Question

Operations ManagementAssignment #4 Page 2 Question 2.(Total 20 points): Refer to Question 1. Assume that unusually mild weather has caused a change in the quantity and timing of orders for golf carts. The revised plan calls for 100 golf carts at the start of week 6, 100 at the start of week 8, and 100 at the start of week 9.a)Determine the timing and quantities of orders for top and baseb)Assume that equipment problems have resulted in the manufacturer being able to assemble supports in lots of 100 and seats in lots of 50. Revise your material requirements plan for supports and seats to reflect this I need help with this question (2b) Question 1 reference is below: Operations ManagementAssignment #4 Page 1 OPERATIONS MANAGEMENT ASSIGNMENT # 4 (Total 100 points)Due Friday, July 31, 2020

Question 1. (Total 50 points) Information concerning the product structure, lead times and quantities on hand for an electric golf cart is shown in the following table. Use this information to do each of the following:a)Draw the product structure treeb)Develop the material requirements plan that will provide 200 golf carts at the start of week 8, assuming lot-for-lot ordering.Note: Template for MRP included here; print as many copies as necessaryParts List for Electric Golf CartLead Time Quantity on HandElectric Golf Cart10Top140Base120TopSupports (4)1200Cover10BaseMotor2300Body350Seats (2)2120BodyFrame135Controls10Wheels (4)1240

Answer 1

Q1.

a) Draw the product structure tree

Golf Cart Top Base Support (4) Cover Motor Body Seats (2) Frame Controls Wheel Assembly (4)

b) Develop the material requirements plan that will provide 200 golf carts at the start of week 8, assuming lot-for-lot ordering

Steps to create the MRP table. 1) Enter the gross requirement as per Master Planning Schedule (MPS). Gross requirement of components is calculated as per usage in parent item. 2) Enter Schedule Order Receipts (SOR), if there are any. 3) Project On hand is calculated by this formula = Previous period project on hand + Scheduled receipts + Planned order receipts - gross requirement 4) Net requirement Gross requirement - Projected on hand 5) Planned Order Release (POR) is manually entered such that time phased planned order receipt is equal to net requirem For example, if lead time is 1 period, and there is net requirement of 80 units in period 3, then there is a planned order release for 80 units in period 2, i.e. 1 period prior to the period in which requirement occurs. Planned Order Release quantity is as per the Lot size specified, i.e. LFL, or Fixed Order Quantity, or POQ or EOQ or in Multiples of a specified quantity 6) If there is safety stock specified for an item, then safety stock quantity is added in Planned Order Release so that Project On Hand remains greater than or equal to safety stock as specified.

1 2 3 4 5 6 7 8 MRP TABLE Item Golf cart SOR = 0 0 0 0 0 0 200 0 0 0 0 0 0 0 0 0 Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 0 Net Requirement Planned Order Receipt Planned Order Release SS= O 0 0 0 0 0 0 0 200 200 0 0 0 0 0 0 0 L= 0 0 0 1 LFL 0 0 0 200 Q= 0 0 0 0 Item 1 2 3 4 5 6 7 8 0 0 0 200 Top SOR = 0 0 0 0 40 0 0 0 0 0 0 0 Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 40 Net Requirement Planned Order Receipt Planned Order Release SS 40 40 40 40 0 0 0 0 0 0 160 160 0 40 0 0 0 0 0 0 0 L = Q = 1 LFL 0 0 0 0 0 0 160 0 Item 1 2 3 4 5 6 7 8 0 0 0 0 0 0 Base SOR = 0 0 200 0 0 0 0 0 Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 20 Net Requirement Planned Order Receipt Planned Order Release SS = 0 0 20 0 20 0 20 0 20 0 20 0 20 0 0 180 180 0 0 0 0 0 0 L = Q = 1 LFL 0 0 0 0 0 180 0 1 2 3 4 5 6 7 8 Item Support SOR = 0 0 0 0 0 640 0 0 0 0 SS= Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 200 Net Requirement Planned Order Receipt Planned Order Release 0 200 0 200 0 0 0 200 0 0 0 0 200 0 0 0 0 200 0 0 440 0 0 440 440 0 0 0 0 0 0 L = Q = 1 LFL 0 0 0 0 0 0 Item Beg. Inv. 1 2 3 4 5 6 7 8 0 0 0 0 0 160 0 0 Cover SOR = SS = 0 0 0 0 0 0 0 0 0 0 0 Gross Requirement Scheduled Receipt Projected on Hand Net Requirement Planned Order Receipt Planned Order Release 0 0 0 0 0 0 0 0 0 0 0 160 0 160 160 0 0 0 0 0 L = Q = 1 LFL 0 0 0 0 0 0 0 0

