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APICS Exam 02 -- Master Planning of Resources: Session 1
Master Planning of Resources
160
Business
Professional
09/10/2013

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Cards

Term
MPC
Definition
Manufacturing planning and control
Term
MPR
Definition
Master planning of resources
Term
ERP
Definition
Enterprise resource planning
Term
What are the objectives of the manufacturing and service industry from the Customer perspective? ("The Right..." x6)
Definition
The objectives of the ____ industry from the customer perspective are:
 
The right...
  1. Quality
  2. Quantity
  3. Place
  4. Price
  5. Products (right goods and services)
  6. Time

"2Q / 3P / 1T"

Term
What are the objectives of the manufacturing and service industry from the Supplier perspective?
Definition

The objectives of the manufacturing and service industry from the ____ perspective are:

  • High levels of customer service
  • Efficient use of resources
  • Low inventory investment

"3-legged stool"

Term
What are the 3 conflicts of Supplier's objectives (3-legged stool)
Definition
The three objectives of customer service, efficient use of resources (machines, labor, etc), and low inventory investments are all in conflict with each other
Term
Explain the Customer Objective "the right goods and services"
Definition
Designing and making products that meet or exceed customer expectations. Requires identifying and selecting products that customers want to buy
Term
Explain the Customer Objective "the right quality"
Definition

Meeting the two aspects of quality:

  1. Conformance
  2. specification
Term
The 2 aspects of quality are ____ and ____
Definition
Conformance and specifications are the 2 aspects of ____
Term
Conformance (quality)
Definition
Addresses the requirement that products meet regulatory standards (EX: pharmaceuticals)
Term
Specification (quality)
Definition
Relates to the need to design, manufacture, and deliver products that provide the requisite functionality, aesthetics, and value that customers want
Term
Explain the Customer Objective "the right quantity"
Definition
Materials in the right quantity are available for delivery
Term
Explain the Customer Objective "the right time"
Definition
Meeting the on-time delivery requirements of customers
Term
What are the four performance objectives in meeting on-time delivery?
Definition

The four performance objectives in meeting ____ are:

  1. Speed
  2. Quality
  3. Flexibility
  4. Dependability

of production and distribution requirements.

Term
Explain the Customer Objective "the right place"
Definition
Depends on a company's sales channels and distribution channels
Term
The 2 components of The Right Place are ____ and ____
Definition
Sales channels and distribution channels are the 2 components of The Right ____
Term
Sales channels
Definition
The internal functions and external parties that support marketing, promotion, and sale of products to customers
Term
Distribution channels
Definition
Determine the physical flow of products to customers at required delivery points
Term
Explain the Customer Objective "the right price"
Definition
The four generic performance objectives (speed, quality, flexibility, and dependability) are related to cost, enabling companies to meet customer requirements for the right ____
Term
What are the five performance objectives in meeting on-time delivery requirements?
Definition

The 5 performance objectives in meeting ____ are:

  1. Speed
  2. Quality
  3. Flexibility
  4. Dependability
  5. Cost
Term
What are the 4 key issues that manufacturing planning addresses?
Definition

The 4 key issues that ____ addresses are:

  1. Flow or product (RM, WIP, and FG) to customers
  2. Delivery lead time customers are willing to accept
  3. Use of production resources
  4. Appropriate relationships with other organizations in the supply chain (outsourcing, partnerships, vertical integration, etc)
Term
Through S&OP and master scheduling (MS), manufacturing planning & control (MPC) plays a key role in balancing what 3 conflicting objectives?
Definition

Through S&OP and master scheduling (MS), ____ balances the following 3 conflicting objectives:

  1. Customer service levels
  2. Inventory investment
  3. Costs of production
Term
What are some examples of customer service level objectives? (3-legged stool example)
Definition

Some examples of ____ objectives are:

  • Acceptable lead times
  • Shipped complete, arrives in time
  • Right quality and place
Term
What are some examples of inventory investment objectives? (3-legged stool example)
Definition

Some examples of ____ objectives are:

  • Low WIP
  • High turnover
  • Faster throughput
Term
What are some examples of costs of production objectives? (3-legged stool example)
Definition

