Manufacturing Resource Planning and Hand Forecast Project

Homework: MRP & MPS
Due: August 12th
Discussion Questions
1.-What is the difference between a gross requirements plan and a net requirements plan? 2.-What are the differences between MRP & MPS?
3.-MRP is more than an inventory system, what additional capabilities does MRP possess? 4.-What functions of the firm affect a MRP systems? How?
5.-How does MRP II differ from MRP?
6.-What are the differences between SOP & MPS?
7.-What is the meaning of Bill of Material ?

Problems
1. You have developed the following simple product structure of items needed for you gift bag for a rush party, for prospective pledges in your organization. Your forecast
200 attendees. Assume that there is no inventory on hand of any of the items. Explode the bill of material (Subscripts indicate the number of units required).

J
K(1)
J

M(2)
L(4)
J
444
2. You are expected to have the gift bags in Problem 1 ready at 5p.m.However you need to
)44
personalize the items(monogrammed pens, note pads, literature from the printer, etc.). The lead time is 1 hour to assembled 200 Js once the other items are prepared. The other items will take a while as well. Given the volunteers you have, the other time estimates are item K (2 hours),item L (1hour),and item M(4 hours).Develop a time-phased assembly plan to prepare the gift bags.
3. The demand for subassembly S is 100 units in week 7.Each unit of S requires 1 unit of T and 2 units of U. Each unit of T requires 1 unit of V,2 units of W and 1 unit of X. Finally , each unit of U

requires 2 units of Y and 3 units of Z. One firm manufactures all items. It takes 2 weeks to make
S,1 week to make T,2 weeks to make U,2 weeks to make V,3 weeks to make W,1 week to make
X,2 weeks to make Y, and 1 week to make Z.
a) Construct a product structure, Identify all levels, parents, and components.
b) Prepare a time-phased product structure.
4. Using discrete available to promise (ATP) logic, calculate the MPS for the following conditions.
How many units are available to promise in period 4 ?
Period
One hand
Forecast
Project
20
available balance ATP(discrete)
MPS
Lot size=30, Safety stock=15 1
25

2
23

3
30

4
20

5.-Level demand

1
15

Forecast
Avaible(End)
MPS
20
On
30
Hand(start)

2
15

3
15

4
15

5
10

6
10

7
10

8
10

9
5

10
5

11
5

12
5

20

20

20

20

20

20

20

20

20

20

20

6.-

1
Forecast
10
Avaible(ending)
MPS
0
On
30
hand(starting)

2
10

3
10

4
10

5
10

6
20

7
20

8
20

9
20

0

0

40

0

0

0

40

0

7.-Rolling through time
Period
On hand
Forecast
Project
15
available balance MPS
Lot size=35
Safety stock =10 units 1
25

2
25

35

3
25

4
15