Term
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Definition
Manufacturing planning and control |
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Term
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Definition
Master planning of resources |
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Term
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Definition
Enterprise resource planning |
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Term
What are the objectives of the manufacturing and service industry from the Customer perspective? ("The Right..." x6) |
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Definition
The objectives of the ____ industry from the customer perspective are:
The right...
- Quality
- Quantity
- Place
- Price
- Products (right goods and services)
- Time
"2Q / 3P / 1T" |
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Term
What are the objectives of the manufacturing and service industry from the Supplier perspective? |
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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" |
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Term
What are the 3 conflicts of Supplier's objectives (3-legged stool) |
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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 |
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Term
Explain the Customer Objective "the right goods and services" |
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Definition
Designing and making products that meet or exceed customer expectations. Requires identifying and selecting products that customers want to buy |
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Term
Explain the Customer Objective "the right quality" |
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Definition
Meeting the two aspects of quality:
- Conformance
- specification
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Term
The 2 aspects of quality are ____ and ____ |
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Definition
Conformance and specifications are the 2 aspects of ____ |
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Term
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Definition
Addresses the requirement that products meet regulatory standards (EX: pharmaceuticals) |
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Term
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Definition
Relates to the need to design, manufacture, and deliver products that provide the requisite functionality, aesthetics, and value that customers want |
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Term
Explain the Customer Objective "the right quantity" |
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Definition
Materials in the right quantity are available for delivery |
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Term
Explain the Customer Objective "the right time" |
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Definition
Meeting the on-time delivery requirements of customers |
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Term
What are the four performance objectives in meeting on-time delivery? |
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Definition
The four performance objectives in meeting ____ are:
- Speed
- Quality
- Flexibility
- Dependability
of production and distribution requirements. |
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Term
Explain the Customer Objective "the right place" |
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Definition
Depends on a company's sales channels and distribution channels |
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Term
The 2 components of The Right Place are ____ and ____ |
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Definition
Sales channels and distribution channels are the 2 components of The Right ____ |
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Term
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Definition
The internal functions and external parties that support marketing, promotion, and sale of products to customers |
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Term
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Definition
Determine the physical flow of products to customers at required delivery points |
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Term
Explain the Customer Objective "the right price" |
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Definition
The four generic performance objectives (speed, quality, flexibility, and dependability) are related to cost, enabling companies to meet customer requirements for the right ____ |
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Term
What are the five performance objectives in meeting on-time delivery requirements? |
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Definition
The 5 performance objectives in meeting ____ are:
- Speed
- Quality
- Flexibility
- Dependability
- Cost
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Term
What are the 4 key issues that manufacturing planning addresses? |
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Definition
The 4 key issues that ____ addresses are:
- Flow or product (RM, WIP, and FG) to customers
- Delivery lead time customers are willing to accept
- Use of production resources
- Appropriate relationships with other organizations in the supply chain (outsourcing, partnerships, vertical integration, etc)
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Term
Through S&OP and master scheduling (MS), manufacturing planning & control (MPC) plays a key role in balancing what 3 conflicting objectives? |
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Definition
Through S&OP and master scheduling (MS), ____ balances the following 3 conflicting objectives:
- Customer service levels
- Inventory investment
- Costs of production
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Term
What are some examples of customer service level objectives? (3-legged stool example) |
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Definition
Some examples of ____ objectives are:
- Acceptable lead times
- Shipped complete, arrives in time
- Right quality and place
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Term
What are some examples of inventory investment objectives? (3-legged stool example) |
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Definition
Some examples of ____ objectives are:
- Low WIP
- High turnover
- Faster throughput
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Term
What are some examples of costs of production objectives? (3-legged stool example) |
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Definition
Some examples of ____ objectives are:
- Minimizing of set ups (reduce changeovers)
- Longer production runs and high utilization
- Low cost of materials
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Term
What are 2 manufacturing practices that can be deployed to mitigate the inherent conflict amount the 3 conflicting objectives? |
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Definition
The deployment of lean and theory of constraints manufacturing practices mitigate ____ |
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Term
What do lean and theory of constraints manufacturing processes do? |
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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 |
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Term
A key role for MPC (manufacturing planning & control) is balancing ____ and ____ |
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Definition