Some examples of ____ objectives are:

  • Minimizing of set ups (reduce changeovers)
  • Longer production runs and high utilization
  • Low cost of materials
Term
What are 2 manufacturing practices that can be deployed to mitigate the inherent conflict amount the 3 conflicting objectives?
Definition
The deployment of lean and theory of constraints manufacturing practices mitigate ____
Term
What do lean and theory of constraints manufacturing processes do?
Definition
The ____ and ____ manufacturing processes use a systems approach to acheiving the five generic performance objectives (speed, quality, dependability, flexibility, and cost) in order to fulfill customer demand in a cost-efficient manner
Term
A key role for MPC (manufacturing planning & control) is balancing ____ and ____
Definition
A key role for ____ is balancing supply and demand
Term
What are some components of demand management?
Definition

Some components of ____ management are:

  • Demand forecasts
  • Order managements
  • Customer relationship management (CRM)
Term
CRM
Definition
Customer relationship management
Term
What are some components of supply management?
Definition

Some components of ____ management are:

  • Efficiency of production and distribution planning
  • Availability of production resources
Term
What are the sources of imbalance between supply and demand?
Definition

Sources of imbalance between ____ and ____ are:

  • Failure to understand and forecast demand accurately
  • Long order-fulfillment lead times through large-batch production, which increase reliance on forecasts rathere than more reliable customer orders in planning production
  • Lack of process flexibility to respond to changes in customer orders or market conditions
Term
What are some problems that come from an imbalance between supply and demand?
Definition

Some problems that come from an imbalance between ____ and ____ are:

  • Poor levels of customer service
  • Buildup of inventory from large-batch production
  • Weakened competitive position
Term
Strategic planning
Definition
Addresses long-term objectives relating to products, customers, and markets
Term
Business planning
Definition
Long-term in focus, denominated in monetary terms
Term
What is the bridge from strategic to tactical/cross-functional planning at the MRP level?
Definition
Business planning is the bridge from ____ to ____ planning at the MPR level
Term
What are the 3 planning activities associated with MPC
Definition

The 3 planning activities associated with ___ are:

  1. Master planning of resources (MPR) (Intermediate- to long-term)
  2. Detailed Scheduling and Planning (DSP) (near-term)
  3. Execution and Control of Operations (ECO) (near-term)
Term
DSP
Definition
Detailed scheduling and planning
Term
ECO
Definition
Execution and control of operations
Term
What are the 6 processes of Master planning of resources (MPR)?
Definition

The 6 processes of ____ are:

  1. Demand management
  2. Distribution planning
  3. S&OP
  4. Resource planning
  5. Master scheduling
  6. Rough-cut capacity planning (RCCP)
Term
S&OP
Definition
Sales & operation planning
Term
RCCP
Definition
Rough-cut capacity planning
Term
What are the 2 types of planning under Master planning of resources (MPR)?
Definition

The 2 types of planning under ___ are:

  1. Priority planning
  2. Capacity planning
Term
What are the 2 cross-functional tactical plans under priority planning?
Definition

The 2 cross-functional tactical plans under ____ are:

  1. S&OP
  2. Master scheduling
Term
What are the 2 cross-functional tactical plans under capacity planning?
Definition

The 2 cross-functional tactical plans under ____ are:

  1. Resource planning
  2. Rough-cut capacity planning (RCCP)
Term
What are the responsibilities of S&OP and resource planning?
Definition

The responsibilities of ____ and ____ are:

  • Processing inputs from the business plan, demand forecasts, production resource planning, and logistics resource requirements planning
  • Translating inputs into plans at the aggregate volume or product family level
  • Validating plans against required production and distribution resources
Term
What are the responsibilities of master scheduling and rough-cut capacity planning (RCCP)?
Definition

The responsibilities of ____ and ____ are:

  • Processing inputs on product volumes
  • Disaggregating product family volume data from the production plan into an MPS for individual end items
  • Validating the MPS against required production and distribution resources
Term
What are the responsibilities of demand management?
Definition

The responsibilities of ____ are:

