Examination Paper
1
IIBM Institute of Business Management
IIBM Institute of Business Management
Examination Paper MM.100
Material Management
..
1. Season Index =
a. =Period average demand / deseasonalized demand
b. =deseasonalized demand / period average demand
c. =Period average demand / average demand for all periods
d. = average demand for all periods / period average demand
2. Poke-yoke was first introduce by
a. Edger Schein of America
b. Lawrence D. Miles of U.S.A
c. Shigeo Shingo of Japan
d. None of the above
3. Utilization is the consolidation of several units into large units, called
a. Units loads
b. Unit system
c. Unit wait
d. None of the above
...
10. Which file contains a record for each part manufactured
a. The routing file
b. The product structure file
c. Item master file
d. Work center master file
Part Two:
1. Write a note on “ERP” (Enterprise Resource Planning).
2. What do you understand by ‘Operation Overloading’?
3. What is “Two –Bin System”.
4. Explain the “Just in time” philosophy.
....
1. Calculate the available to promise (ATP) using the following data. There are 100 units on hand.
Week 1 2 3 4 5 6
Customer Orders 70 70 20 40 10
MPS 100 100 100
ATP
2. Given the following data, can an order for 30 more units delivery in week 5 be accepted? If not,
what do you suggest can be done?
Week 1 2 3 4
Forecast 80 80 80 70
Customer Orders 100 90 50 40
Projected Available
Balance
140
MPS
3. Given the following parents and components, construct a product tree. Figures in parentheses
show the quantities per item. How many Gs are needed to make one A?
Parent A B C E
Component B(2) E(2) G(2) G(4)
C(4) F(1) F(3)
D(4) H(2)
4. An order for 100 of a product is processed on operations A and operations B. the setup time on A
is 50 minutes, and the run time per piece is 9 minutes. The setup time on B is 30 minutes, and the
run time is 6 minutes per piece. It takes 20 minutes to move a lot between A and B. since this is a
rush order, it is given top priority (president’s edict) and is run as soon as it arrives at either
workstation.
It is decided to overlap the two operations and to split the lot of 100 into two lots of 60 and 40.
When the first lot is finished on operation A, it is moved to operation B where it is set up and run.
Meanwhile, operation A completes the balance of the 100 units (40) and sends the units over to
operation B. These 40 units should arrive as operation B is completing the first batch of 60; thus,
operation B can continue without interruption until all 100 are completed.
a. Calculate the total manufacturing lead time for operation A and for B without overlapping.
Examination Paper
4
IIBM Institute of Business Management
b. Calculate the manufacturing lead time if the operations are overlapped. How much time is
saved?
...
1. Suppose a manufacturer makes wagons composed of a box body, a handle assembly, and two
wheel assemblies. Demand for the wagons is 500 a week. The wheel assembly capacity is 1200
sets a week, the handle assembly capacity is 450 a week, and final assembly can produce 550
wagons a week.
a. What is the capacity of the factory?
b. What limits the throughput of the factory?
c. How many wheel assemblies should be made each week?
d. What is the utilization of the wheel assembly operation?
e. What happens if the wheel assembly utilization is increased to 100?
2. If the annual cost of goods sold is $12 million and the average inventory is $2.5 million:
a. What is the inventory turns ratio?
b. What would be the reduction in average inventory if, through better materials management,
inventory turns were increased to 10 times per year?
c. If the cost of carrying inventory is 20% of the average inventory, what is the annual savings?
3. Suppose management stated that it could tolerate only one stock out per year for a specific item.
For this particular item, the annual demand is 52,000 units, it is ordered in quantities of 2600, and
the standard deviation of demand during the lead time is 100 units. The lead time is one week.
Calculate:
a. Number of orders per year.
b. Service level.
c. Safety stock.
d. Order point.
4. Delivery of goods from a supplier is in transit for ten days. If the annual demand is 4200 units,
what is the average annual inventory in transit?
