Product Y is manufactured from one component P, three components Q and two comp

P is manufactured from two parts of S.

Q is made from a part of S
R is made from two S parts and three T parts

Using data from question 3

Master Program for Y:
Yo
Waiting time 2 Lot size
Availability Week 30 Planning time
01 23
Forecast 20 25 20
Customer orders 26 21 13
Availability Projection

Available for pledge

PMP 50

Part Wait time Lot size Availability

AND 1 Lot x lot 30

Q 2 40 15
Q 2 100 8

R 3 120 30
Yes 2 500 20
T 2 600 370
to. Complete the MRP explosion for product Y. Identify any problems

Y COMPONENT MRP (One P component is needed, three comp

1
Wait time Lot size
Availability 30 Scheduled reception
Week 0 1 2 3
Greater demand 26 25 20
Gross Requirement
Scheduled Receptions
Availability Projection 30 13 5 5
Net Requirement 9 17 20
Planned Order Releases 9 17 20 30

P COMPONENT MRP (A P component is needed to manufacture

Wait time 2 Lot size

Availability 15 Scheduled reception
Week -1 0 1
9 17
Planned Order Releases (Y)
Gross Requirement 9 17
Scheduled Receptions
Availability Projection 15 6 29
Net Requirement 11
Planned Order Releases 40 40

Q COMPONENT MRP (Three components of Q are needed to

Waiting time Availability Lot size

Scheduled reception
Week -2 -1 0 1

9 17
Planned Order Releases (Y)
Gross Requirement 27 51
Scheduled Receptions 0 0 0
Availability Projection 8 81 30
Net Requirement 19
Planned Order Releases 100 100 100

MRP OF COMPONENT R (Two components of R are needed to

3
Wait time Lot size
Availability 30 Program reception
- -
Week 2 1 0
Gross Requirement 18
Scheduled Receptions
Availability Projection 30 12
Net Requirement
Planned Order Releases 120 120

MRP OF COMPONENT S (Two components of S are needed to

and two components of S to make a single product of R)
Wait time 2 Lot size
Availability 20 Program reception
Week -2 -1 0
LPP of P - S (2) 40
LPP of Q - S (1) 100 100
LPP of R - S (2) 120 120
Gross Requirement 340 80 340
Scheduled Receptions 500
Availability Projection 20 180 100 260
Net Requirement 240
Planned Order Releases 500 500
Planned Order Releases (Y) 9
T COMPONENT MRP (Three T components are needed to
2
Wait time Lot size
Availability 370 Scheduled reception
Week -2
LPP of R - T (3) 120
Gross Requirement 360
Scheduled Receptions
Availability Projection 370 610
Net Requirement 60
Planned Order Releases 600

The demand of the first weeks is affected since, m

b. The Part S provider tells you that your delivery will be delayed for a week.
3 Lot size
Waiting time Availability 20 Program reception
Week -3 -2 -1 0
LPP of P - S (2) 40
LPP of Q - S (1) 100 100
LPP of R - S (2) 120 120
Gross Requirement 340 80 340
Scheduled Receptions 500
Availability Projection 20 180 100 260
Net Requirement 240
Planned Order Releases 500 500
onentes R.

50 Inv.
urity 0
Sec
ion 10
4 5 67 8 9 10
30 20 20 25 25 25 25
8 3 10 0 5 0

50 50 50 50

Inv. Security
Scheduled receptions
None 5
None None
None 8

None None
500, week 1 20
None 50
 ma and analyze possible solutions

components Q and two components R to make a single product Y)

Lot x lot Inv. Security 5
to None
4 5 678 9 10
30 20 20 25 25 25 25

5 5 555 55
30 20 20 25 25 25 25
20 20 25 25 25 25

ar a single product of Y)
40 Inv. Security None
to None
2 3 456 789

20 30 20 20 25 25 25 25

20 30 20 20 25 25 25 25

9 19 39 19 34 9 24 39
21 16 16 1
40 40 40 40

manufacture a single product of Y)

100 Inv. Security 8
to None Component of Q 3
 2 3 4 5 6 7 8 9
20 30 20 20 25 25 25 25

60 90 60 60 75 75 75 75
0 0 0 0 0 0 0
70 80 20 60 85 10 35 60
30 20 40 15 65 40
100 100 100 100

manufacture a single product of Y)