  • Recognize demand for products through forecasts, customer order management, or order servicing
  • Provide input on demand for goods at the product family level to S&OP and end-item level for MS
Term
What is the relationship between priority planning and capacity planning?
Definition
____ plans don't get released until ____ planning determines available capacity to do so
Term
What are the two types of support to S&OP and Master Scheduling (MS) that distribution planning provides?
Definition

The two types of support to S&OP and MS that ____ planning provides are:

  1. Planning of inventory levels at stocking points based on demand
  2. Inputs on distribution resources necessary to support S&OP and MPS through "logistics resource requirement planning"
Term
MRP
Definition
Material requirements planning
Term
CRP
Definition
Capacity requirements planning
Term
What are the 2 processes of detailed scheduling and planning with a near-term planning horizon
Definition

The two process of ____ with a ____ planning horizon are:

  1. Material requirements planning
  2. Capacity requirements planning
Term
What is the objective of DSP (detailed scheduling and planning)?
Definition

The objective of ____ is to determine the required below resources to support the master production schedule for individual end items:

  1. Material capacity
  2. Labor capacity
  3. Equipment capacity
Term
What are the 5 things that material requirements planning (MRP) and Capacity requirements planning (CRP) determine?
Definition

The 5 things that ____ and ____ determine are:

  1. End item and component quantities needed to fulfill MPS
  2. When these items and quantities are needed
  3. How many are now in stock
  4. Which are on order
  5. Sufficiency of workers and equipment
Term
Another term for Execution and Control is ____
Definition
Another term for Production activity control (PAC) is ____
Term
DSP
Definition
Detailed scheduling and planning
Term
PAC
Definition
Production activity and control
Term
ECO
Definition
Execution and control
Term
What are the 3 objectives of production activity and control (PAC)?
Definition

The 3 objectives of ___ are:

  1. Prioritize and sequence work to be performed
  2. Executing plans, implementing factory floor controls, and reporting activity results
  3. Performance reporting and feedback (to adjust for shortages or overages in production)
Term
What is the history of MRP?
Definition
___ was revised every weekend, and was the first example of a non-human application of computers. It had the ability to explode and plan materials requirements for the master production schedule (MPS)
Term
What functions did MRP calculator (MRP) support?
Definition

The functions supported by ____ were:

  1. DSP (detailed capacity planning and detailed material planning)
Term
When was MRP Calculator active?
Definition
____ was active in the 1960s - 70s
Term
What did MRP II and MES help to do?
Definition
____ and ____ helped to "close the loop", providing feedback of what actually happened and inputting that back into the system
Term
When were MRP II and MES active?
Definition
____ were active in the 1970s - 80s
Term
What functions did MRP II and MES support?
Definition

The functions supported by ____ and ____ were:

  1. Master Planning of Resources (MPR) (demand management, S&OP, distribution planning, resource planning, and MPS
  2. Detailed scheduling and planning (DSP) (detailed capacity planning and detailed material planning)
  3. Execution and control of operations (ECO) (priorities and sequencing, controls and reporting, PAC, and supplier systems
Term
ERP
Definition
Enterprise resource planning
Term
What was the emphasis of enterprise resource planning (ERP)?
Definition
The emphasis of ____ was standardizing supply chain management practices among suppliers and customers across industries
Term
When was enterprise resource planning (ERP) active?
Definition
____ was active in the 1990s - 00s
Term
What functions did enterprise resource planning (ERP) support?
Definition

The functions supported by ____ were:

  1. MPR (demand management, S&OP, distribution planning, resource planning, and MPS
  2. DSP (detailed capacity planning and detailed material planning)
  3. ECO (priorities and sequencing, controls and reporting, PAC, and supplier systems
  4. Support systems (finance and accounting, CRM/SRM, sales and marketing, HR)
Term
Describe the volume variety curve structure
Definition
The ____ is the downward sloping curve with "number of parts" on the Y-axis and "rate of production" on the X-axis. Volume increases from left to right, and variety decreases from left to right.
Term
What are the 5 main process choices?
Definition

The 5 main ____ are:

  1. Project
  2. Job shop and batch
  3. Cellular
  4. Repetitive
  5. Flow
Term
What are the 5 elements of the volume variety curve, going from upper left to lower right of the curve?
Definition

