Operations Management: Processes and Supply Chains (12th Edition) (What's New in Operations Management)
12th Edition
ISBN: 9780134741062
Author: Lee J. Krajewski, Manoj K. Malhotra, Larry P. Ritzman
Publisher: PEARSON
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Chapter 11, Problem 29P
The bill of materials and the data from the inventory records for product A are shown in Figure 11.47. Assume that the MPS start quantities for A are 50 units in weeks 1, 2, and 3, and 150 units in weeks 6 and 8. Derive an MRP plan for the components going into product A using the data in Table 11.17.
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The bill of materials and the data from the inventory records for product A are shown in the figure to the right. Assume that the MPS start quantities for A are 70 units in weeks 1, 2, and 7. Derive an MRP plan for the components going into product A using the data in the table below.
Item
D
Data Category
Lot-sizing rule
Lead time
Scheduled receipts
Beginning inventory
Complete the material requirements plan. (Enter your responses as integers. A response of "0" is equivalent to being not applicable.)
Item: C
Item: D
L4L
1 week
None
155
с
Gross requirements
Scheduled receipts
Projected on-hand inventory 155
Planned receipts
Planned order releases
Item: E
L4L
2 weeks
70 (week 2)
230
Gross requirements
Scheduled receipts
Projected on-hand inventory 230
Planned receipts
Planned order releases
Gross requirements
Scheduled receipts
Projected on-hand inventory
Planned receipts
Planned order releases
160
1
10
10
0
0
1
0
0
0
10
1
0
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E
FOQ = 200
2 weeks
None
160
2
0
0
0
0
NOOOO
2
70
0
ON
2…
Figure 1 shows the BOM for product A. Table 1 shows the MPS quantity start dates for product
A, and Table 2 contains data from inventory records for items B, C, and D. The production planner
wants to determine the material requirements plan for items B, C, and D for the next 8 weeks.
What is the planned receipts quantity for item D for week 6?
C (3)
D (2)
8 (1)
D (2)
C2)
Figure 1. BOM for product A
Table 1. MPS quantity start dates for product A
Week
Product
1
3
70
4.
6.
7.
8.
80
100
70
100
Table 2. Inventory record data
Item
Data category
Lot-sizing rule
Lead time
Scheduled receipts
Beginning inventory
Safety stock
LAL
2 weeks
100 (week 3)
FOQ= 500
1 week
150 (week 1)
POQ (P-4)
1 week
500 (week 1)
600
100
200
None
130
Develop a material requirements plan for component H. Lead times for the end item and each component except B are one week. The lead time for B is three weeks. Sixty units of A are needed at the startof week 8. There are currently 15 units of B on hand and 130 of E on hand, and 50 units of H are inproduction and will be completed by the start of week 2. Lot-for-lot ordering will be used for all items.
Chapter 11 Solutions
Operations Management: Processes and Supply Chains (12th Edition) (What's New in Operations Management)
Ch. 11 - Consider the master flight schedule of a major...Ch. 11 - For an organization of your choice, such as where...Ch. 11 - Consider a service provider that is in the...Ch. 11 - Complete the MPS record in Figure 11.29 for a...Ch. 11 - Complete the MPS record in Figure 11.30 for a...Ch. 11 - Prob. 3PCh. 11 - Figure 11.31 shows a partially completed MPS...Ch. 11 - Tabard Industries forecasted the following demand...Ch. 11 - Figure 11.32 shows a partially completed MPS...Ch. 11 - The forecasted requirements for an electric hand...
