14

Posted on May 11, 2018 in Other subjects

Problem #14-1:

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

Problem #14-2:

The following product structure tree indicates the components needed to assemble one unit of product W. Determine the quantities of each component needed to assemble 100 units of W.

Problem #14-3:

Eighty units of end item E are needed at the beginning of week 6. Three cases (30 units per case) of J have been ordered and one case is scheduled to arrive in week 3, one in week 4 and one in week 5. Note: J must be ordered by the case, and B must be produced in multiples of 120 units. There are 60 units of B and 20 units of J now on hand. Lead times are two weeks each for E and B, and one week for J.

a.prepare a material requirements plan for component J.

b.Suppose that in week 4 the quantity of E need is changed from 80 to 70. The planned order releases through week 3 have been executed. How many Bs and Js will be on hand in week 6?

Problem #14-4:

End item P is composed of three subassemblies: K, L, W. K is assembled using 3 Gs and 4 Hs. L is made of 2 Ms and 2 Ns. W is made of 3 Zs. On-hand inventories are 20 Ls, 40 Gs and 200 Hs. Scheduled receipts are 10 Ks at the start of week 3, 30 Ks at the start of week 6 and 200 Ws at the start of week 3. One hundred Ps will be shipped at the start of week 6, and another 100 at the start of week 7. Lead times are two weeks for subassemblies and one week for components G, H and M. Final assembly of P requires one week. Include an extra 10 percent scrap allowance in each planned order of G. The minimum order size for H is 200 units. Develop each of the following:

a.a product structure tree

b.a master schedule for P

c.a material requirements plan for K, G and H using lot-for-lot ordering

Problem #14-5:

Oh No!, Inc. sells three models of radar detector units. It buys the three basic models (E, F and G) from a Japanese manufacturer and adds one, two or four lights (component D) to further differentiate the models. D is bought from a domestic producer.

Lead times are one week for all items except C, which is two weeks. There are ample supplies of the basic units (E, F, and G) on hand. There are also 10 units of B, 10 units of C and 25 units of D on hand. Lot-sizing rules are lot-for-lot ordering for all items except D, which must be ordered in multiples of 100 units. There is a scheduled receipt of 100 units of D in week 1. The master scheduled calls for 40 units of A to be produced in week 4, 60 units of B in week 5 and 30 units of C in week 6. Prepare a material requirements planned for D and its parents.

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *

Solution #14-1:

F: 2	G: 1	H: 1
J: 2 x 2 = 4	L: 1 x 2 = 2	A: 1 x 4 = 4
D: 2 x 4 = 8	J: 1 x 2 = 2	D: 1 x 2 = 2

Totals: F = 2; G = 1; H = 1; J = 6; D = 10; L = 2; A = 4

Solution #14-2:

W = 100, A=100, B=200, C=400, E=500, F=200, G=800, D=2200

Solution #14-3a:

Master Schedule	Week	Beg. Inv.	1	2	3	4	5	6
Master Schedule	Quantity E							80

E LT = 2 wks. LFL		Beg. Inv.	1	2	3	4	5	6
Gross requirements								80
Scheduled receipts
Projected on hand
Net requirements								80
Planned-order receipts								80
Planned-order releases						80

B(2) LT = 2 wks. 120/lot		Beg. Inv.	1	2	3	4	5	6
Gross requirements						160
Scheduled receipts
Projected on hand		60	60	60	60	60	20	20
Net requirements						100
Planned-order receipts						120
Planned-order releases				120

J(4xB) & J(3xE) LT = 30/lot 1 wk.	Beg. Inv.	1	2	3	4	5	6
Gross requirements			480		240
Scheduled receipts				30	30	30
Projected on hand	20	20	20	50	80	50	50
Net requirements			460		160
Planned-order receipts			480		180
Planned-order releases		480		180

Solution #14-3b:

Master Schedule	Week	Beg. Inv.	1	2	3	4	5	6
Master Schedule	Quantity E							70

E LT = 2 wks. Lot: LFL		Beg. Inv.	1	2	3	4	5	6
Gross requirements								70
Scheduled receipts
Projected on hand
Net requirements								70
Planned-order receipts								70
Planned-order releases						70

B(2) LT = 2 wks. 120/lot		Beg. Inv.	1	2	3	4	5	6
Gross requirements						140
Scheduled receipts
Projected on hand		60	60	60	60	60	40	40
Net requirements						80
Planned-order receipts						120
Planned-order releases				120

J(4xB) & J(3xE) LT = 30/lot 1 wk.	Beg. Inv.	1	2	3	4	5	6
Gross requirements			480		210
Scheduled receipts				30	30	30
Projected on hand	20	20	20	50	80	80	80
Net requirements			460		130
Planned-order receipts			480		150
Planned-order releases		480		180

There will be 40 units of B and 80 units of J.

Solution #14-4:

a. Product Structure Tree

	Master Schedule	Weeks	Beg. Inv.	1	2	3	4	5	6	7
	Master Schedule	Quantity							100	100

c.	P LT = 1 wk. Lot: LFL		Beg. Inv.	1	2	3	4	5	6	7
	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. Lot: LFL		Beg. Inv.	1	2	3	4	5	6	7
	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. Lot: LFL		Beg. Inv.	1	2	3	4	5	6	7
	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

	H(4) LT = 1 wk. Lot: 200 units min		Beg. Inv.	1	2	3	4	5	6	7
	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

Solution #14-5:

Master Schedule	Week	Beg. Inv.	1	2	3	4	5	6
Master Schedule	Quantity					40A	60B	30C


A LT = 1 wk.		Beg. Inv.	1	2	3	4	5	6
Gross requirements						40
Scheduled receipts
Projected on hand
Net requirements						40
Planned order receipt						40
Planned order release					40


B LT = 1 wk.		Beg. Inv.	1	2	3	4	5	6
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. Inv.	1	2	3	4	5	6
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. Inv.	1	2	3	4	5	6
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

14