120 Inv. Security None
gives None Component of R 2
1 2 3 4 5 6 7 8
17 20 30 20 20 25 25 25

34 40 60 40 40 50 50 50

98 58 118 78 38 108 58 8
22 2 12
120 120

make a single product of P, a component of S to make a so

500 Inv. Security 20

gives 500
1 2 3 4 5 6 7 8
40 40 40 40 40

100 100 100 100 100

120 120
180 80 340 180 420 180

80 500 160 480 480 60 380 380

20 40 120
500 500
open a single product from R)
600 Inv. Security 50
to None T 3 component
-1 0 1 23456
120 120 120
360 360 360

610 250 250 250 490 490 490 130

160
600

More time to order batches for subsequent production execution

What problems does this cause and what possible alternatives are there?
500 Inv. Security 20
gives 500
1 2 3 4 5 6 7 8
40 40 40 40 40
100 100 100 100 100
120 120
180 80 340 180 420 180

80 500 160 480 480 60 380 380

20 40 120
500 500
01
0
0

39
 1
0
0

60

9 10
25 0

50 0

78 78
42

or product of Q

9 10

380 380
 7 8 9 10

130 130 130 130

9 10

380 380
Product Y is manufactured from one component P, three components Q and two comp
P is manufactured from two parts of S.
Q is made from a part of S
R is made from two S parts and three T parts

Using data from question 3

Master Program for Y:
Wait time 2 Lot size
Availability 30 Planning time
Week 0 1 2 3
Forecast 20 25 20
Customer orders 26 21 13
Availability Projection 30 4 33 13
Available for pledge 4 16
PMP 50

Part Wait time Lot size Availability

AND 1 Lot x lot 30

Q 2 40 15
Q 2 100 8

R 3 120 30
Yes 2 500 20
T 2 600 0 370 0
a. Complete the MRP explosion for product Y. Identify any problems

Y COMPONENT MRP (One P component is needed, three comp

1
Wait time Lot size
Availability 30 Scheduled reception
Week 0 1 2 3
Gross Requirement 50
Scheduled Receptions 0 0 0
Availability Projection 30 30 5 5
Net Requirement 25
Planned Order Releases 25 50

P COMPONENT MRP (A P component is needed to manufacture

2 Lot size
Waiting time Availability 15 Scheduled reception
Week 0 1 2
Gross Requirement 25
Scheduled Receptions 0 0 0
Availability Projection 15 15 30 30
Net Requirement 10
Planned Order Releases 40 40

Q COMPONENT MRP (Three components of Q are needed to

2
Wait time Lot size
Availability 8 Scheduled reception
Week 012
Gross Requirement 75
Scheduled Receptions 0
 Availability Projection 8 8 33 33
Net Requirement 75
Planned Order Releases 100 200

MRP OF COMPONENT R (Two components of R are needed to

3
Wait time Lot size
Availability 30 Program reception
Week -1 0 1
Gross Requirement 50
Scheduled Receptions 000
Availability Projection 30 30 30 100
Net Requirement 20
Planned Order Releases 120

MRP OF COMPONENT S (Two components of S are needed for a

single product of Q and two components of S to manufacture a single
product
2
Wait time Lot size
Availability 20 Program reception
Week 012
Gross Requirement 280 240
Scheduled Receptions 0 500 0
Availability Projection 20 20 260 20
Net Requirement
Planned Order Releases 500

T COMPONENT MRP (Three T components are needed to

2
Wait time Lot size
Availability 370 Scheduled reception
Week 012
Gross Requirement 360
Scheduled Receptions 0
Availability Projection 370 370 370 610
Net Requirement 0 060
Planned Order Releases 600

The demand of the first weeks is affected since, m

b. The Part S provider tells you that your delivery will be delayed for a week.
Wait time 3 Lot size
Availability 20 Scheduled reception
Week -1 0 1
Gross Requirement 280
Scheduled Receptions 500
Availability Projection 20 20 20 260
Net Requirement
Planned Order Releases 500
onentes R.

50 Inv. Security 0
ion 10
4 5 6 7 8 9 10
30 20 20 25 25 25 25
8 3 1 0 0 5 0
33 13 43 18 43 18 43
39 49 45 50
50 50 50 50

Inv. Security
Scheduled receptions
None 5
None None
None 8

None None
500, week 1 20
None 50
ma and analyze possible solutions

components Q and two components R to make a single product Y)

lo
t ex lo te e Inv. Security 5
to None
4 5 6 7 8 9 10
50 50 50 50
0 0 0 0 0 0 0
5 5 5 5 5 5 5
50 50 50 50

50 50 50

ar a single product of Y)

