ANSWER THE FOLLOWING QUESTIONS IN ESSAY FORM:

63. Symbols are often used on Gantt charts so actual progress can be monitored and compared with planned progress. Draw four commonly used symbols and explain their meaning.

64. Name the two network models that were the foundation of the various network models used today.

65. Discuss the purpose of a bill of materials

66. According to Douglas McGregor, what caused the average worker to behave a certain way in the work environment?

67. What are the advantages in developing a flowchart for resources?

68. Who was probably the original designer of the flow process chart?

69. Name five commonly used symbols for designating activities in a flow process chart.

70. Discuss the reasons demand management is conducted by organizations

71. Name three external factors affecting demand.

72. Name three internal factors affecting demand.

73. What is the difference between qualitative and quantitative demand forecasting?

74. Name three techniques for qualitative forecasting.

ANSWER THE FOLLOWING QUESTIONS BY SHOWING ALL YOUR WORK OR STEPS. ALSO REMEMBER TO SHOW AND EXPLAIN HOW YOU ARRIVE AT YOUR ANSWERS.

75. A supervisor needs to produce metal nameplates for bicycles. Two machines are available. The first requires a single die that costs $600. The plates will take 3 minutes each to produce at a total cost of $60 an hour. The second machine requires no initial expense but takes 6 minutes to produce at a total cost of $60 an hour. Calculate the break- even point.

76. The chart below shows last year’s sales data on widgets adjusted for the number of sale days in the month. Believing there is no seasonal variation, the company has used the previous month’s sales as forecasting data. On the first day of each month, the demand manager compiles last month’s sales figures and forecast sales for the new month.
a. What would the October sales forecast have been using a four-month moving average?

b. What would the November sales forecast have been using a four-month moving average?

c. What would the October sales forecast have been using a four-month weighting scale of 0.40, 0.30, 0.20, and 0.10?

d. Using exponential smoothing with a (+0.40), what would the sales forecast have been for October if the September forecast had b en 380.

e. What would the November forecast have been using exponential smoothing?

MONTH SALES MONTH SALES
January 360 July 378
February 360 August 375
March 355 September 385
April 365 October 390
May 375 November 380
June 370 December 370

77. A manufacturer of entertainment centers use the completion of new homes as part of their demand forecast. They consider that for every nine new homes that cost over 300,000 in the city, they make one sale. For every 15 new homes that cost over $150,000 but less than $300,000 in the city, they make one sale. Their projected demand for the future period, before they consider home sales, is for fourteen entertainment centers. They now receive home figures of seventy-two new homes of over $300,000 and 105 new homes of $150,000-$300,000. What should their new forecast be?

78. A printing company receives an order for 15,000 printed pamphlets. Either of two methods can be used to make the pamphlets. Method A requires 2 hours of preparation time. Method B requires 30 minutes of preparation time. Method A will produce copies at a cost of $5 per hundred for the 1,000, $4 per hundred for the next 1,000, and $3.50 per hundred for additional copies. Method B will produce copies at a cost of $7 per hundred for the first 1,000, $5 per hundred for the first 1,000, $5 per hundred for the second 1,000, and $4 per hundred for additional copies. Preparation time is charged at a rate of $40 an hour. Draw a graph of the costs. Read from the graph:

a. Number of copies at which the costs of the two methods are equal.

b. Cost to produce 5,000 copies using Method A.

c. Cost to produce 5,000 copies using Method B.

d. Method of choice if 1,000 pamphlets are ordered.

79. Product A is assembled from the three subassemblies B, C, D, and component E. Subassembly B is assembled from the three assemblies F, G, and H. Subassembly C is assembled from components J and K and subassembly L. Subassembly D is assembled from component M and subassembly N.

• Subassembly F is assembled from P-Q-R
• Subassembly G is assembled from S-T
• Subassembly H is assembled from W-X
• Subassembly L is assembled from Y-Z
• Subassembly N is assembled from W-aa
• Subassembly T is assembled from Y-W-bb
Now consider the following:
• It takes four days to produce or assemble B, D, F, L, and W.
• It takes four days to produce or assemble A, E, G, H, K, and N.
• It takes four days to produce or assemble C, J, M, Q, S, and T.
• It takes four days to produce or assemble P, R, X, Y, Z, aa, and bb.
a. Design a product structure tree to show how parts come together for completion of the product.

b. Calculate the earliest time to complete the work if all parts are to be produced.

c. Calculate the time needed for complete if the production of J, E, and T has been under-estimated by four days, three days, and one day, respectively.

d. Assume all parts except A, E, F, Z, Y, and N are held in inventory. How long will it take to produce the product? Explain your answer.

e. Assume all parts except A, B, H, L, Q, and N are held in inventory. How long will it take to produce the product? Explain your answer.

f. Assume no inventory of subassemblies or components is held. Construct a Gantt chart showing the last possible starting and finishing time for all work to ensure that completion of the final product is not delayed.