The 5 elements of the ____ are:

  1. Project
  2. Job shop and batch
  3. Cellular
  4. Repetitive
  5. Flow
Term
What are 4 factors that help decide which process choice to use?
Definition

The 4 factors that help decide which ____ to use are:

  1. Nature of a product
  2. Complexity of its inputs (number of subparts)
  3. Variety and volume of outputs
  4. Rate of production
Term
What is the typical environment of a "project" process choice?
Definition
The typical environment of a____ process choice is engineered-to-order (ETO)
Term
sdWhat is the typical environment of a "job shop and batch" process choice?
Definition
The typical environment of a____ process choice is make-to-order (MTO)
Term
What is the typical environment of a "cellular" process choice?
Definition
The typical environment of a____ process choice is MTO or ATO
Term
What is the typical environment of a "repetitive" process choice?
Definition
The typical environment of a____ process choice is MTS or ATO
Term
What is the typical environment of a "flow" process choice?
Definition
The typical environment of a____ process choice is MTS, MTO, or ATO
Term
ETO
Definition
Engineer-to-order
Term
MTO
Definition
Make-to-order
Term
ATO
Definition
Assemble-to-order
Term
MTS
Definition
Make-to-stock
Term
Heijunka
Definition
Production leveling or smoothing, a technique to reduce muda
Term
Muda
Definition
Waste
Term
What are the 4 Vs that differentiate types of production organizations?
Definition

The 4 ____s that differentiate different types of ____ are:

  1. Volume
  2. Variety
  3. Variation
  4. Visibility
Term
Volume
Definition
How many products or services are made by the operation
Term
Variety
Definition
How many different types of products or services are made by the operation
Term
Variation
Definition
How much does the level of demand change over time
Term
Visibility
Definition
How much of the operation's internal working are 'exposed' to its customers
Term
What are the 4 driving forces (or market forces) to which MPC systems are susceptible?
Definition

The 4 ____ to which MPC systems are susceptible are:

  1. Increasing cost competition
  2. Influx of foreign competitors
  3. Expansion into foreign markets
  4. Outsourcing
Term
What does the business plan do?
Definition
The ____ begins with a statement of strategic objectives (based on the strategic plan) and then translates the strategic objectives into more quantifiable objectives and requirements that guide MPC
Term
What are some examples of "quantifiable" objectives and requirements of the business plan?
Definition

Some examples of "quantifiable" objectives and requirements of the ____ are:

  • Revenue growth assumptions by product family/product line
  • Long-lead-time facility, technology, and equipment requirements
  • Marketing, sales, and distribution channel strategy
  • Labor force requirements, acquisition, and development plans
  • nvestment and working capital requirements
  • Revenue, cost, budget, and cash flow projections
Term
What are the 3 subprocesses of demand management?
Definition

The 3 subprocesses of ____ are:

  1. Forecasting
  2. Order management
  3. CRM
Term
Forecasts
Definition
Estimates of customer demand
Term
What are the 2 types of forecasts?
Definition

The 2 types of ____ are:

  1. Quantitative
  2. Qualitative
Term
What is the level of forecast detail for S&OP?
Definition
The level of forecast detail for ____ is the overall market demand trends at the product family level
Term
What is the level of forecast detail for master scheduling?
Definition
The level of forecast detail for ____ is for the product mix at the individual end-item level as required by the MPS
Term
What is the level of forecast detail for distribution planning?
Definition
The level of forecast detail for ____ are for both product families and end-item/SKUs at inventory stocking locations (ISLs)
Term
ISL
Definition
Inventory stocking locations
Term
Order service
Definition
____ encompasses the receiving, entering, and process of orders from internal and external sources
Term
What are the 3 internal and external sources of orders?
Definition

The 3 internal and external sources of ____ are:

  1. Customers
  2. Distribution centers
  3. Interplant operations
Term
What are the 2 focuses of CRM?
Definition

The 2 focuses of ____are:

  1. Understanding and influencing customer needs and preferences
  2. Anticipating customer demand
Term
What inputs to demand do sales representatives provide?
Definition