A key role for ____ is balancing supply and demand |
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Term
What are some components of demand management? |
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Definition
Some components of ____ management are:
- Demand forecasts
- Order managements
- Customer relationship management (CRM)
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Term
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Definition
Customer relationship management |
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Term
What are some components of supply management? |
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Definition
Some components of ____ management are:
- Efficiency of production and distribution planning
- Availability of production resources
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Term
What are the sources of imbalance between supply and demand? |
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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
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Term
What are some problems that come from an imbalance between supply and demand? |
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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
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Term
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Definition
Addresses long-term objectives relating to products, customers, and markets |
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Term
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Definition
Long-term in focus, denominated in monetary terms |
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Term
What is the bridge from strategic to tactical/cross-functional planning at the MRP level? |
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Definition
Business planning is the bridge from ____ to ____ planning at the MPR level |
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Term
What are the 3 planning activities associated with MPC |
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Definition
The 3 planning activities associated with ___ are:
- Master planning of resources (MPR) (Intermediate- to long-term)
- Detailed Scheduling and Planning (DSP) (near-term)
- Execution and Control of Operations (ECO) (near-term)
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Term
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Definition
Detailed scheduling and planning |
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Term
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Definition
Execution and control of operations |
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Term
What are the 6 processes of Master planning of resources (MPR)? |
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Definition
The 6 processes of ____ are:
- Demand management
- Distribution planning
- S&OP
- Resource planning
- Master scheduling
- Rough-cut capacity planning (RCCP)
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Term
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Definition
Sales & operation planning |
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Term
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Definition
Rough-cut capacity planning |
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Term
What are the 2 types of planning under Master planning of resources (MPR)? |
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Definition
The 2 types of planning under ___ are:
- Priority planning
- Capacity planning
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Term
What are the 2 cross-functional tactical plans under priority planning? |
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Definition
The 2 cross-functional tactical plans under ____ are:
- S&OP
- Master scheduling
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Term
What are the 2 cross-functional tactical plans under capacity planning? |
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Definition
The 2 cross-functional tactical plans under ____ are:
- Resource planning
- Rough-cut capacity planning (RCCP)
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Term
What are the responsibilities of S&OP and resource planning? |
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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
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Term
What are the responsibilities of master scheduling and rough-cut capacity planning (RCCP)? |
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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
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Term
What are the responsibilities of demand management? |
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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
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Term
What is the relationship between priority planning and capacity planning? |
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Definition
____ plans don't get released until ____ planning determines available capacity to do so |
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Term
What are the two types of support to S&OP and Master Scheduling (MS) that distribution planning provides? |
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Definition
The two types of support to S&OP and MS that ____ planning provides are:
- Planning of inventory levels at stocking points based on demand
- Inputs on distribution resources necessary to support S&OP and MPS through "logistics resource requirement planning"
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Term
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Definition
Material requirements planning |
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Term
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Definition
Capacity requirements planning |
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Term
What are the 2 processes of detailed scheduling and planning with a near-term planning horizon |
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Definition
The two process of ____ with a ____ planning horizon are:
- Material requirements planning
- Capacity requirements planning
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Term
What is the objective of DSP (detailed scheduling and planning)? |
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Definition
The objective of ____ is to determine the required below resources to support the master production schedule for individual end items:
- Material capacity
- Labor capacity
- Equipment capacity
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Term
What are the 5 things that material requirements planning (MRP) and Capacity requirements planning (CRP) determine? |
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Definition
The 5 things that ____ and ____ determine are:
- End item and component quantities needed to fulfill MPS
- When these items and quantities are needed
- How many are now in stock
- Which are on order
- Sufficiency of workers and equipment
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Term
Another term for Execution and Control is ____ |
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Definition
Another term for Production activity control (PAC) is ____ |
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Term
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Definition
Detailed scheduling and planning |
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Term
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Definition
Production activity and control |