80. The ABC Company is looking ahead to next week’s production. The plant will operate for 45 hours. Three jobs are scheduled for the operation at a workstation. The first will utilize the workstation 30% of the time; the second will utilize the workstation 25% of the time. The third job has not had the utilization time calculated, but it will take two hours to set up the workstation and six hours to complete the operation. A fourth job is received, and it will take three hours to set up and seven hours to complete.
a. Calculate whether the fourth job can be completed during the week. Explain your answer.

b. What is the total utilization rate, including the fourth job? Explain your answer.
81. A company needs to produce widgets. Two machines are able to make the widgets. Machine A costs $10.00 to set up to begin production. Machine B cost $50.00 to set up. Machine A can make widgets at a cost of $2.00 each; Machine B can make widgets at a cost of $1.50 each. Machine A is stopped every time it has made 15 widgets for maintenance. This costs $5.

a. Prepare a table or chart in Microsoft Word to compare costs.

b. Using the table or chart, identify the break-even point.

c. Determine the least costly method and the cost to produce 40 widgets.

d. Determine the least costly method and the cost to produce 10 widgets.

82. The XYZ Company is planning to make widgets. It costs $112.00 to set up machine A and then the widgets can be produced at a cost of $0.25 apiece. It costs $30.00 to set up machine B and then the widgets can be produced at a cost of $0.35 apiece. When should machine A be used? Explain?

83. Mary, Davies, or Davies’ Ceramics, believes the company’s sales are dependent on construction of new home in the area. This is because all her customers discuss the new homes they are building when they purchase material. If Mary could identify the relationship between home construction and company sales, then she may be able to anticipate demand and better serve her customers. New home construction for the past 12 months is listed below, alone with sale for each month. Explain any relationship between the two.
HOME CONSTRUCTION SALES HOME CONSTRUCTION SALES
(1) 215 90 (7) 265 104
(2) 225 86 (8) 255 108
(3) 240 86 (9) 245 106
(4) 250 90 (10) 230 102
(5) 260 96 (11) 225 98
(6) 270 100 (12) 215 92
84. In Question 81, Machine A works flawlessly, almost never producing scrap (possibly because of regular maintenance). However, Machine B produces scrap regularly. The operation of Machine B projects that in a batch of between 40-60 widgets, there is a 30% change no widgets will be scrapped, a 50% change of producing one scrap part (therefore requiring one extra to be made), and a 20% chance of producing two scrap parts (requiring two extra to be made). The cost of a scrap widget, because of the accumulated time and material, is $14.00. What machine should the company use to produce 40, 50, and 60 widgets?

85. Below are the numbers of a certain product used by Swansea Bay Manufacturing during the last 10 weeks: 58, 55, 51, 56, 48, 57, 47, 56, 51, and 61. Use the numbers to answer the following:

a. Calculate the arithmetic mean
b. Calculate the median
c. Calculate the mode
d. Calculate the range
e. Calculate the mean absolute deviation
f. Calculate the standard deviation

86. Product A is assembled from 4 components. These components are B, C, D, and E. Component B is assembled from 3 parts (F, G, and H) Component E is assembled from parts X, Y and Z. All assembles (A, C, and E) take two (2) periods to assemble component B and parts F, G, and Z take six (6) periods each to produce. All other components take four (4) periods to produce.
a. Design a product structure tree that depicts the relationships as listed above.
b. Design a Gantt chart depicting the earliest beginning and ending for the production of all the work.
c. Design a bill of materials that shows the relationship of where the parts fit.

87. A group of five workstations produces a product. Answer the following questions using the input, output, and capability per hour data in the chart below.

a. Calculate the number of units waiting at Workstations 2, 3, 4, and 5 after eight hours. Explain your answers.

b. Which machine is the bottle-neck? Explain your answer.

1 2 3 4 5
INPUT 60 60 40 40 38
CAPABILITY 60 40 60 38 60
OUTPUT 60 40 40 38 38

88. Below are the numbers of a certain product used by Swansea Bay Manufacturing during the last 20 weeks.

57 47 50 49 47
54 56 58 53 54
50 46 52 51 49
55 55 45 58 54

Use the numbers to answer the following:

a. Calculate the arithmetic mean or average

b. Calculate the median

c. Calculate the mode

d. Calculate the mean absolute deviation (MAD)

e. Calculate the variance

f. Calculate the standard deviation (x)

ANSWER THE FOLLOWING QUESTIONS IN ESSAY FORM: 63. Symbols are of...