CPIM Detailed Scheduling 3 — Questions and Answers
Question 1: What is the difference between 'scheduled receipt' and 'planned order receipt' in MRP?
- There is no difference; they are the same
- Scheduled receipts are open orders already released; planned orders are not yet released (Correct answer)
- Planned orders are customer orders; scheduled receipts are purchase orders
- Scheduled receipts appear only in the master schedule
Correct answer: Scheduled receipts are open orders already released; planned orders are not yet released
Scheduled receipts represent work orders or purchase orders already released and in progress, while planned orders exist only in the MRP system and have not yet been released.
Question 2: In detailed scheduling, 'pegging' refers to:
- Fixing a work order to a specific machine
- Tracing the source of demand back through the MRP records to the parent item (Correct answer)
- Setting a fixed lead time for all operations
- Allocating labor to specific shifts
Correct answer: Tracing the source of demand back through the MRP records to the parent item
Pegging allows planners to trace a requirement upward through the bill of materials to identify which parent demands are driving a specific lower-level requirement.
Question 3: A plant operates 5 days per week, 2 shifts per day, 8 hours per shift. With 10 machines, what is the available capacity per week?
- 400 machine-hours
- 800 machine-hours (Correct answer)
- 80 machine-hours
- 160 machine-hours
Correct answer: 800 machine-hours
Available capacity = 5 days × 2 shifts × 8 hours × 10 machines = 800 machine-hours per week.
Question 4: Which technique is used to level production by smoothing out demand fluctuations over a planning horizon?
- Expediting
- Production leveling (heijunka) (Correct answer)
- Backward scheduling
- Lot sizing
Correct answer: Production leveling (heijunka)
Production leveling (heijunka) distributes production evenly over time to reduce variability and improve flow, a core lean manufacturing concept.
Question 5: What is the effect of using large lot sizes in a detailed schedule?
- Reduced setup costs but increased average inventory (Correct answer)
- Increased setup costs and reduced inventory
- Reduced lead times and improved flow
- No effect on inventory levels
Correct answer: Reduced setup costs but increased average inventory
Larger lot sizes spread setup costs over more units but result in higher average inventory levels due to longer time between replenishments.
Question 6: In a job shop environment, which scheduling challenge is most common?
- Linear, predictable routing for all jobs
- High variety of job types with different routings creating complex scheduling (Correct answer)
- Fixed sequence of operations for all products
- Minimal setup time requirements
Correct answer: High variety of job types with different routings creating complex scheduling
Job shops face high complexity because each job may have a unique routing, creating bottlenecks and making sequencing optimization very difficult.
Question 7: What is 'overlapping' (operation overlapping) in detailed scheduling?
- Running two work centers simultaneously on different jobs
- Sending part of a lot to the next operation before the entire lot is finished at the current operation (Correct answer)
- Combining two work orders into one
- Scheduling overtime on all operations
Correct answer: Sending part of a lot to the next operation before the entire lot is finished at the current operation
Overlapping reduces lead time by transferring a partial quantity to the next operation before the full batch is completed at the current step.
CPIM Detailed Scheduling 3
What is the difference between 'scheduled receipt' and 'planned order receipt' in MRP?