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Term
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Definition
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Term
What are the 3 objectives of production activity and control (PAC)? |
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Definition
The 3 objectives of ___ are:
- Prioritize and sequence work to be performed
- Executing plans, implementing factory floor controls, and reporting activity results
- Performance reporting and feedback (to adjust for shortages or overages in production)
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Term
What is the history of MRP? |
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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) |
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Term
What functions did MRP calculator (MRP) support? |
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Definition
The functions supported by ____ were:
- DSP (detailed capacity planning and detailed material planning)
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Term
When was MRP Calculator active? |
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Definition
____ was active in the 1960s - 70s |
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Term
What did MRP II and MES help to do? |
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Definition
____ and ____ helped to "close the loop", providing feedback of what actually happened and inputting that back into the system |
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Term
When were MRP II and MES active? |
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Definition
____ were active in the 1970s - 80s |
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Term
What functions did MRP II and MES support? |
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Definition
The functions supported by ____ and ____ were:
- Master Planning of Resources (MPR) (demand management, S&OP, distribution planning, resource planning, and MPS
- Detailed scheduling and planning (DSP) (detailed capacity planning and detailed material planning)
- Execution and control of operations (ECO) (priorities and sequencing, controls and reporting, PAC, and supplier systems
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Term
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Definition
Enterprise resource planning |
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Term
What was the emphasis of enterprise resource planning (ERP)? |
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Definition
The emphasis of ____ was standardizing supply chain management practices among suppliers and customers across industries |
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Term
When was enterprise resource planning (ERP) active? |
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Definition
____ was active in the 1990s - 00s |
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Term
What functions did enterprise resource planning (ERP) support? |
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Definition
The functions supported by ____ were:
- MPR (demand management, S&OP, distribution planning, resource planning, and MPS
- DSP (detailed capacity planning and detailed material planning)
- ECO (priorities and sequencing, controls and reporting, PAC, and supplier systems
- Support systems (finance and accounting, CRM/SRM, sales and marketing, HR)
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Term
Describe the volume variety curve structure |
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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. |
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Term
What are the 5 main process choices? |
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Definition
The 5 main ____ are:
- Project
- Job shop and batch
- Cellular
- Repetitive
- Flow
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Term
What are the 5 elements of the volume variety curve, going from upper left to lower right of the curve? |
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Definition
The 5 elements of the ____ are:
- Project
- Job shop and batch
- Cellular
- Repetitive
- Flow
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Term
What are 4 factors that help decide which process choice to use? |
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Definition
The 4 factors that help decide which ____ to use are:
- Nature of a product
- Complexity of its inputs (number of subparts)
- Variety and volume of outputs
- Rate of production
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Term
What is the typical environment of a "project" process choice? |
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Definition
The typical environment of a____ process choice is engineered-to-order (ETO) |
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Term
sdWhat is the typical environment of a "job shop and batch" process choice? |
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Definition
The typical environment of a____ process choice is make-to-order (MTO) |
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Term
What is the typical environment of a "cellular" process choice? |
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Definition
The typical environment of a____ process choice is MTO or ATO |
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Term
What is the typical environment of a "repetitive" process choice? |
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Definition
The typical environment of a____ process choice is MTS or ATO |
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Term
What is the typical environment of a "flow" process choice? |
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Definition
The typical environment of a____ process choice is MTS, MTO, or ATO |
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Term
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Definition
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Term
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Definition
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Term
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Definition
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Term
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Definition
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Term
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Definition
Production leveling or smoothing, a technique to reduce muda |
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Term
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Definition
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Term
What are the 4 Vs that differentiate types of production organizations? |
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Definition
The 4 ____s that differentiate different types of ____ are:
- Volume
- Variety
- Variation
- Visibility
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Term
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Definition
How many products or services are made by the operation |
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Term
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Definition
How many different types of products or services are made by the operation |
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Term
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Definition
How much does the level of demand change over time |
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Term
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Definition