Inputs to demand that ____ provide are:

  • Customers' long-term buying intentions
  • Short-term product-mix requirements
Term
What are the 3 things that can consumer capacity?
Definition

The 3 things that can consume ____ are:

  1. Orders
  2. Knowledge
  3. Forecast
Term
What is the forecast consumption curve?
Definition
The forecast consumption curve is the three elements that consume capacity: orders, knowledge, and forecast. Traditionally, the forecast is consumed by customer orders, and knowledge of impending orders can replace the forecast
Term
In terms of the forecast consumption curve, what does knowledge represent?
Definition
In terms of the forecast consumption curve, ____ represents orders that have a high degree of certainty of being received
Term
What are the 4 key characteristics that contrast the 4 major manufacturing environments?
Definition

The 4 key characteristics that contrast the ____ environments are:

  1. Inventory used to fulfill customer orders
  2. Information needed for SO&P
  3. Information needed for the MPS
  4. Planning and control
Term
Decoupling point
Definition
The point at which inventory necessary to begin fulfilling the customer order is in stock
Term
What is the decoupling point for ETO?
Definition
The decoupling point for ____ is knowledge
Term
What is the decoupling point for MTO?
Definition
The decoupling point for ____ is raw materials
Term
What is the decoupling point for ATO?
Definition
The decoupling point for ____ is components and subassemblies
Term
What is the decoupling point for MTS?
Definition
The decoupling point for ____ is finished goods inventory
Term
As you move from MTS to ETO, the information needed for S&OP becomes more ____
Definition
As you move from ____ to ____, the information needed for S&OP becomes more complex
Term
As you move from MTS to ETO, the end-item volumes become ____
Definition
As you move from ____ to ____, the end-item volumes become smaller
Term
In terms of planning and control, what is the focus of MTS?
Definition
In terms of planning and control, the focus of ____ is on balancing inventory, cost, and customer service objectives
Term
In terms of planning and control, what is the focus of ATO?
Definition
In terms of planning and control, the focus of ____ is meeting delivery dates
Term
In terms of planning and control, what is the focus of MTO?
Definition
In terms of planning and control, the focus of ____ is providing and managing capacity needed for production
Term
In terms of planning and control, what is the focus of ETO?
Definition
In terms of planning and control, the focus of ____ is providing and managing capacity needed for production
Term

What is the A-X-V concept for decoupling points?

 

Definition

The _-_-_ concept for decoupling points is that you stock at the thinnest point

 

 

FG   FG   FG

A  X  V

RM    RM    RM

Term
In the A-X-V concept for decoupling points, which manufacturing environment does A represent?
Definition
In the A-X-V concept for decoupling points, the manufacturing environment represented by ____ is MTS
Term
In the A-X-V concept for decoupling points, which manufacturing environment does X represent?
Definition
In the A-X-V concept for decoupling points, the manufacturing environment represented by ____ is ATO
Term
In the A-X-V concept for decoupling points, which manufacturing environment does V represent?
Definition
In the A-X-V concept for decoupling points, the manufacturing environment represented by ____ is MTO
Term
Delayed manufacturing
Definition
Delaying final differentiation of products until as late as possible, in order to delay the decoupling point
Term
What is the purpose of S&OP?
Definition
The purpose of ____ is to connect business planning with tactical planning at the MPR level
Term
S&OP balances ____ and ____ at the product family level
Definition
S&OP balances supply and demand at the ____ level
Term
S&OP is concerned with planning at ____ level, not the ____ level.
Definition
____ is concerned with planning at the volume level, not the individual product mix level
Term
How often should S&OP be reviewed?
Definition
____ should be reviewed on a monthly cycle with a formal review
Term
In S&OP, what does strategic and business planning do?
Definition
In S&OP, ____ provides direction setting
Term
In S&OP, what does demand management provide?
Definition
In S&OP, ____ provides forecast and customer order information
Term
In S&OP, what does resource planning do?
Definition
In S&OP, ____ serves as a check on capacity and resource availability required
Term
In S&OP, what are the 3 things that distribution planning does?
Definition

In S&OP, the 3 things that ____ does are:

