Question 3 (a) BioShamp is a global shampoo brand with its own store in Singapore. The company sells three types of shampoo - silky smooth, hair fall and dandruff. All shampoos are produced at their single production facility in Hanoi. The production facility has already received some orders for different shampoos for the next 4 weeks, as shown in Table 3. Table 3: Orders for Shampoo Week 1 2 3 4 Silky Smooth (SS) 100 40 20 10 Hairfall (HF) 50 Dandruff (DD) 10 25 5 10 The company estimated the demand for each type of shampoo would be 500, 100 and 25 per week, respectively, on top of the orders already received. The company has an aggregate plan of 2,500 bottles for the month and wants to keep its production stable over the weeks. There are 200 bottles of silky smooth, 100 bottles of hair fall and 20 bottles of dandruff shampoo in stock at the start of the month. Develop a master schedule for the month for all types of shampoo. (b) BioShamp produces thousands of bottles of shampoo daily using a sophisticated continuous automated process. Identify the inventory approach (e.g., JIT, MRP, Deterministic demand, Probabilistic demand etc.) that the company should use to order/produce the following items: (i) Sodium lauryl sulfate, the main ingredient for producing shampoo (ii) Shampoo (iii) Bottles for the shampoo Give reasons for choosing the approaches. Table 4: MRP Schedule D E Material Requirement Planning 3 Week 4 Level 0- Solar Car (lead time 1 week) 5 Gross requirements 6 Opening stock 7 Scheduled receipts 8 Net requirements 9 Place order start assembly 10 H 1 2 3 4 5 6 9 10 100 200 20 20 20 20 20 20 20 20 20 80 200 80 200 80 200 11 Level 1- Body Assembly (1 per car, lead time 1 week) 12 Gross requirements 13 Opening stock 80 200 110 110 110 110 110 110 110 110 30 30 170 170 170 14 Scheduled receipts 15 Net requirements 16 Place order start assembly 17 18 Level 1-Wheels(4 per car, lead time 3 weeks) 19 Gross requirements 20 Opening stock 21 Scheduled receipts 22 Net requirements 23 Place order start assembly 320 800 200 200 200 200 200 200 200 200 120 800 120 800 120 800 24 Level 2 - Motor (1 per Body Assembly, lead time 3 weeks, lot size 200) 25 Gross requirements 26 Opening stock 27 Scheduled receipts 28 Net requirements 29 Place order start assembly 30 Level 2 - Solar Panel (2 per Body Assembly, lead time 1 week, lot size 400) 31 Gress requirements 32 Opening stock 33 Scheduled receipts 34 Net requirements 35 Place order start assembly (i) Develop the BOM based on the MRP table. 170 30 30 200 170 200 340 60 60 400 340 400 (ii) How many solar-powered toy cars have to be in stock at Week 0 if no material is required to be procured? (iii) The materials manager made a mistake in developing the MRP. The wheels must be purchased in a batch of 250 instead of lot-for-lot. Apply MRP to determine the schedule for the wheels. (b) Solve for the number of outstanding orders if the lead time is 3.1 and the cycle time is 1.6 months, respectively.

Transcribed Image Text:Question 3 (a) BioShamp is a global shampoo brand with its own store in Singapore. The company sells three types of shampoo - silky smooth, hair fall and dandruff. All shampoos are produced at their single production facility in Hanoi. The production facility has already received some orders for different shampoos for the next 4 weeks, as shown in Table 3. Table 3: Orders for Shampoo Week 1 2 3 4 Silky Smooth (SS) 100 40 20 10 Hairfall (HF) 50 Dandruff (DD) 10 25 5 10 The company estimated the demand for each type of shampoo would be 500, 100 and 25 per week, respectively, on top of the orders already received. The company has an aggregate plan of 2,500 bottles for the month and wants to keep its production stable over the weeks. There are 200 bottles of silky smooth, 100 bottles of hair fall and 20 bottles of dandruff shampoo in stock at the start of the month. Develop a master schedule for the month for all types of shampoo. (b) BioShamp produces thousands of bottles of shampoo daily using a sophisticated continuous automated process. Identify the inventory approach (e.g., JIT, MRP, Deterministic demand, Probabilistic demand etc.) that the company should use to order/produce the following items: (i) Sodium lauryl sulfate, the main ingredient for producing shampoo (ii) Shampoo (iii) Bottles for the shampoo Give reasons for choosing the approaches.