Class Problems: Chapter 14, Material Requirements Planning Problem 1: ‘The Hunicut and Hallock Corporation makes two versions of the same basic file cabinet, the TOL (Top-of-the-line) five drawer file cabinet and the HQ (High-quality) five drawer filing cabinet. ‘The TOL and HQ use one unit each of the same cabinet frame and locking mechanism (A). The drawer assemblies are different (5 units of B for each TOL and 5 units of F for cach HQ). Both drawer assemblies B and F use one unit of the same drawer frame assembly (C) for each drawer assembly. Further, the drawer assembly B for the TOL cabinet uses one sliding assembly (D) that requires eight bearings (E), and the drawer assembly F for the HQ cabinet uses one sliding assembly (G) and each G requires only four of the same bearings (E). Develop a material structure tree for the TOL and the HQ file cabinets. LEVEL O ToL. leer 4 Aw Be Lever a Cup Deo) ae fie cs) Eat? ae Coot met Lrome ae tet (Care Br Drawaev assenlly Ec Drawev Asstt mB es ng cz Drawer Leame (Common fx Ds sliding ately fa a Ga Sliding assenby fn F poe frac) re) MPS jhee: TOK, HQ oO vender thease: AC, & U A, e,F wie (Wok 74 -proen) ts BDF, 6- 2Problem 2: Determine the overall lead time for the two end products TOL and HQ. Item Lead time re Time phaoch product Prvcwe. A anmooeProblem 3: Suppose that the production of 100 TOL and 300 HQ file cabinets is planned. Further suppose that the following inventories are available. Determine the low-level code and calculate the net requirements for all the component items. Item ___Available : Ree ooble ctl ee ee A = 8 Sool ey eel econo ae Lie c a Tac leo eo. TH, HR E S00 eee Aes ecco : A, B,F a2 F 350 Cy & G 1000 » 3 € fi Item Gross requirement Available Net requirement cag = Txsoly (x HO 400-200 A 2 1Gs6) 1 (08) =40D ace) [Be] Sx you S00-320 6 per 5 Clos SOO oe =([ae0 c SAH 1s00-150 Ne 5 Gena (cee (i 3se] Lever > 1KB + ILE iSse- 1 (200) = 200 G IxF = 1 (135d)= 1350FOR = Pwmjeten on hanrK Por for weeks + SR for week b- GR for Por 2 Wek tat = SR=s, veeek Problem 4: Develop a net material requirements plan for the TOL and HQ file cabinets. Item Scheduled Receipts Available A Week #1 = 200 200 B None 250 c Week #1 =600, Week #2 = 600 800 D Week #1 = 200 100 € Week #1 = 3000, Week #2 =3000 3000 F Week #1 =800 = G Week #1 = 500. NRet Lead time 1) Loan g Lot Ta. 3 1 Ae Ge 1 nies Co, : > & 2 a Re age eee eat ten te ep Yn We Gen vssele)) Week: 1 2 3 6 7 8 MPS for TOL 50 40 40 a 60 80 MPS for HQ. 100 200, 200, 200 300 oot 20, Ta Te Wa GRE I MPS OPTOL TC Mes END Week: 1 2 4 5 6 7 8 Gross reauiremeMeR) | Frool*? _[h2.,| reo [6° [€9,5| soo [BO Scheduled receipts - 00 | Pajeded Boot qedenkons 4 Proieted ontand [Aoo |QOO*aSe|210| 0 | o | o |Plo ak We) | net Requirement ap 20 [200 | 66 2b0 [Sp | Bo Atle Planned receipts SWE Zo [200 [60 [abo |300 [So Plamen ordcrcimes Bo|a0o bo [Rbo [3m [so Curent Hee item {> UT= | week = Sx MPS ef TOL. Week: ae Sea | AT | TT Gross requirement ASC |2o00| Roo 30 |z00 4yeo Scheduled receipts Projected on-hand |ASO|250/ O | O o|o ° o|o Net Requirement 220 |Q00 300 |200 Zz Planned receipts pZyy7ja0o 200 Bo |Zp0 a Planned order releases 260 |Qa00 200| 300 400 CR fv b= (Pon fe wnat + 26-fr,) ip posinve - Oflewise NR =OItem t= 2 neke