Documentos de Académico
Documentos de Profesional
Documentos de Cultura
3 Prepare a spreadsheet to enable material requirements planning and calculate economic order quantities.
Manufacturing
1
Gross Requirements Scheduled Receipts Available Net Requirements Planned Order Receipts Planned Order Releases
2 20
3 30
4 25
5 15 8 7 7
computer information system Determines quantity & timing of dependent demand items
2 5 25
23
33
33
another item. Consider Ford Explorer: Fords demand for auto tires and radiators depend on the production of Explorer. o 4 tires and 1 radiator go into each finished Explorer.
Computer system Mainly discrete products Accurate bill-of-material Accurate inventory status 99% inventory accuracy Stable lead times
delivery schedules Faster response to market changes Improved labor & equipment utilization Better inventory planning & scheduling Reduced inventory levels without reduced customer service
1. Master Production Schedule (MPS) 2. Bills of Materials (BOM) 3. Accurate Inventory Records 4. Purchase Orders Outstanding
Marketing: Customer Demand Aggregate Production Plan Master Production Schedule (MPS) Material Requirements Plan (MRP) Execute capacity plans
Months
Aggregate Production Plan (shows the total quantity of amplifiers
January
1,500
February
1,200
Weeks
Master Production Schedule (Shows the specific type and quantity of amplifier to be produced 240 watt amplifier
100
100
100
100
500
300
500
450
100
450
Stock to Forecast
Schedule orders
Schedule modules
Motorcycles, autos, Print shop Machine shop TVs, fast-food Fine dining restaurant restaurant
List
of the raw materials, sub-assemblies, intermediate assemblies, sub-components, components, parts and the quantities of each needed to manufacture an end product do vary somewhat in scope E.g: recipe for cake, specifying ingredients and quantities/amount, full set of drawings for an ambulance
Speaker Kits, Inc., packages high-fidelity components for mail order. Components for the top-of-the-line speaker kit, AiWA II (A), include 2 standard 12-inch speaker kits (Bs) and 3 standard 12-inch speaker kits with amp-booster (Cs). Each B consists of two 12-inch speakers (Ds) and 2 shipping boxes each with an installation kit (E). Each of the three speaker kits with amp-booster kits (Cs) has 2 speaker boosters (Fs) and 2 installation kits (Es). Each speaker booster (F) includes two 12-inch speakers (Ds) and 1 amp-booster (G). The total for each AiWA II is 4 standard 12-inch speakers and twelve 12-inch speakers with the amp-booster (Gs). As we can see, the demand for B, C, D, E, F and G is completely dependent on the master production schedule for A the AiWA II speaker kits.
Level 0 1
A
B(2) Std 12 Speaker kit C(3) Std 12 Speaker kit
w/ amp-booster
E(2)
E(2)
F(2)
12 speaker
D(2)
G(1)
amp-booster
12 speaker
D(2)
four parents: A, B, C, F - has at least one level below B, C, D, E, F, G are components (children) has at least one level above B, C, F are both parent and component (children) Number in parentheses ( ) no.of units needed to make the item immediately above it.
Determine the number of units of each item required to satisfy demand for a new order of 50 AiWA II speaker kits. Part A = 50 units
Part B = 2 x number of As Part C = 3 x number of As
= 2 (50) = 3 (50)
= 100 = 150
purchasing and inventory-control department Good purchasing data (purchase data execute, records of those orders and scheduled delivery dates available) good production plans effective MRP system.
B C D
F G
3 weeks 2 weeks
Must have D and E completed here so production can begin on B 1 week 2 weeks to produced
Start production of D
D
2 weeks
B E A
2 weeks 2 weeks
E
G
3 weeks
1 week
1 week
C F
1 week
D
1 2 3 4 5 6 7 8
Outcome 4: Use software-generated information to make decisions at operational, tactical and strategic levels in an organization. Assessment Criteria: 4.3 Prepare a spreadsheet to enable material requirements planning and calculate economic order quantities.
WEEK
1
A. Required date Order released date
1 week
100 150 200 200 300 150 300 300 200 200 300 300
2 weeks
1 week 2 weeks 3 weeks 1 week
300 600
600
net requirement plan include: i. gross requirement ii. on-hand inventory ii. net requirements iv. planned order receipt (quantity planned to be received at a future date) v. planned order release (schedule date for an order to be released)
ITEM ON HAND A B C D E F G 10 15 20 10 10 5 0
Constructing a net requirements plan is similar to constructing a GRP. Stating with item A - work backward to determine net requirements for all item.