How much of the operation's internal working are 'exposed' to its customers |
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Term
What are the 4 driving forces (or market forces) to which MPC systems are susceptible? |
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Definition
The 4 ____ to which MPC systems are susceptible are:
- Increasing cost competition
- Influx of foreign competitors
- Expansion into foreign markets
- Outsourcing
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Term
What does the business plan do? |
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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 |
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Term
What are some examples of "quantifiable" objectives and requirements of the business plan? |
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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
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Term
What are the 3 subprocesses of demand management? |
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Definition
The 3 subprocesses of ____ are:
- Forecasting
- Order management
- CRM
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Term
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Definition
Estimates of customer demand |
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Term
What are the 2 types of forecasts? |
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Definition
The 2 types of ____ are:
- Quantitative
- Qualitative
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Term
What is the level of forecast detail for S&OP? |
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Definition
The level of forecast detail for ____ is the overall market demand trends at the product family level |
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Term
What is the level of forecast detail for master scheduling? |
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Definition
The level of forecast detail for ____ is for the product mix at the individual end-item level as required by the MPS |
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Term
What is the level of forecast detail for distribution planning? |
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Definition
The level of forecast detail for ____ are for both product families and end-item/SKUs at inventory stocking locations (ISLs) |
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Term
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Definition
Inventory stocking locations |
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Term
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Definition
____ encompasses the receiving, entering, and process of orders from internal and external sources |
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Term
What are the 3 internal and external sources of orders? |
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Definition
The 3 internal and external sources of ____ are:
- Customers
- Distribution centers
- Interplant operations
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Term
What are the 2 focuses of CRM? |
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Definition
The 2 focuses of ____are:
- Understanding and influencing customer needs and preferences
- Anticipating customer demand
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Term
What inputs to demand do sales representatives provide? |
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Definition
Inputs to demand that ____ provide are:
- Customers' long-term buying intentions
- Short-term product-mix requirements
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Term
What are the 3 things that can consumer capacity? |
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Definition
The 3 things that can consume ____ are:
- Orders
- Knowledge
- Forecast
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Term
What is the forecast consumption curve? |
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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 |
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Term
In terms of the forecast consumption curve, what does knowledge represent? |
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Definition
In terms of the forecast consumption curve, ____ represents orders that have a high degree of certainty of being received |
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Term
What are the 4 key characteristics that contrast the 4 major manufacturing environments? |
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Definition
The 4 key characteristics that contrast the ____ environments are:
- Inventory used to fulfill customer orders
- Information needed for SO&P
- Information needed for the MPS
- Planning and control
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Term
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Definition
The point at which inventory necessary to begin fulfilling the customer order is in stock |
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Term
What is the decoupling point for ETO? |
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Definition
The decoupling point for ____ is knowledge |
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Term
What is the decoupling point for MTO? |
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Definition
The decoupling point for ____ is raw materials |
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Term
What is the decoupling point for ATO? |
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Definition
The decoupling point for ____ is components and subassemblies |
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Term
What is the decoupling point for MTS? |
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Definition
The decoupling point for ____ is finished goods inventory |
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Term
As you move from MTS to ETO, the information needed for S&OP becomes more ____ |
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Definition
As you move from ____ to ____, the information needed for S&OP becomes more complex |
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Term
As you move from MTS to ETO, the end-item volumes become ____ |
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Definition
As you move from ____ to ____, the end-item volumes become smaller |
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Term
In terms of planning and control, what is the focus of MTS? |
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Definition
In terms of planning and control, the focus of ____ is on balancing inventory, cost, and customer service objectives |
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Term
In terms of planning and control, what is the focus of ATO? |
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Definition
In terms of planning and control, the focus of ____ is meeting delivery dates |
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Term
In terms of planning and control, what is the focus of MTO? |
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Definition
In terms of planning and control, the focus of ____ is providing and managing capacity needed for production |
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Term
In terms of planning and control, what is the focus of ETO? |
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Definition
In terms of planning and control, the focus of ____ is providing and managing capacity needed for production |
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Term
What is the A-X-V concept for decoupling points?
