1. Instructions: Complete the MPS table
2. Instructions: Find the Reorder Point for product X & show your calculations.
3. Instructions: Complete all empty cells in the MRP tables below for all components shown in the product tree for Product Z (highlighted in green at right).
Assume that lead-time is strictly followed, and you are not able to get or build material inside of lead-time.
4. Instructions:
1) Sort Job Numbers in table above in the correct order based on the Priority Rule = Earliest Delivery Date
2) Complete Job Number Mapping in columns J-AJ by showing correct order of jobs and duration of each job
3) Complete cells highlighted in green in the table (E-H) above
For the following questions, calculate the answer and enter that in column C (Show your calculations):
3) Make Span =
4) Job Flow Time =
5) Average # Jobs in System =
5. Instructions:
1) Sort Job Numbers in table above in the correct order based on the Priority Rule = Earliest Delivery Date
2) Complete Job Number Mapping in columns J-AJ by showing correct order of jobs and duration of each job
3) Complete cells highlighted in green in the table (E-H) above
For the following questions, enter the answer in column C:
3) Make Span =
4) Job Flow Time =
5) Average # Jobs in System =
6) Explain what type of company or what scenario would want to use EDD instead of CR as the priority rule and why.
6. Instructions:
1) Replace the "?" above in cells D9 and D10 with the correct number.
2) Complete table for products Z-W (E9:W11).
3) Answer the following questions. Put answer in the green cells in column E.
What is the Minimum Batch MPS?
How often need to repeat the Minimum Batch MPS per day?
7. Answer each of the following questions by placing an "X" next to the best response, based on your reading of "Decoding the DNA of the Toyota Production System".
0. example: How many dogs does Prof. Lowell have?
A) 1
X B) 2
C) 3
D) Zero, she has cats.
1. Products and services follow simple, specified paths. This describes Rule #_____.
A) 1
B) 2
C) 3
D) 4
2. Rule 4 says improvements are made using trial and error, under guidance of a teacher, and at the lowest possible organization level.
A) True
B) False
3. _______________________ was an original architect of the Toyota Production System.
A) Fujio Cho
B) Hajime Ohba
C) Taiichi Ohno
D) Steven Spear
4. Name three circumstances that may require a company to hold inventory.
A) unpredictable downtime, unknown yields and long set-up times
B) volatility of product mix, known customer demands, and 100% yield
C) small batch sizes, immediate delivery, and defect free
D) none of the above
5. According to the authors of "Decoding the DNA of the Toyota Production System", why has it been difficult for other companies to duplicate Toyota's success?
A) Other companies don't realize activities, connections and flows are rigid with no flexibility
B) Toyota is very secretive about what goes into the Toyota Production System
C) Other companies confuse the tools and practices of the Toyota Production System as being the system itself
D) All of the above
6. The Toyota Production System creates a community of ________________.
A) Students
B) Teachers
C) Learners
D) Scientists
7. A set of instructions with details on how to complete a task and how long it should take is an example of ________________________.
A) Rule 1
B) Rule 2
C) Rule 3
D) Rule 4
8. Kanban cards and andon cords establish links between customers and suppliers. This is a concept of ______________________.
A) Rule 1
B) Rule 2
C) Rule 3
D) Rule 4
9. How does Toyota teach new employees about the rules of the Toyota Production System?
A) Rigorous training classes
B) Sends them to the OMCD center
C) Gives new employees a manual
D) Asks questions (socratic method)
8. Instructions:
1) Calculate EOQ based on the following inputs, using formula shown at right:
D = 65 units per week
S = set-up cost
H = holding cost
2) Fill in the table above (Net Requirements, Projected on-hand, Planned Order Receipts) using your calculated EOQ as the Lot Size
Note: Projected On-Hand = amount of material left in inventory at the end of the period.
3) Determine Total Cost for this lot size strategy and enter that in the Total Cost cell in L9.
9. Instructions:
1) Determine Net Requirements, then determine Planned Order Receipts based on Least Total Cost lot size strategy.
- Use tab called "LTC-side" to determine how to group requirements
2) Fill in the table above (Net Requirements, Projected on-hand, Planned Order Receipts) using the lot size groups that you determine for the Least Total Cost lot size strategy.
Note: Projected On-Hand = amount of material left in inventory at the end of the period.
3) Determine Total Cost for this lot size strategy and enter that in the Total Cost cell in L9.
10. Instructions:
1) Fill in the table above (Net Requirements, Projected on-hand, Planned Order Receipts) using "Lot-for-Lot" lot size strategy.
Note: Projected On-Hand = amount of material left in inventory at the end of the period.
2) Determine Total Cost for this lot size strategy and enter that in the Total Cost cell in L9.
Instructions: Put an "X" in the yellow shaded area next to your answer.
Which Lot Size strategy has the Lowest Cost?
A) EOQ
B) LTC
C) Lot-4-Lot
Attachment:- Planning.rar