Lead LowItem Lot On Safety AlloTime level IdentiSize Hand Stock cated (weeks) Code fication Gross Requirements Schedule Receipts Project On Hand Net Requirement Planned Order Receipts Planned Order Releases
Week
Lot Size
Lead Low- Item On Safety AlloTime level IdentiHand Stock cated (weeks) Code fication
Week
1
Gross Requirements
Lotforlot
10
50
Schedule Receipts
Project On Hand Planned Order Receipts Planned Order Releases
Net Requirement
ii. ITEM B: Gross requirement = 100 units (week 7) - BA item on-hand = 15 units ** Requirement for item B depends on the net requirement of A: net requirement for A = 40 Requirement for BA = 2(40) = 80 (at week 7) net requirement & planned order receipts for BA = 80 15 = 65 (at week 7) Lead times = 2 week, so planned order release = 65 (week 5)
PT TP
Lot Size
Lead Low- Item On Safety AlloTime level IdentiHand Stock cated (weeks) Code fication
Week
1
Gross Requirements
Lotforlot
15
80
Schedule Receipts
Project On Hand Planned Order Receipts Planned Order Releases
Net Requirement
E D
iii. ITEM C: Gross requirement = 150 units (week 7) - CA item on-hand = 20 units ** Requirement for item C depends on the net requirement of A: net requirement for A = 40 Requirement for CA = 3(40) = 120 (at week 7) net requirement & planned order receipts for CA = 120 20 = 100 (at week 7) Lead times = 1 week, so planned order release = 100 (week 6)
Lot Size
Lead Low- Item On Safety AlloTime level IdentiHand Stock cated (weeks) Code fication
Week
1
Gross Requirements
Lotforlot
20
120
Schedule Receipts
Project On Hand Planned Order Receipts Planned Order Releases
20 20
20 20 20
Net Requirement
iv. ITEM E: Gross requirement = 200 units (week 5) - EB = 300 units (week 6) - Ec item on-hand = 10 units ** Requirement for item E depends on the net requirement of B: net requirement for B = 65 Requirement for EB = 2(65) = 130 (at week 5) net requirement & planned order receipts for EB = 130 10 = 120 (at week 5) Lead times = 2 weeks, so planned order release = 120 (week 3)
Net E
Lot Size
Lead Low- Item On Safety AlloTime level IdentiHand Stock cated (weeks) Code fication
Week
1
Gross Requirements Schedule Receipts Project On 10 10 Hand Net Requirement
Lotforlot
10
130B 200C
10 10 10 10
v. ITEM F: Gross requirement = 300 units (week 6) - FC item on-hand = 5 units ** Requirement for item F depends on the net requirement of C: net requirement for C = 100 Requirement for FC = 2(100) = 200 (at week 6) net requirement & planned order receipts for FC = 200 5 = 195 (at week 6) Lead times = 3 week, so planned order release = 195 (week 3)
Lot Size
Lead Low- Item On Safety AlloTime level IdentiHand Stock cated (weeks) Code fication
Week
1
Gross Requirements Schedule Receipts Project On 5 Hand Net Requirement
Lotforlot
200C
5 195 195
D G
vi. ITEM D: Gross requirement = 600 units (week 5) - DF = 200 units (week 6) - DB item on-hand = 10 units ** Requirement for item D depends on the net requirement of F: net requirement for F = 195 Requirement for DF = 2(195) = 390 (at week 3) net requirement & planned order receipts for DF = 390 - 10= 380 (at week 3) Lead times = 1 weeks, so planned order release = 380 (week 2)
Net D
ITEM D: Gross requirement = 200 units (week 6) - DB item on-hand = 10 units ** Requirement for item D is also depends on the net requirement of B: net requirement for B = 65 Requirement for DB = 2(65) = 130 (at week 5) net requirement & planned order receipts for DB = 130 (**no more on-hand inventory for item D - after been used for F) Lead times = 1 weeks, so planned order release = 130 (week 4)
Net D
Lot Size
Lead Low- Item On Safety AlloTime level IdentiHand Stock cated (weeks) Code fication
Week
1
Gross Requirements Schedule Receipts Project On 10 10 Hand Net Requirement
Lotforlot
10
390F
130B
0 130 130
130
F B
vii. ITEM G: Gross requirement = 300 units (week 3) - GF item on-hand = 0 units ** Requirement of item G depends on the net requirement of F: net requirement for F = 195 Requirement for GF = 1(195) = 195 (at week 3) net requirement & planned order receipts for GF = 195 (at week 3) Lead times = 2 weeks, so planned order release = 195 (week 1)
Lot Size
Lead Low- Item On Safety AlloTime level IdentiHand Stock cated (weeks) Code fication
Week
1
Gross Requirements Schedule Receipts Project On 0 Hand Net Requirement
Lotforlot
195F
0
195
Assessment Criteria: 4.3 Prepare a spreadsheet to enable material requirements planning and calculate economic order quantities.
BOM
Purchase advice
Purchasing data
Exception report
Lead Time
Lot Size
Minimum quantity
50
10
Net Requirement Planned Order Receipts Planned Order Releases
10
10
10
10
10
10
10
10 40 40
40
BOM AiWAII
Gross Requirements Schedule Receipts Project On Hand =BOM!$ =BOM!$E =BOM!$E =BOM!$E =BOM!$E =BOM!$E =BOM!$E =BOM!$E =BOM!$E E$7 $7 $7 $7 $7 $7 $7 $7 $7 Net Requirement Planned Order Receipts Planned Order Releases
=$L$7$L$9 =$L$10
=$L$11
Lead Minimum 1 Lot Size Time quantity Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 =BOM!$G $7