Ch. 11 - A forecast of 240 units in January, 320 units in...Ch. 11 - An end items demand forecasts for the next 6 weeks...Ch. 11 - An end items demand forecasts for the next 10...Ch. 11 - Consider the bill of materials (BOM) in Figure...Ch. 11 - Product A is made from components B, C, and D....Ch. 11 - What is the lead time (in weeks) to respond to a...Ch. 11 - Product A is made from components B and C. Item B,...Ch. 11 - Refer to Figure 11.23 and Solved Problem 1. If...Ch. 11 - The partially completed inventory record for the...Ch. 11 - The partially completed inventory record for the...Ch. 11 - The partially completed inventory record for the...Ch. 11 - Figure 11.38 shows a partially completed inventory...Ch. 11 - A partially completed inventory record for the...Ch. 11 - The BOM for product A is shown in Figure 11.40,...Ch. 11 - The BOMs for products A & B and data from the...Ch. 11 - Figure 11.42 illustrates the BOM for product A....Ch. 11 - The following information is available for three...Ch. 11 - Figure 11.44 shows the BOMs for two products, A...Ch. 11 - The BOM for product A is shown in Figure 11.45....Ch. 11 - Refer to Solved Problem 1 (Figure 11.23) for the...Ch. 11 - The bill of materials and the data from the...Ch. 11 - The bill of materials and the data from the...Ch. 11 - The McDuff Credit Union advertises their ability...Ch. 11 - Suppose that the POQ for item B is changed from 3...Ch. 11 - As the on-hand inventory for item C increases from...Ch. 11 - As the fixed order quantity (FOQ) for item D...Ch. 11 - As the lead time for item C changes, what happens...
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- a. One hundred twenty units of end item Z are needed at the beginning of week 7. Prepare a material requirements plan for component C. Take into account that on hand there are 40 units of Z,70 units of A, 100 units of B, and 30 units of C. Also, there is a scheduled receipt of 20 units ofcomponent C in week 4. Lead times are two weeks for Z and B, and one week for the other components. Lot-for-lot ordering will be used for all items b. Ninety-five units of end item E are needed at the beginning of week 7. Prepare a material requirements plan for component D. Take into account that 5 units of E are currently on hand, as well as50 units of B, 100 units of C, and 80 units of D. Also, 30 units of C have been outsourced and areexpected to arrive in week 4. Lead times are two weeks for E and C, and one week for the othercomponents. Assume lot-for-lot ordering except for D, where multiples of 40 must be used.arrow_forwardThe MRP gross requirements for Item A are shown here for the next 10 weeks. Lead time for A is three weeks and setup cost is $10. There is a carrying cost of $0.010 per unit per week. Beginning inventory is 100 units. WEEK 4 10 Gross requirements 40 205 40 20 30 60 80 20 60 100 Use the least total cost and the least unit cost lot-sizing methods to determine the quantity to order with the first order released with each method and which periods' requirements will be covered by that order. Quantity Ordered Periods Covered Least total cost Least unt costarrow_forwardWhat will be projected on hand inventory of item S in week6?arrow_forward
- Item STUVWX>N Y 2. The demand for assembly S is 100 units and it is due in Week 15. Each unit of S requires one unit of T and 0.5 units of U. Each unit of T requires one unit of V, two units of W, and one unit of X. Finally, each unit of U requires 0.5 units of Y and three units of Z. Z Item S T U V W X Y Z a) Calculate the planned orders for all the items. b) Use time phasing to determine an overall schedule. S OH Gross Requirements Inv 100 20 20 10 30 30 15 25 10 2 1 1 1 2 2 1 Lead Time Due Date (weeks) (week) 15 1 T W (2) X Net Requirements Release Date U (0.5) Y (0.5) Planned Order Z (3) Lot Size Policy L4L X10 X5 Min 50 F100 X50 F100 Min 100arrow_forwardThe gross requirements for item A are specified for the beginning of weeks 1 through 12 in the table that follows. Item A, Level 0 01 02 03 04 05 06 07 08 09 10 11 12 0 60 0 50 0 70 0 40 0 60 0 50 60 ? ? ? ? ? ? ? ? ? ? ? ???????????? Gross requirements. Projected on hand Planned order release The lead time is 2 weeks. The current on hand inventory, at the beginning of week 1 is 60 units. If the order cost is $80 per order and the inventory cost is $1 per unit per period, and the order quantity is the computed part period (or a multiple of the computed part period) when it is necessary to place an order, what is the total cost for the 12 week period? Answer:arrow_forward3. Item Z has a lead time of two weeks; A, B, C and D take one week each and E takes 3 weeks. Fifty units of Z are required in period 10. Assume that there is currently no inventory on hand of any of these items. Consider the following Bill of material and develop an MRP schedule for A, B, C, D and E showing gross and net requirements and order releases and order receipt dates. Assume Lot-for-lot ordering. C(3) A(2) Z D(4) E(2) B(4) Level 0 1 2 3arrow_forward