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Definition
The _-_-_ concept for decoupling points is that you stock at the thinnest point
FG FG FG
A X V
RM RM RM |
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Term
In the A-X-V concept for decoupling points, which manufacturing environment does A represent? |
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Definition
In the A-X-V concept for decoupling points, the manufacturing environment represented by ____ is MTS |
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Term
In the A-X-V concept for decoupling points, which manufacturing environment does X represent? |
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Definition
In the A-X-V concept for decoupling points, the manufacturing environment represented by ____ is ATO |
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Term
In the A-X-V concept for decoupling points, which manufacturing environment does V represent? |
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Definition
In the A-X-V concept for decoupling points, the manufacturing environment represented by ____ is MTO |
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Term
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Definition
Delaying final differentiation of products until as late as possible, in order to delay the decoupling point |
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Term
What is the purpose of S&OP? |
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Definition
The purpose of ____ is to connect business planning with tactical planning at the MPR level |
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Term
S&OP balances ____ and ____ at the product family level |
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Definition
S&OP balances supply and demand at the ____ level |
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Term
S&OP is concerned with planning at ____ level, not the ____ level. |
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Definition
____ is concerned with planning at the volume level, not the individual product mix level |
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Term
How often should S&OP be reviewed? |
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Definition
____ should be reviewed on a monthly cycle with a formal review |
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Term
In S&OP, what does strategic and business planning do? |
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Definition
In S&OP, ____ provides direction setting |
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Term
In S&OP, what does demand management provide? |
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Definition
In S&OP, ____ provides forecast and customer order information |
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Term
In S&OP, what does resource planning do? |
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Definition
In S&OP, ____ serves as a check on capacity and resource availability required |
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Term
In S&OP, what are the 3 things that distribution planning does? |
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Definition
In S&OP, the 3 things that ____ does are:
- Serve as a source of demand forecasts and actual orders generated by ISL
- Use demand data from S&OP systems for logistics planning at the product family level
- Validates the accuracy of distribution resources to carry out the production plan
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Term
What are some key S&OP activities? |
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Definition
Some key ____ activities are:
- Aggregating all sources of demand
- Establishing meaningful units of measure
- Identifying mid- to long-term changes and developments
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Term
What are 3 things that resource planning does? |
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Definition
3 things that ____ does are:
- Establishes, measures, and adjusts long-range capacity
- Identifies long lead time items
- Requires management approval of major capital investments
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Term
What does resource planning NOT show you, in terms of capital needs? |
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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.) |
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Term
The meaningful unit of measure for MTS is ____ |
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Definition
The meaningful unit of measure for ____ is material supply capacity |
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Term
The meaningful unit of measure for MTO is ____ |
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Definition
The meaningful unit of measure for ____ is machine and labor hours |
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Term
The meaningful unit of measure for ETO is ____ |
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Definition
The meaningful unit of measure for ____ is engineering labor hours |
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Term
What are the 5 things that describe master scheduling? |
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Definition
The 5 things that describe ____ are:
- It's based on the product family data
- Breaks product family volume into end-item mix
- Produces master production schedule (MPS) for individual end items
- Balances MPS with available capacity
- May link to finite scheduling system
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Term
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Definition
Master production schedule |
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Term
What is the primary input to master scheduling? |
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Definition
The primary input to ____ is the production plan (consisting of family volumes and due dates) |
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Term
How does RCCP interact with the MPS? |
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Definition
____ converts the preliminary MPS into requirements for critical production resources, such as labor, equipment, and materials |
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Term
What is the Unilever equivalent of distribution planning? |
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Definition
The Unilever equivalent of ____ is LOT planning |
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Term
In which manufacturing environments is distribution planning relevant? |
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Definition
____ planning is relevant in MTS and ATO in which finished goods inventory is stored at distributed ISL |
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Term
Distribution planning uses aggregated product family demand data to do what? |
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Definition
Distribution planning uses ____ to plan warehouse and transportation capacity requirements |
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Term
Distribution planning uses individual end-item data to do what? |
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Definition
Distribution planning uses ____ to plan inventory levels and logistics requirements |
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Term
Distribution planning plans the release of orders to where and for what? |
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Definition
____ plans the release of orders to factory supply points for replenishment shipments to ISLs |
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Term
What is the Unilever equivalent of replenishment order releases? |
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Definition
The Unilever equivalent of ____ is STOs |
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Term
Customer relationship management |
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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 |
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Term
Rough-cut capacity planning |
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Definition
The process of converting the MPS into requirements for key resources |
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Term
Distribution requirements planning |
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Definition
The function of determining the need to replenish inventory at branch warehouses |
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The function of recognizing all demands for goods and services to support the marketplace |
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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 |
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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 |
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Manufacturing environment |
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Definition
Often refers to whether a company, plant, product or service is MTS, MTO, or ATO |
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Definition
The proportion of individual items that make up the total production or sales volume |
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Term
Sales and operations planning |
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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 |
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Capacity planning conducted at the business plan level |
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The location in the product structure or distribution network where inventory is placed to create independence between processes or entities |
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Definition
The process where, upon review, adjustments are made to the MPS to ensure consistency with the production plan |
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