978-0073525242 Chapter 16 Part 2

Left Side 1 2 3 4 5

Gross Requirements 100 500

On Hand/Scheduled Receipts 50 100

NAME:

SECT:

DATE:

CHAPTER 16, PROBLEM 7

LAMP ASSEMBLY

**** WEEK ****

*****PART*****

1

2

3

4

5

6

7

8

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

LAMP

GROSS REQUIREMENTS:

0

1000

1500

ON HAND/SCH RECEIPTS

200

0

NET REQUIREMENTS

0

800

1500

PLAN. ORDER RELEASES

0

800

1500

0

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

SHADE

GROSS REQUIREMENTS:

0

800

1500

0

ON HAND/SCH RECEIPTS

400

0

NET REQUIREMENTS

0

400

1500

0

PLAN. ORDER RELEASES

0

400

1500

0

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

FRAME

GROSS REQUIREMENTS:

0

800

1500

0

ON HAND/SCH RECEIPTS

100

0

NET REQUIREMENTS

0

700

1500

0

PLAN. ORDER RELEASES

0

700

1500

0

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

NECK

GROSS REQUIREMENTS:

0

700

1500

0

ON HAND/SCH RECEIPTS

0

NET REQUIREMENTS

0

700

1500

0

PLAN. ORDER RELEASES

700

1500

0

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

SOCKET

GROSS REQUIREMENTS:

0

700

1500

0

ON HAND/SCH RECEIPTS

300

0

NET REQUIREMENTS

0

400

1500

0

PLAN. ORDER RELEASES

0

400

1500

0

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

BASE

GROSS REQUIREMENTS:

0

700

1500

0

ON HAND/SCH RECEIPTS

200

0

NET REQUIREMENTS

0

500

1500

0

PLAN. ORDER RELEASES

500

1500

0

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

Actions to be taken immediately include ordering 700 necks and 500 bases.

b.

CAPACITY PLAN FOR ASSEMBLY

***WEEK***

1

2

3

4

5

6

7

8

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

FRAME ASSEMBLY MINUTES

0

10500

22500

0

LAMP ASSEMBLY MINUTES

0

4000

7500

0

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

TOTAL ASSEMBLY MINUTES

0

10500

22500

4000

7500

0

TOTAL ASSEMBLY HOURS

0

175

375

66.67

125

0

175 hours are required in week 4, 375 in week 5, 66 2/3 in week 6, and 125 hours

in week 7. If insufficient assembly time is available, the firm can either use

overtime or adjust the master schedule.

c. If the lead time for assembly of lamps will be extended from one to two weeks, it

will be necessary to find a way to obtain the 500 bases and 700 necks required to

the 2 week lead time for frames compressed.

8. a. 200 phones can be delivered from inventory in week 1, 250 can be assembled from

handset and base subassemblies and delivered in week 2, and 125 can be assembled

from component parts and delivered in week 3.

Materials Plan:

9. a.

**** WEEK ****

*****PART*****

1

2

3

4

BODY

GROSS REQUIREMENTS:

0

200

0

ON HAND/SCH RECEIPTS

25

0

NET REQUIREMENTS

0

175

0

PLAN. ORDER RELEASES

175

0

——-

——————–

—–

—-

–

—–

–

HEAD

GROSS REQUIREMENTS:

0

200

0

ON HAND/SCH RECEIPTS

50

0

NET REQUIREMENTS

0

150

0

PLAN. ORDER RELEASES

0

150

0

——-

——————–

—–

—-

–

—–

–

ARM

GROSS REQUIREMENTS:

0

400

0

ON HAND/SCH RECEIPTS

60

0

NET REQUIREMENTS

0

340

0

PLAN. ORDER RELEASES

340

0

——-

——————–

—–

—-

–

—–

–

LEG

GROSS REQUIREMENTS:

0

400

0

ON HAND/SCH RECEIPTS

80

0

NET REQUIREMENTS

0

320

0

PLAN. ORDER RELEASES

0

320

0

——-

——————–

—–

—-

–

—–

–

All orders are allowed one week for assembling. To meet the plan we need to order

immediately 340 arms and 175 bodies.

b. 25 robots can be assembled in one week and delivered to the customer ASAP. The

implication from this example is that this MRP system needs one week in order to

assemble the final product. For orders bigger than 25 we need the full four weeks

to be able to deliver on time.

c. This will move the order for heads one week ahead, so we need to place an

immediate order for 150 units from that supplier. This will protect the MRP

schedule and allow for assembly by week 4 as planned.

