BSIE Production Management 3 — Questions and Answers
Question 1: In MRP (Material Requirements Planning), which input document lists the components and subassemblies needed to make each finished product?
- Master Production Schedule (MPS)
- Inventory Status File
- Bill of Materials (BOM) (Correct answer)
- Capacity Requirements Plan (CRP)
Correct answer: Bill of Materials (BOM)
The Bill of Materials specifies every component and quantity required to manufacture one unit of the parent item.
Question 2: A manufacturer produces 500 units/day and the defect rate is 2%. Using Six Sigma terminology, reducing defects to 3.4 per million opportunities represents which sigma level?
- Three sigma
- Four sigma
- Five sigma
- Six sigma (Correct answer)
Correct answer: Six sigma
Six Sigma by definition targets no more than 3.4 defects per million opportunities.
Question 3: Which queuing model assumes infinite calling population, Poisson arrivals, and exponential service times with a single server?
- M/D/1
- M/M/s
- M/M/1 (Correct answer)
- G/G/1
Correct answer: M/M/1
The M/M/1 model denotes Markovian (Poisson) arrivals, Markovian (exponential) service, and one server.
Question 4: Frozen zone in a Master Production Schedule refers to the period during which:
- No production is scheduled due to planned downtime
- Changes to the schedule are not permitted without management approval (Correct answer)
- Safety stock is consumed before new orders are released
- Lead times are calculated for component procurement
Correct answer: Changes to the schedule are not permitted without management approval
The frozen zone protects near-term commitments by restricting unauthorized changes to the MPS.
Question 5: Which lean tool uses a visual card or signal to authorize production or material movement between processes?
- Poka-yoke
- 5S
- Kanban (Correct answer)
- Kaizen
Correct answer: Kanban
Kanban cards serve as authorization signals that trigger replenishment only when downstream consumption occurs.
Question 6: A Gantt chart is primarily used in production management to:
- Calculate the EOQ for raw materials
- Visualize the schedule and progress of jobs over time (Correct answer)
- Determine the number of kanbans required
- Perform a failure mode analysis on equipment
Correct answer: Visualize the schedule and progress of jobs over time
Gantt charts display planned versus actual job timelines across machines or workstations.
Question 7: In the context of capacity management, the ratio of actual output to effective capacity is called:
- Utilization
- Efficiency (Correct answer)
- Throughput ratio
- Takt ratio
Correct answer: Efficiency
Efficiency = actual output ÷ effective capacity, measuring how well effective capacity is being used.
BSIE Production Management 3
In MRP (Material Requirements Planning), which input document lists the components and subassemblies needed to make each finished product?