END OF SECTION C
----------------------------------------------------------- ***--------------------------------------------------------
1
IIBM Institute of Business Management
IIBM Institute of Business Management
Examination Paper MM.100
Material Management
..
1. Season Index =
a. =Period average demand / deseasonalized demand
b. =deseasonalized demand / period average demand
c. =Period average demand / average demand for all periods
d. = average demand for all periods / period average demand
2. Poke-yoke was first introduce by
a. Edger Schein of America
b. Lawrence D. Miles of U.S.A
c. Shigeo Shingo of Japan
d. None of the above
3. Utilization is the consolidation of several units into large units, called
a. Units loads
b. Unit system
c. Unit wait
d. None of the above
...
10. Which file contains a record for each part manufactured
a. The routing file
b. The product structure file
c. Item master file
d. Work center master file
Part Two:
1. Write a note on “ERP” (Enterprise Resource Planning).
2. What do you understand by ‘Operation Overloading’?
3. What is “Two –Bin System”.
4. Explain the “Just in time” philosophy.
....
1. Calculate the available to promise (ATP) using the following data. There are 100 units on hand.
Week 1 2 3 4 5 6
Customer Orders 70 70 20 40 10
MPS 100 100 100
ATP
2. Given the following data, can an order for 30 more units delivery in week 5 be accepted? If not,
what do you suggest can be done?
Week 1 2 3 4
Forecast 80 80 80 70
Customer Orders 100 90 50 40
Projected Available
Balance
140
MPS
3. Given the following parents and components, construct a product tree. Figures in parentheses
show the quantities per item. How many Gs are needed to make one A?
Parent A B C E
Component B(2) E(2) G(2) G(4)
C(4) F(1) F(3)
D(4) H(2)
4. An order for 100 of a product is processed on operations A and operations B. the setup time on A
is 50 minutes, and the run time per piece is 9 minutes. The setup time on B is 30 minutes, and the
run time is 6 minutes per piece. It takes 20 minutes to move a lot between A and B. since this is a
rush order, it is given top priority (president’s edict) and is run as soon as it arrives at either
workstation.
It is decided to overlap the two operations and to split the lot of 100 into two lots of 60 and 40.
When the first lot is finished on operation A, it is moved to operation B where it is set up and run.
Meanwhile, operation A completes the balance of the 100 units (40) and sends the units over to
operation B. These 40 units should arrive as operation B is completing the first batch of 60; thus,
operation B can continue without interruption until all 100 are completed.
a. Calculate the total manufacturing lead time for operation A and for B without overlapping.
Examination Paper
4
IIBM Institute of Business Management
b. Calculate the manufacturing lead time if the operations are overlapped. How much time is
saved?
...
1. Suppose a manufacturer makes wagons composed of a box body, a handle assembly, and two
wheel assemblies. Demand for the wagons is 500 a week. The wheel assembly capacity is 1200
sets a week, the handle assembly capacity is 450 a week, and final assembly can produce 550
wagons a week.
a. What is the capacity of the factory?
b. What limits the throughput of the factory?
c. How many wheel assemblies should be made each week?
d. What is the utilization of the wheel assembly operation?
e. What happens if the wheel assembly utilization is increased to 100?
2. If the annual cost of goods sold is $12 million and the average inventory is $2.5 million:
a. What is the inventory turns ratio?
b. What would be the reduction in average inventory if, through better materials management,
inventory turns were increased to 10 times per year?
c. If the cost of carrying inventory is 20% of the average inventory, what is the annual savings?
3. Suppose management stated that it could tolerate only one stock out per year for a specific item.
For this particular item, the annual demand is 52,000 units, it is ordered in quantities of 2600, and
the standard deviation of demand during the lead time is 100 units. The lead time is one week.
Calculate:
a. Number of orders per year.
b. Service level.
c. Safety stock.
d. Order point.
4. Delivery of goods from a supplier is in transit for ten days. If the annual demand is 4200 units,
what is the average annual inventory in transit?
END OF SECTION C
----------------------------------------------------------- ***--------------------------------------------------------
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