*****PART*****

1

2

3

4

5

6

7

8

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

LAMP

GROSS REQUIREMENTS:

0

1000

1500

ON HAND/SCH RECEIPTS

200

0

NET REQUIREMENTS

0

800

1500

PLAN. ORDER RELEASES

0

800

1500

0

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

SHADE

GROSS REQUIREMENTS:

0

800

1500

0

ON HAND/SCH RECEIPTS

400

0

NET REQUIREMENTS

0

400

1500

0

PLAN. ORDER RELEASES

0

400

1500

0

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

FRAME

GROSS REQUIREMENTS:

0

800

1500

0

ON HAND/SCH RECEIPTS

100

0

NET REQUIREMENTS

0

700

1500

0

PLAN. ORDER RELEASES

0

700

1500

0

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

NECK

GROSS REQUIREMENTS:

0

700

1500

0

ON HAND/SCH RECEIPTS

0

NET REQUIREMENTS

0

700

1500

0

PLAN. ORDER RELEASES

700

1500

0

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

SOCKET

GROSS REQUIREMENTS:

0

700

1500

0

ON HAND/SCH RECEIPTS

300

0

NET REQUIREMENTS

0

400

1500

0

PLAN. ORDER RELEASES

0

400

1500

0

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

BASE

GROSS REQUIREMENTS:

0

700

1500

0

ON HAND/SCH RECEIPTS

200

0

NET REQUIREMENTS

0

500

1500

0

PLAN. ORDER RELEASES

500

1500

0

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

Actions to be taken immediately include ordering 700 necks and 500 bases.

b.

CAPACITY PLAN FOR ASSEMBLY

***WEEK***

1

2

3

4

5

6

7

8

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

FRAME ASSEMBLY MINUTES

0

10500

22500

0

LAMP ASSEMBLY MINUTES

0

4000

7500

0

——-

——————–

—–

—-

–

—–

–

—–

–

—–

–

—–

–

—–

–

TOTAL ASSEMBLY MINUTES

0

10500

22500

4000

7500

0

TOTAL ASSEMBLY HOURS

0

175

375

66.67

125

0

175 hours are required in week 4, 375 in week 5, 66 2/3 in week 6, and 125 hours

in week 7. If insufficient assembly time is available, the firm can either use

overtime or adjust the master schedule.

c. If the lead time for assembly of lamps will be extended from one to two weeks, it

will be necessary to find a way to obtain the 500 bases and 700 necks required to

the 2 week lead time for frames compressed.

8. a. 200 phones can be delivered from inventory in week 1, 250 can be assembled from

handset and base subassemblies and delivered in week 2, and 125 can be assembled

from component parts and delivered in week 3.

Materials Plan:

9. a.

**** WEEK ****

*****PART*****

1

2

3

4

BODY

GROSS REQUIREMENTS:

0

200

0

ON HAND/SCH RECEIPTS

25

0

NET REQUIREMENTS

0

175

0

PLAN. ORDER RELEASES

175

0

——-

——————–

—–

—-

–

—–

–

HEAD

GROSS REQUIREMENTS:

0

200

0

ON HAND/SCH RECEIPTS

50

0

NET REQUIREMENTS

0

150

0

PLAN. ORDER RELEASES

0

150

0

——-

——————–

—–

—-

–

—–

–

ARM

GROSS REQUIREMENTS:

0

400

0

ON HAND/SCH RECEIPTS

60

0

NET REQUIREMENTS

0

340

0

PLAN. ORDER RELEASES

340

0

——-

——————–

—–

—-

–

—–

–

LEG

GROSS REQUIREMENTS:

0

400

0

ON HAND/SCH RECEIPTS

80

0

NET REQUIREMENTS

0

320

0

PLAN. ORDER RELEASES

0

320

0

——-

——————–

—–

—-

–

—–

–

All orders are allowed one week for assembling. To meet the plan we need to order

immediately 340 arms and 175 bodies.

b. 25 robots can be assembled in one week and delivered to the customer ASAP. The

implication from this example is that this MRP system needs one week in order to

assemble the final product. For orders bigger than 25 we need the full four weeks

to be able to deliver on time.

c. This will move the order for heads one week ahead, so we need to place an

immediate order for 150 units from that supplier. This will protect the MRP

schedule and allow for assembly by week 4 as planned.