- The three tables above show the master production schedule and the bill of materials of part A, and the inventory records of all the parts. There are no scheduled receipts. Given this information, what is the net requirement of part A in Week 4?arrow_forwardProblem 9-11 (Algo) Assume that Product Z is made of two units of A and three units of B. A is made of three units of C and four of D. D is made of two units of E. Lead times for purchase or fabrication of each unit to final assembly are: Z takes two weeks; A, B, C, and D take one week each; and E takes three weeks. Fifty five units of Product Z are required in Period 10. (Assume that there is currently no inventory on-hand of any of these items.) b. Develop an MRP planning schedule showing gross and net requirements and order release and order receipt dates. (Leave the cells blank, whenever zero (0) is required.) Item: Z OH: 0 LT: 2 SS: 0 Q: L4L Item: A OH: 0 LT: 1 SS: 0 Q: L4L Item: B OH: 0 LT: 1 SS: 0 Q: L4L Period: Gross requirements Scheduled receipts Projected available balance Net requirements Planned order receipts Planned order releases Gross requirements Scheduled receipts Projected available balance Net requirements Planned order receipts Planned order releases Gross…arrow_forwardThe bill of materials and the data from the inventory records for product A are shown in the figure to the right. Assume that the MPS start quantities for A are 70 units in weeks 1, 2, and 7. Derive an MRP plan for the components going into product A using the data in the table below. Data Category Lot-sizing rule Lead time Scheduled receipts Beginning inventory Item: C L4L 1 week None 155 Item: D с Gross requirements Scheduled receipts Projected on-hand inventory 155 Planned receipts Planned order releases Item: E Complete the material requirements plan. (Enter your responses as integers. A response of "0" is equivalent to being not applicable.) Gross requirements Scheduled receipts Projected on-hand inventory Planned receipts Planned order releases L4L 2 weeks 70 (week 2) 230 Item D 230 Gross requirements Scheduled receipts Projected on-hand inventory 160 Planned receipts Planned order releases 1 П 1 E FOQ = 200 2 weeks 1 None 160 2 0 N200 70 2 ☐☐☐ 3 ☐☐☐ 1 3 3 4 0 4 ☐☐☐ 4 Lot Size:…arrow_forward
- Product A is made from components B and C. Item B, inturn, is made from D and E. Item C also is an intermediateitem, made from F and H. Finally, intermediate item E ismade from H and G. Note that item H has two parents. Thefollowing are item lead times: a. What lead time (in weeks) is needed to respond to a cus-tomer order for product A, assuming no existing invento-ries or scheduled receipts?b. What is the customer response time if all purchased items(i.e., D, F, G, and H) are in inventory?c. If you are allowed to keep just one purchased item instock, which one would you choose?arrow_forwardProduct A is made from components B and C. Item B, inturn, is made from D and E. Item C also is an intermediateitem, made from F and H. Finally, intermediate item E ismade from H and G. Note that item H has two parents. Thefollowing are item lead times:a. What lead time (in weeks) is needed to respond to a cus-tomer order for product A, assuming no existing invento-ries or scheduled receipts?b. What is the customer response time if all purchased items(i.e., D, F, G, and H) are in inventory?c. If you are allowed to keep just one purchased item instock, which one would you choose?arrow_forwardIn the following MRP planning schedule for Item J, indicate the planned order releases to meet the gross requirements. Lead time is one week and there is no inventory on hand and no safety stock.arrow_forward
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