Solution-Review 2

#1: Given the following diagram for a product, determine the quantity of each component required to assemble one unit of the finished product.

-13335212725

E F (2) G H

J (2) D (4) L (2) J (2) A (4) D (3)

Answer the following questions.

Determine the quantity of each subcomponent to produce 1 end item E. Show your answer in the table below.

F 2

G 1

H 1

J 6

D 10

L 2

A 4

Determine the quantity of each subcomponent to produce 200 E’s. Show your answer in the table below.

F 400

G 200

H 200

J 1200

D 2000

L 400

A 800

#2: The following product structure tree shows the subcomponents for an end item. Also, the lead times and the quantity on hand are given.

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End Item B (2) C D (3) E (2) F (3) G (2) E (2) H (4) E (2)

Item End B C D E F G H

LT (wk) 1 2 3 3 1 2 1 2

Amount on hand 0 10 10 25 12 30 5 0

530225-13328652403475-13328654277360-133286562230-947420

Answer the following questions. This problem must be done manually.

If 24 units of the end item are to be assembled, how many additional units of E are needed?

138

A order for the end item is scheduled to be shipped at the start of week 14. What is the latest week that the order can be started and still be ready to ship on time?

The beginning of week 5

#3: Prepare a material requirements plan for braces using lot-for-lot ordering. Complete the table below. You do not need to enter values of 0.

Week Number 1 2 3 4 5 6 7 8 9

Demand 300 450 600 Gross requirements 300 450 600 OH/ SR 60 150 Projected on hand 60 60 210 0 0 Net requirements 90 450 600 Planned-order receipts 90 450 600 Planned-order releases 90 450 600 Prepare a material requirements plan for legs using a lot size of 60. Complete the table below. You do not need to enter values of 0.

Week Number 1 2 3 4 5 6 7 8 9

Demand 400 600 800 Gross requirements 400 600 800 OH/ SR 120 200 Projected on hand 120 320 320 40 40 40 20 20 20

Net requirements 80 560 760 Planned-order receipts 120 600 780 Planned-order releases 120 600 780

#6: Solution: Golf

Master Week Beg. 1 2 3 4 5 6 Inv. Schedule Quantity 40A 60B 30C A LT = 1 wk. Beg. 1 2 3 4 5 6 Inv. Gross requirements 40 Scheduled receipts Projected on hand Net requirements 40 Planned order receipt 40 Planned order release 40 B LT = 1 wk. Beg. 1 2 3 4 5 6 Inv. Gross requirements 60 Scheduled receipts Projected on hand 10 10 10 10 10 10 Net requirements 50 Planned order receipt 50 Planned order release 50 C LT = 2 wks. Beg. 1 2 3 4 5 6 Inv. Gross requirements 30 Scheduled receipts Projected on hand 10 10 10 10 10 10 10 Net requirements 20 Planned order receipt 20 Planned order release 20 D LT = 1 wk. Beg. 1 2 3 4 5 6 Inv. Gross requirements 40 180 Scheduled receipts 100 Projected on hand 25 125 125 125 85 5 Net requirements 95 Planned order receipt 100 Planned order release 100 a. Develop a product structure tree for the GC. GC Electric Golf Cart T B Top Base S (4) CV M BO SE (2) Supports Cover Motor Body Seats F Frame CN Controls WA (4) Wheel Assemblies -13335-2988945

For this problem disregard the quantities on hand, and determine the Bill of Material quantities for each subassembly and components that are required to produce 200 golf carts. Show your answers in the table below.

GC 200

T 200

S 800

CV 200

B 200

M 200

BO 200

SE 400

F 200

CN 200

WA 800

Prepare an MRP for GC, B, BO, and WA using lot-for-lot ordering in the following questions.

Show the MRP for GC by completing the table below. You do not need to enter values of 0.

Week Number 1 2 3 4 5 6 7 8 9

Demand 200 Gross requirements 200 OH/ SR Projected on hand Net requirements 200 Planned-order receipts 200 Planned-order releases 200 Show the MRP for B by completing the table below. You do not need to enter values of 0.

Week Number 1 2 3 4 5 6 7 8 9

Demand 200 Gross requirements 200 OH/ SR 20 Projected on hand 20 20 20 20 20 20 20 Net requirements 180 Planned-order receipts 180 Planned-order releases 180 Show the MRP for BO by completing the table below. You do not need to enter values of 0.

Week Number 1 2 3 4 5 6 7 8 9

Demand 180 Gross requirements 180 OH/ SR 50 Projected on hand 50 50 50 50 50 50 Net requirements 130 Planned-order receipts 130 Planned-order releases 130 Show the MRP for WA by completing the table below. You do not need to enter values of 0.

Week Number 1 2 3 4 5 6 7 8 9

Demand 520 Gross requirements 520 OH/ SR 240 Projected on hand 240 240 240 Net requirements 280 Planned-order receipts 280 Planned-order releases 280 0 Show the assembly time chart for GC – BO – B – WA. What is the lead time for this assembly sequence?

40640158115

Assemblly Time Chart -1 0 1 2 3 4 5 6 7

0 1 WA BO B GC 2 3

4

5

6

7

8

9

The assembly sequence GC – BO – B – WA lead time is 6 weeks.

#7olution: a. Product Structure Tree P K L W 3G 4H 2 2N 3Z c. Master Weeks Beg. 1 2 3 4 5 6 7 Inv. Schedule Quantity 100 100 d. P LT = 1 wk. Beg. 1 2 3 4 5 6 7 Inv. Gross requirements 100 100 Scheduled receipts Projected on hand Net requirements 100 100 Planned-order receipts 100 100 Planned-order releases 100 100 K LT = 2 wk. Beg. 1 2 3 4 5 6 7 Inv. Gross requirements 100 100 Scheduled receipts 10 30 Projected on hand 10 10 10 Net requirements 90 70 Planned-order receipts 90 70 Planned-order releases 90 70 G(3) LT = 1 wk. Beg. 1 2 3 4 5 6 7 Inv. Gross requirements 270 210 Scheduled receipts Projected on hand 40 40 40 40 Net requirements 230 210 Planned-order receipts 253 231 Planned-order releases 253 231 1123950-7195820

H(4) LT = 1 wk. Beg. 1 2 3 4 5 6 7 Inv. Gross requirements 360 280 Scheduled receipts Projected on hand 200 200 200 200 40 Net requirements 160 240 Planned-order receipts 200 240 Planned-order releases 200 240

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