ToysPlus, Inc.
Teaching Notes
3
release. Therefore, we will not have enough of part #523 to support the master schedule. In
the case of part number 525 all of the net requirements have been translated into planned order
releases, so we will have enough of these parts. This process of examination is continued and
indicates the following components are short of parts to support the master schedule #730,
#732, #734, and #736. This situation must be relieved by revising the master schedule to “live”
within the available parts.
The new master schedule is shown in Exhibit 2. This master schedule reflects the available
components and is reduced in capacity toward the end of the six-week period in order to
achieve 15 turns. This master schedule is constructed by using all of the available parts,
including the safety stock, but no more in scheduling each toy. For example, starting with
robots which have the lowest runout time, we can schedule 1600 robots based on the availabil-
ity of components. The constraining component in this case is robot bodies which take two
weeks to get. The next lowest runout time is autos, and we can schedule 2450 autos before we
run out of parts (900 in week 1 and 1550 in week 2).
This constraint of 2450 is based on the 9800 wheels which are used at the rate of 4 per auto
and it takes 2 weeks to get more. This process is continued until there is sufficient lead time to
schedule more units of each toy.
Note, that capacity is reduced to 315 hours in week 3 and then to 280 hours for the remainder of
the schedule. These numbers were selected by trial-and-error in order to increase inventory
turns. However, this capacity plan is not entirely satisfactory, because we should have enough
capacity at the end of the planning horizon to sustain the schedule. The required capacity in
week 6 and beyond can be computed as follows: 1500(.1) + 300(.2) + 600(.15) = 300 hours
based on a continuing demand of 1500 autos, 300 trucks and 600 robots from week 6 onward.
At the end of the horizon we have only 280 hours of capacity, so perhaps we should cut
capacity sooner, but not as deeply.
Review of the parts explosion in Exhibit 2 shows that the plan is feasible and all net
requirements are met with planned order releases or safety stock. This plan also meets
management’s requirement for 15 turns. We have no way of estimating the service level
provided without knowing more about the standard deviation of forecast errors.
So far, we have answered the first 4 case discussion questions. Question 5 asks how Andrea
should deal with the organization issues presented in this case. I think that the essence of the
answer to this question is that she needs cooperation from all of the departments to develop
and implement her production plans. Marketing should be held accountable for the accuracy of
its forecasts. Andrea should not adjust the forecasts that marketing gives her without
negotiating changes with marketing. Purchasing should buy what is ordered by production.
When everyone is working to the same production plan, improved results will be achieved. This
is easier said than done, but cooperation among functions is the essence to achieving good
results from a formal production planning system.
One way to help achieve the level of cooperation needed is to have all Department Heads and
the General Manager meet each week to review and approve the final production plans
developed. This meeting will help insure that everyone has agreed to the same set of numbers
and assumptions. The company must also reward a cooperative team approach and