This document provides answers to a BAM 421 Unit 4 examination. It contains 23 multiple choice questions related to production planning and control topics like master production scheduling, bills of materials, scheduling methods, production files, lean concepts like 5S and JIT, and reliability calculations. The questions assess understanding of key concepts and calculations in these areas.

1. BAM 421 UNIT 4 EXAMINATION ANSWERS
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BAM 421 Unit 4 Examination Answers
1. The aggregate plan gets input or feedback from which of the following areas?
2. engineering
3. finance, marketing and human resources
4. the master production schedule
5. procurement, production and general management
6. All of the above.
2. Which portion of the master production schedule is normally fixed, frozen or firm?
3. the entire schedule
4. only the aggregate schedule
5. only the middle of the schedule
6. only the near-term portion
7. only the far-term portion
3. In continuous (stock-to-forecast) operations, the master production schedule is usually
expressed in terms of _______________.
4. end items
5. modules
6. kits
7. customer orders
8. warehouse orders

2. 4. In job shop (make-to-order) operations, the master production schedule is usually expressed
in
_______________.
1. end items
2. modules
3. kits
4. customer orders
5. warehouse orders
5. A document calls for the production of 50 small garden tractors in week 1, 50 small garden
tractors and 100 riding mowers in week 2, 100 riding mowers and 200 garden utility carts in
week 3 and 100 riding mowers in week 4. This document is most likely a(n)
_______________.
6. net requirements document
7. resource requirements profile
8. aggregate plan
9. master production schedule
10. Wagner-Whitin finite capacity document
6. The _______________ is the input to material requirements planning which lists the
assemblies, subassemblies, parts and raw materials needed to produce one unit of finished
product.
7. bill of material
8. master production schedule
9. inventory records
10. assembly time chart
11. net requirements chart
7. A bill of material lists the _______________.
8. times needed to perform all phases of production
9. production schedules for all products

3. 10. components, ingredients and materials required to produce an item
11. operations required to produce an item
12. components, ingredients, materials and assembly operations required to produce an item
8. Forward scheduling _______________.
9. begins with a delivery date, then offsets each operation one at a time, in reverse order
10. is well suited where the supplier is usually able to meet precise delivery dates
11. tends to minimize work-in-process inventory
12. assumes that procurement of material and operations start as soon as requirements are
known
13. produces a schedule only if it meets the due date
9. Scheduling is rather straightforward in product-focused facilities because _______________.
10. kanban automates the scheduling of the assembly line
11. demand is reasonably stable and capacities, set-up times and run times are generally known
12. assembly line balancing assures the highest possible production efficiency
13. finite capacity scheduling has made MRP much more realistic
14. All of the above are true.
10. Which file contains important information regarding an item’s flow through the shop?
11. item master file
12. work-center master file
13. control files
14. routing file
15. None of the above provides information regarding an item’s flow through the shop.
11. Which of these is not part of the planning files of a production planning and control system?
12. a progress file
13. a work-center master file
14. an item master file
15. a routing file
16. All of the above are all part of the planning files.

4. 12. Which of the following files tracks work order progress?
13. work-center master files
14. routing files
15. item master files
16. control files
17. None of the above tracks work order progress.
13. The production database containing information about each of the components that a firm
produces or purchases is the _______________.
14. routing file
15. work-center master file
16. control file
17. item master file
18. None of the above.
14. Which of the following is not one of the Seven Wastes?
15. overproduction
16. transportation
17. assignment
18. defective product
19. motion
15. The 5Ss ________________.
16. have the “flavor” of a housekeeping list
17. are a checklist for lean operations
18. have become a list of seven items in American practice
19. can be used to assist with necessary changes in organizational culture
20. All of these are true.
16. The list of 5Ss, although it looks like a housekeeping directive, supports lean production by
________________.

5. 1. identifying non-value items and removing them in the “sort/segregate” item
2. reducing inventory in the “standardize” item
3. increasing variability through standardized procedures in the “standardize” item
4. eliminating wasted motion through ergonomic studies in the “support” item
5. building good safety practices in the “shine/sweep” item
17. Concerning relationships with suppliers, which of the following combinations is critical to the
success of JIT?
18. close relationships with trust
19. close relationships with skepticism
20. distant relationships with trust
21. distant relationships with skepticism
22. None of the above.
18. Which one of the following is not a benefit of the implementation of JIT?
19. cost reduction
20. variability increase
21. rapid throughput
22. quality improvement
23. rework reduction
19. If the goals of JIT partnerships are met, which of the following is a result?
20. For incoming goods, receiving activity and inspection are outsourced.
21. In-transit inventory falls as suppliers are located closer to facilities.
22. The number of suppliers increases.
23. In-plant inventory replaces in-transit inventory.
24. All of the above are consequences of meeting the JIT partnership goals.
20. Ten high-technology batteries are tested for 200 hours each. One failed at 20 hours; all
others completed the test. FR(%) is _______________ and MTBF is ________________.
21. 10%; 1/1820
22. 90%; 1/1820
23. 10%; 1820 hours
24. 10%; 1980 hours
25. cannot calculate from information provided

6. 21. Ten high-technology batteries are tested for 200 hours each. One failed at 50 hours; all
others completed the test. FR(%) is _____________ and FR(N) is _______________.
22. 10%; 1/1850
23. 10%; 1/2000
24. 25%; 1850 hours
25. 90%; 1/2000
26. Indeterminate; no standard deviation is given.
22. Ten high-technology batteries are tested for 200 hours each. One failed at 20 hours, another
failed at 140 hours and all others completed the test. FR(%) is _______________ and MTBF
is ________________.
23. 20%; 880 hours
24. 10%; 1980 hours
25. 20%; 1760 hours
26. 80%; 920 hours
27. cannot calculate from information provided
23. MTBF measures the average _________________.
24. calendar time between failures
25. operating time between failures
26. number of failures per unit time
27. number of operations between failures
28. downtime per breakdown
24. A system is composed of four parts, J, K, L and M. All four must function for the system to
function. The four component reliabilities are .99, .98, .992 and .998. The designers are
considering putting a .80 reliable backup at K. This backup will change the system reliability
from ______________ to ________________.
25. 0.9762 to 0.9605
26. 0.9605 to 0.9762
27. 0.9605 to some smaller value
28. cannot be determined
29. None of the above.

7. 25. Suppose that a process is comprised of multiple components, each having a 75% success
rate. What is the change in reliability going from a series layout to a parallel layout if the
process has 5 components?
26. 0%
27. 100%
28. 76.2%
29. -76.2 %
30. unable to determine