40 Inv. Security None

to None
3 4 5 6 7 8 9 10
50 50 50 50

0 0 0 0 0 0 0
20 20 10 10 0 0 30 30
20 30 40 50
40 40 80

manufacture a single product of Y)

100 Inv. Security 8
to None Q component 3
3 4 5 67 8 9 10
150 150 150 150
0 0 0 00 0 0
 83 83 33 33 83 83 33 33
125 75 109 75
100 200 100

manufacture a single product of Y)

120 Inv. Security None
gives None Component of R 2
2 3 4 5 6 7 8 9
100 100 100 100
0 0 0 0 0 0 0 0

100 0 0 20 20 40 40 60
100 80 60
120 120 120

manufacture a single product of P, a component of S to manufacture a

product of R)
500 Inv. Security 20
gives 500
3 4 5 6 7 8 9 10
180 240 280 240 180 0 0 0
0 0 0 0 0 0 0
340 100 320 80 400 400 400 400
180 200 120
500 500

manufacture a single product of R)

600 Inv. Security 50
to None
3 4 5 6 7 8 9 10
360 360
0 0 0 0 0 0 0 0
610 250 250 490 490 490 490 490

16
0
 60
0

More time to order batches for subsequent production execution

What problems does this cause and what possible alternatives are there?
500 Inv. Security 20
to 500 weeks1
2 3 456 789
240 180 240 280 240 180 0 0

0 0 000 000
20 320 80 300 60 380 380 380
-140 -180 -100
500 500
10

0
60
 10
0
0
380
 Product “X” has the following product structure. Additionally, they present
themselves to. Complete the master schedule and generate the MRP records for
each of the

b. Suppose the supplier of the 600 “C” parts scheduled for the week implications
of this? Describe ALL possible options in this case.

Product "X"
Master Program for Y: 1
Y COMPONENT MRP (One P component is needed, three comp 2
P COMPONENT MRP (A P component is needed to manufacture 2
Q COMPONENT MRP (Three components of Q are needed to 2
MRP OF COMPONENT R (Two components of R are needed to 3
T COMPONENT MRP (Three T components are needed to 4
components Q and two components R to make a single product Y) 6
manufacture a single product of Y) 6
manufacture a single product of Y) 7
make a single product of P, a component of S to make a so 7
open a single product from R) 8
or product of Q 11
Y COMPONENT MRP (One P component is needed, three comp 14
P COMPONENT MRP (A P component is needed to manufacture 14
Q COMPONENT MRP (Three components of Q are needed to 14
MRP OF COMPONENT R (Two components of R are needed to 15
MRP OF COMPONENT S (Two components of S are needed for a single product of Q
and two components of S to manufacture a single product 15
T COMPONENT MRP (Three T components are needed to 15
components Q and two components R to make a single product Y) 18
manufacture a single product of Y) 18
manufacture a single product of Y) 19
manufacture a single product of P, a component of S to manufacture a product of R) 19
manufacture a single product of R) 19
MRP OF COMPONENT A 27
COMPONENT B MRP 27
COMPONENT C MRP 27
COMPONENT D MRP 28
COMPONENT E MRP 28
3) 30
MRP OF COMPONENT C (Three components of C are needed to 39
MRP OF COMPONENT D (2 components of D are needed for only product C) 39
MRP OF COMPONENT D (2 components of D are needed for only product C) 40
MRP OF COMPONENT E (Two components of E are needed to 40
enrich a single product A) 42
to manufacture a single product A) 43
manufacture a single product B and 1 single component of D to manufacture a 43
manufacture a single product B and 1 single component of D to manufacture a 200
to manufacture a single product C) 200
List of Materials to produce A 45
MRP OF COMPONENT A 45
COMPONENT B MRP 46
COMPONENT C MRP 46
COMPONENT D MRP 46
COMPONENT E MRP 47
D (1) E 54
(2) 58
List of Materials to produce A 60
*' 60
B (3) C (2) 60
E (2) D (1) E (1) D ( 60
MRP OF COMPONENT B (Three components are needed 60
MRP OF COMPONENT C (Two components are needed 61
MRP OF COMPONENT D (One component d is needed to manufacture a single product
of B) 61
MRP OF COMPONENT E (Two components are needed to make a single product of C) 61
MRP OF COMPONENT E (With 140 defective units 63
2) 64
of B to manufacture a single product A) 64
of C to manufacture a single product A) 65
e C to manufacture a single product of B and two components of C to 65
E to manufacture a single product of B and a component of E to 65
List of Materials to produce A 69
B (1) 69