BILLS OF MATERIAL

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Definition

Define the term bill of material as it applies to production control.

Data collection

Select a software program for storing, analyzing, and updating bills of material.

Application

Store bills of material using a computer.

Analyze bills of material using a computer

Update bills of material using a computer.

MRP II LOGIC

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Closed-loop MRP

Diagram a closed-loop MRP II.

Manual scheduling

Describe the manual scheduling system and the forms it requires for managing information.

Computer system

Discuss the advantages of a computerized MRP II system.

Hardware

Select a computer hardware system which answers specific manufacturing resources planning requirements.

Software

Select a computer software program which will satisfy a given MRP II production requirement.

INVENTORY PLANNING

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Manual records

Contrast the information recorded on an identifying record with that of a controlling record.

Automatic identification systems

Discuss the use of bar code to identify items.

Describe the factors involved in choosing a code and labeling system.

Design an item label with bar code.

Guidelines

Locate and modify, if needed, a computer software program for inventory control.

Develop guidelines for the application of a computer software program for inventory control.

MASTER PRODUCTION  SCHEDULE

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Economic order quantities

Define the term economic order quantity (EOQ).

Contrast batch and continuous production as applied to an EOQ of production control.

Costs

Discuss the items which are labeled carrying costs associated with developing an EOQ.

Define ordering costs.

Define order point.

Compare the terms inventory usage rate and lead time as applied to developing an MPS.

Contrast the terms safety stock and stockout as applied to developing an MPS.

EOQ model

Graph a typical inventory usage pattern.

Indicate the EOQ on the graph.

Find the EOQ for a given product.

Guidelines

Locate and modify, if needed, a computer software program for developing a master production schedule.

Write the guidelines for application of a computer software program used for developing a master production schedule.

PLANNING POLICIES

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Customer service

Develop a policy which describes the objectives of customer service.

Inventory level

Develop a policy that describes planning inventory level which meets the objectives of the customer service policy.

STATISTICAL QUALITY CONTROL (SQC)

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Traditional approach

Describe the function of a traditional quality control unit within the manufacturing process.

Worker centered

Discuss the workers' responsibilities for maintaining product quality when the "quality at the source" method is used.

QUALITY AT THE SOURCE

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Process-controlled quality

Establish the requirements for a manufacturing process which will produce 100 percent quality.

Instrumentation

Select measuring equipment which will automatically stop a process when the process is out of tolerance.

Feedback

Develop a feedback system which will identify a process defect and the point of origin.

Kanban

Describe how the kanban system is used to keep production inventories at optimum levels.

Application

Develop an MRP II system for a process using the methods associated with the zero inventory/just-in-time and quality at the source concepts.