  1. Serve as a source of demand forecasts and actual orders generated by ISL
  2. Use demand data from S&OP systems for logistics planning at the product family level
  3. Validates the accuracy of distribution resources to carry out the production plan
Term
What are some key S&OP activities?
Definition

Some key ____ activities are:

  • Aggregating all sources of demand
  • Establishing meaningful units of measure
  • Identifying mid- to long-term changes and developments
Term
What are 3 things that resource planning does?
Definition

3 things that ____ does are:

  1. Establishes, measures, and adjusts long-range capacity
  2. Identifies long lead time items
  3. Requires management approval of major capital investments
Term
What does resource planning NOT show you, in terms of capital needs?
Definition
In terms of capital needs, ____ does not show you the need, but only shows you the timing. (If the need was missed, go back to S&OP.)
Term
The meaningful unit of measure for MTS is ____
Definition
The meaningful unit of measure for ____ is material supply capacity
Term
The meaningful unit of measure for MTO is ____
Definition
The meaningful unit of measure for ____ is machine and labor hours
Term
The meaningful unit of measure for ETO is ____
Definition
The meaningful unit of measure for ____ is engineering labor hours
Term
What are the 5 things that describe master scheduling?
Definition

The 5 things that describe ____ are:

  1. It's based on the product family data
  2. Breaks product family volume into end-item mix
  3. Produces master production schedule (MPS) for individual end items
  4. Balances MPS with available capacity
  5. May link to finite scheduling system
Term
MPS
Definition
Master production schedule
Term
What is the primary input to master scheduling?
Definition
The primary input to ____ is the production plan (consisting of family volumes and due dates)
Term
How does RCCP interact with the MPS?
Definition
____ converts the preliminary MPS into requirements for critical production resources, such as labor, equipment, and materials
Term
What is the Unilever equivalent of distribution planning?
Definition
The Unilever equivalent of ____ is LOT planning
Term
In which manufacturing environments is distribution planning relevant?
Definition
____ planning is relevant in MTS and ATO in which finished goods inventory is stored at distributed ISL
Term
Distribution planning uses aggregated product family demand data to do what?
Definition
Distribution planning uses ____ to plan warehouse and transportation capacity requirements
Term
Distribution planning uses individual end-item data to do what?
Definition
Distribution planning uses ____ to plan inventory levels and logistics requirements
Term
Distribution planning plans the release of orders to where and for what?
Definition
____ plans the release of orders to factory supply points for replenishment shipments to ISLs
Term
What is the Unilever equivalent of replenishment order releases?
Definition
The Unilever equivalent of ____ is STOs
Term
Customer relationship management
Definition
The collection and analysis of information designed for sales and marketing decision support, as contrasted with ERP information, to understand and support existing and potential customer needs
Term
Rough-cut capacity planning
Definition
The process of converting the MPS into requirements for key resources
Term
Distribution requirements planning
Definition
The function of determining the need to replenish inventory at branch warehouses
Term
Demand management
Definition
The function of recognizing all demands for goods and services to support the marketplace
Term
Distribution planning
Definition
The planning activities associated with resources (transportation, warehousing, inventory levels, materials handling, order admin, site/location planing, industrial packaging, data processing, and communication networks) to support distribution
Term
Business plan
Definition
A statement of long-range strategy and revenue, cost, and profit objectives usually accompanied by budgets, a projected balance sheet, and a cash flow or source of application of funds statement
Term
Manufacturing environment
Definition
Often refers to whether a company, plant, product or service is MTS, MTO, or ATO
Term
Product mix
Definition
The proportion of individual items that make up the total production or sales volume
Term
Sales and operations planning
Definition
A process to develop tactical plans that provide management with the ability to strategically direct its business to achieve competitive advantage on a continuous basis by integrating customer-focused marketing plans for new and existing products with the management of the supply chain
Term
Resource planning
Definition
Capacity planning conducted at the business plan level
Term
Decoupling point
Definition
The location in the product structure or distribution network where inventory is placed to create independence between processes or entities
Term
Master scheduling
Definition
The process where, upon review, adjustments are made to the MPS to ensure consistency with the production plan
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