Determine which option is more economical
[5 Marks]
b) If you have a third option where the costs is only $ 4,000 and takes 25 days, what is your
most economical plan?
[5 Marks]
ANSWER
a) Daily holding cost
= (Annual holding cost  Cost)/Days in year
11
SULIT
(BMFP 4513)
SULIT
= (30 %  $100,000)/365 = $82.20.
Difference in cost per day between shipping options
= ($4,800 – $3,800)/10 days = $100.
Since the daily holding cost ($82.20) is less than the daily cost of faster shipping with
option b ($100), use the slower shipping, option a.
b) Difference in cost per day between shipping options = ($4,000 – $3,800)/10 days = $20.
Since the daily holding cost ($82.20) is more than the daily cost of faster shipping ($20),
use the faster shipping, option a.
12
SULIT
(BMFP 4513)
SULIT
PART B
ANSWER ONE OF THE QUESTION ONLY
QUESTION 10
Qlic-Qlic Instruments, The Bandoengers producer of portable ‘korek kuping’ unit and other
medical products, develops a 4 –month aggregate plan. Demand and capacity (in units) are
forecast as follows:
Capacity Source
LABOR
Regular Time
Overtime
SUBCONTRACT
DEMAND
Month -1
Month-2
Month-3
Month-4
235
20
12
225
255
24
15
294
290
26
15
321
300
24
17
301
The cost of producing each ‘korek kuping’ unit is RM 985 on regular time, RM 1,310 on
overtime, and RM 1500 on a subcontract. Inventory carrying cost is RM 100 per unit per
month. There is to be no beginning or ending inventory in stock and backorders are not
permitted.
Set up a production plan that minimizes cost using the transportation method.
[15 Marks]
ANSWER
Total cost
= RM 1,186,810
13
SULIT
(BMFP 4513)
SULIT
QUESTION 11
Buih Soda, Inc., has a new ‘tarik’ drink for which it has high hopes. Encik Tareq, the
production planner, has assembled the following cost data and demand forecast:
Quarter
Forecast
1
2
3
4
1,800
1,100
1,600
900
Cost / Other data
Previous quarter’s output
Beginning Inventory
Stockout Cost
Inventory Holding Cost
Hiring Employees
Terminating Employees
Subcontracting Cost
Unit Cost on regular time
Overtime Cost
Capacity in regular time
1,300 cases
0 cases
RM 150
RM 40 per case at end of quarter
RM 40 per case
RM 80 per case
RM 60 per case
RM 30 per case
RM 15 extra per case
1,800 cases per quarter
Encik Tareq job is to develop aggregate plan. The three initial options he wants to evaluate
are:
• Plan A : A chase strategy that hires and fires personnel as necessary to meet the
forecast.
• Plan B : A level strategy
• Plan C : A level strategy that produces 1,200 cases per quarter and meets the
forecasted demand with inventory and subcontracting
Evaluate which strategy are the lowest plan between Plan A, B, and C
[15 marks]
14
SULIT
(BMFP 4513)
SULIT
ANSWER
•
Plan A: Chase plan
Period
Demand
Quarter 1
Quarter 2
Quarter 3
Quarter 4
Total
Cost
1,800
1,100
1,600
900
5,400
Total Cost:
•
Reg. Time
Production
Hiring
(Increase)
Change
1,800
1,100
1,600
900
5,400
RM162,000
500
–700
500
–700
Layoffs
(Decrease)
500
0
500
0
1,000
0
700
0
700
1,400
RM112,000
RM40,000
RM 314,000
Plan B: Level Strategy of 1,350 cases
Period
Quarter 1
Quarter 2
Quarter 3
Quarter 4
Total
Cost
Total Cost:
Forecast
1,800
1,100
1,600
900
5,400
Reg. Time
Production
1,350
1,350
1,350
1,350
5,400
RM162,000
Inventory
Holding
–450
–200
–450
0
0
0
0
0
0
RM0
Shortage
Change
450
200
450
0
1,100
RM165,000
Hiring
(Increase)
50
0
0
0
Layoffs
(Decrease)
50
0
0
0
50
RM2,000
0
0
0
0
0
RM0
RM329,000
An alternative way of viewing this problem assigns the same costs to regular time
production and to hiring (i.e., $162,000 and $2,000) but places holding cost at
$28,000 and shortage cost at $67,500. Total cost is then $259,500.
•
Plan C: Level Strategy at 1200, plus subcontracting:
Period
Forecast
Quarter 1
1,800
Quarter 2
1,100
Quarter 3
1,600
Quarter 4
900
Total
5,400
Cost
Total Cost: RM222,000
Reg. Time
Production
1,200
1,200
1,200
1,200
4,800
RM144,000
Overtime
Production
Subcontract
Production
600
300
0
RM0
900
RM54,000
Inventory Holding Change
0
100
0
300
0
–100
100
0
0
0
300
0
400
RM16,000
Hiring
(Increase)
Layoffs
(Decrease)
0
0
0
0
0
RM0
100
0
0
0
100
RM8,000
 Plan C, because it is not only the lowest cost, but has the added advantage of providing
steady employment for the employees after the initial first quarter layoff.
15
SULIT