GRz FSX MPS HQ Week: 1 2 3 4 5 6 7 8 Gross requirement, 500 1006] 1000 | (000 | 500) ‘Scheduled receipts 800 Projectedon-hand |/50 |150 |450 |U490| O ° o ° Net Requirement 550 |1n00 {000 [1500 Planned receipts 550 | Jovo [200 |15o0 Plannedorderreleases — |S50°7 |o00 loco | soo 49 PORL= Planned oder velonsee (Tre last reve item _C t= weeks GR= Ix PORL FB4 ( its [week GR= |x PORLOLB Week: eas (lar ats | marae ats 3 Gross requirement A [Ao 3e0| 300 Scheduled receipts 200 Projected on-hand | | [100 |10O | O Olo 2) ° Net Requirement 100 200 |200 4400 Planned receipts | loo 200 |3p0 4oo Planned order releases loo 200| j00 4noitem ue | Wie Ge = (x PORE LE Week: 1 laa una Wea | EES ci] eva |e Gross requirement 550 | ex? {o00} 1500 Scheduled receipts 500 Projected on-hand | Onin. ° ea |e Net Requirement So | {000 (000 ||IS00 Planned receipts 50 | ooo lv00 | (500 Planned order releasds 5D)! ( 00>) (00° | (500. exuprm eae WD Wake GRE EXPORT D + PORE C— Semmes eae eet Scheduled receipts 3000 | 2e00 | | Projected on-hand [p00 3000 | |a00|/4200| 0 | 2 | o Net Requirement 250 Gyo 222 Planned receipts yoo Der Planned order releases 2200 Yo D200 Actin The t repal be eateries aie al Lash of Port for weele #1 Biss ec secures eae sa over ; fov 30 unl oe orto 200 ui op @ Lorde S50 unileg G Ges (270 uvilA © ede loo une A D ovhe loco wilh F Ca pda, 2200 units PE 4 Excopion roped 1. Se units q & is rapeseed Ufa prook A bub net avetlble.Problem 5: For item B, the setup cost is $250 per setup and the inventory carrying cost is $0.90 per unit per week. Determine the lot sizes and total cost for this item under (i) Lot- for-Lot, (ii) EOQ, and (iii) POQ methods. Let Jead time be 1 week. (i) Lot-for-lot @='2s0 , H= 0 Fe /awit [wok . Item & its | week . Week: Tot | ata 0he | taerat | era eS elm] Ravel uule Gross requirement. 250 200 200 250 300 300 0 400 Scheduled receipts 150 oO oO oO oO O oO oO Projected on-rand | 10 [100 |(o |» |» | o | 2 | © | ® Net Requirement 00 |o00 | 250 | zoe | 30? 4ood Planned receipts 2p | 200 JAS | g00 | FeO od Planned order releases 200 | 200]250 | Goo | 300 Goo Tel costs Tole? setup ot + Torr? a No. per =6& fou le = 6x f2se = 500 Jwventosen x + Tok Canmyes Ciel S Sum of tke Exdivg : are Crtina \nvandnd-ts = Projected on bond es~§ or weld £2 ie] =o % f£0.%+ 2 aoe oil als ToRe cove Pe Leh -Uet(ii) EOQ Item its {| week Week ae rs | a | TS |r || Gross requirement 250 | 200 200 | 250 300 300 oO 400 Scheduled receipts 150 oO 0 oO oO co) oO 0 Projected on-hand |100 |ioo | © |Ib3 | 226] 76 | 139 |202|202 Net Requirement 200 |37 Day | lot 148 Planned receipts 3b3 [24> 362 | 363 363 Planned orderreleases | BL | 242 2b | b> 363 Sc Fese | itz to 8 Janik | ade OR. |ZP= 2As8 an cone [ ae ot Ae Sema Thee Apis sy asso hl 2575 = NO- of yieelty ae r ee ee Rae scree ©.40 feo cork [yedle . cot [weobe Carrgi Toe Ort rvsole = ovdoing [wv Oi i ase Seve = a0 S (2504 (ce) oe . a 4 163.352 F326 4z| wel Tork ast f- 8 wate = ote eke(ii) POQ Item us Week: 1 2 3 4 5 6 7 8 Gross requirement 250 200 200 250 300 300 oO 400 Scheduled receipts 150 0 0 oO co) oO 0 0 Projectedon-hand [100 loo [fo |Roo| © [200] © | o | o a Net Requirement 200 250 300 oo Planned receipts 00 $So 200 joo Planned order releases Yoo SSO Boo Yoo Ee previo raz,