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Production Planning And Control Question Paper
Production Planning And Control
Course:Bachelor Of Science In Manufacturing Engineering And Technology
Institution: Kenyatta University question papers
Exam Year:2008
KENYATTA UNIVERSITY
UNIVERSITY EXAMINATIONS 2008/2009
FIRST SEMESTER EXAMINATION FOR THE DEGREE OF BACHELOR OF
SCIENCE IN MANUFACTURING ENGINEERING
SET 504: PRODUCTION PLANNING AND CONTROL
DATE: Thursday 27th November, 2008
TIME: 11.00 a.m. – 1.00 p.m.
INSTRUCTIONS
This paper contains FIVE questions.
Answer any three questions.
1.
(a)
(i)
What is the advantage of using exponential smoothing over weighted moving average technique in forecasting? [2 marks]
(ii)
Outline the procedure for computing the least squares regression line. [8 marks]
(b)
The sales records of Home Grown company over a period of 12 years are indicated in Table Q1. Use the least square regression technique to predict the sales of the 13th year. Indicate any suitable assumptions.
Table Q1
Year
1
2
3
4
5
6
7
8
9
10 11 12
Annual sales
13 14 17 16 20 25 20 20 23 25 30 25
(1000 Units)
[10 marks]
2.
(a)
(i)
List three categories of production planning activities. [3 marks]
(ii)
Assume you are a production planner and have just received an order from your customer. What will you do until you initiate the production process? [9 marks]
(b)
Waweru designs and manufactures wooden desks. He works five days a week, eight hours a day and takes four weeks of vacation every year. On average, each desk takes Waweru about 20 hours from start to finish. Waweru also spends about three hours a week on preventive maintenance and two hours picking up supplies. Determine:
(i)
Actual capacity
(ii)
Design capacity
(iii)
Effective capacity
[8 marks]
3.
(a)
The real question facing a production manager is the lot size which is just right in terms minimizing production costs. Discuss. [12 marks]
(b)
The following data were found in an annual production report of a company which manufactures and exports products:
? Annual requirement = 1000 units
? Set-up cost = kshs 14000 per set-up
? Inventory carrying cost = ksh 112 per unit per year
? Production rate = 2000 units per year
? Demand rate = 1000 units per year
Determine:
(i) Optimum production lot size [4 marks]
(ii) Total incremental cost [4 marks]
4.
(a)
Describe how computers and data processing systems can be used in production planning and control. [7 marks]
(b)
(i)
What is different between Gantt Chart and productrol board. [2 marks]
(ii)
You are given orders in a workshop by numbers 100, 200 and 300 and there are only three operations done in the plant: assembling, manufacturing and painting. Order 100 is right on schedule, order 200 is one day behind schedule and order 300 is one day ahead of schedule. If both painting and assembling takes 2 days each, perform 5 days scheduling using Gantt Chart and indicate any assumption and explain your answer. [11 marks]
5.
(a)
(i)
Give the definitions of the following terms:
(i)
Rough cut planning
[1½ marks]
(ii)
Total Quality Management
[1½ marks]
(iii)
Lead indicator
[1½ marks]
(iv)
Route sheet
[1½ marks]
(ii)
With suitable examples discuss the follow types of production control:
(i)
Flow control
[4 marks]
(ii)
Block control
[4 marks]
(b)
A calculator manufacturing company based in Kenya has demand from both domestic and foreign markets. Currently the company has produced 100,000 calculators, and the unit production cost is Ksh.210. The company believes that an 85% experience curve is about right for its production capacity.
(i)
What is the company’s unit production cost if the cumulative production volume reaches 800,000? [4 marks]
(ii)
At approximately what cumulative production volume can the company reduce production cost to below Ksh.140? [2 marks]
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