Item 1 2 3 4 5 6 7 8 0 0 0 0 0 180 0 0 Motor SOR = 0 0 0 0 SS= Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 300 Net Requirement Planned Order Receipt Planned Order Release 120 0 300 0 0 0 300 0 0 300 0 300 0 0 0 300 0 0 0 0 120 0 0 0 120 0 La 2 LFL 0 0 0 0 0 0 Q = 0 0 0 1 2 3 4 5 6 7 8 Item Body SOR = 0 0 0 0 180 0 0 0 0 0 0 0 0 SS = Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand Net Requirement Planned Order Receipt Planned Order Release 50 50 50 50 50 0 0 50 0 0 0 0 0 0 0 0 130 130 0 0 0 0 0 0 LE 0 3 LFL 0 0 0 130 0 0 0 0 Q = 0 Item 1 2 3 4 5 6 7 8 Seats 0 0 0 0 360 0 0 SOR = 0 0 120 0 0 0 0 0 Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 120 Net Requirement Planned Order Receipt Planned Order Release SS = 0 0 0 120 0 120 0 120 0 0 120 0 240 240 0 0 0 L = Q = 0 2 LFL 0 0 0 0 0 0 240 0 0 0 1 2 3 5 6 7 00 Item Frame SOR = 0 0 130 0 0 0 0 0 0 0 0 0 Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 35 Net Requirement Planned Order Receipt Planned Order Release SS = 0 35 0 0 35 0 0 0 0 0 95 95 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 L = Q= 1 LFL 0 0 95 0 0 0 0 0 0 Item 1 2 3 4 5 6 7 00 0 0 130 0 0 0 0 0 Controls SOR 0 0 0 0 0 0 0 0 SS = Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand Net Requirement Planned Order Receipt Planned Order Release 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 130 130 L = 0 0 0 0 0 1 LFL 0 130 Q= 0 0 0 0 0

12 3 4 5 6 7 8 0 0 520 0 0 0 0 0 0 0 0 0 0 Item Beg. Inv. Wheel assembly Gross Requirement SOR = Scheduled Receipt SS= Projected on Hand 240 Net Requirement L = 1 Planned Order Receipt Q = LFL Planned Order Release 0 0 0 0 0 0 0 0 240 0 0 0 0 240 0 0 0 280 280 0 0 0 0 0 0 0 0 0 0 280 0 0 0

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Q2.

Revised plan:  The revised plan calls for 100 golf carts at the start of week 6, 100 at the start of week 8, and 100 at the start of week 9

MRP based on revised plan is following:

1 2 3 4 5 6 7 8 9 MRP TABLE Item Golf cart SOR = SS= 0 0 0 0 0 100 0 100 0 0 0 Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand Net Requirement Planned Order Receipt Planned Order Release 0 0 0 0 0 100 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 100 100 0 0 0 0 L = 0 0 100 1 LFL 0 0 100 100 100 100 100 0 Q= 0 0 0 100 Item 1 2 3 4 5 6 7 8 9 Top 0 0 0 0 100 100 0 100 0 SOR = 0 0 Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 40 Net Requirement Planned Order Receipt Planned Order Release 0 0 40 0 SS = 0 40 0 40 0 0 40 0 0 0 0 0 0 0 0 0 0 0 0 100 100 100 60 60 0 0 100 100 0 0 0 L = Q = 1 LFL 0 0 0 60 0 100 0 Item 1 2 3 4 5 6 7 8 9 0 0 0 100 0 100 0 Base SOR = 0 0 0 0 0 Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 20 Net Requirement Planned Order Receipt Planned Order Release 0 0 20 0 SS 20 20 20 0 100 0 0 100 100 0 0 80 80 0 0 0 100 100 100 0 0 0 0 0 0 0 0 LE Q = 1 LFL 0 0 0 80 0 100 0 0 0 Item 1 2 3 4 5 6 7 8 9 Support 0 0 240 0 400 400 0 0 0 0 200 0 0 SOR = SS = 0 Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 200 Net Requirement Planned Order Receipt Planned Order Release 0 200 0 0 0 0 0 0 200 0 0 0 0 40 40 0 0 0 400 400 400 L = 0 1 LFL 0 0 0 40 400 400 0 0 0 0 0 0 0 Q= 0 0 400

1 2 3 4 5 6 7 8 9 0 0 0 0 100 0 0 Item Cover SOR = SS= 60 0 0 Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 0 Net Requirement Planned Order Receipt Planned Order Release 0 0 100 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 60 60 0 0 0 0 100 0 0 0 0 0 LE 100 100 100 0 0 1 LFL 100 100 0 0 60 Q = 0 0 0 0 Item 1 2 3 4 5 6 7 8 9 0 0 0 0 Motor SOR = 0 0 0 0 Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 300 Net Requirement Planned Order Receipt Planned Order Release 0 300 100 0 120 SS = 300 80 0 220 0 0 300 0 0 20 100 0 20 0 0 0 220 0 0 0 0 20 0 0 0 0 0 0 0 L = Q = 2 LFL 0 0 0 0 0 0 0 0 0 1 2 3 4 5 6 7 8 9 Item Body SOR = 0 0 0 80 0 100 0 0 0 0 0 0 0 0 SS= Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 50 Net Requirement Planned Order Receipt Planned Order Release 50 50 0 0 0 50 0 0 30 100 0 0 100 100 0 0 0 30 30 100 0 0 0 0 O 100 100 0 0 0 0 LE Q = 3 LFL 0 100 0 Item 1 2 3 4 5 5 7 8 9 0 0 160 0 200 200 Seats SOR = 0 0 0 0 0 0 0 0 0 0 SS= Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 120 Net Requirement Planned Order Receipt Planned Order Release 0 0 120 0 0 0 O 120 0 0 0 120 0 0 0 0 0 200 200 0 0 200 200 2 40 40 200 0 0 0 L = Q = 0 LFL 0 40 0 200 0 0

Item 1 2 3 4 5 6 7 00 9 0 0 0 0 Frame SOR = 30 0 5 100 0 100 0 0 0 0 0 Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 35 Net Requirement Planned Order Receipt Planned Order Release 0 0 0 0 0 0 0 SS= 5 0 0 0 0 100 0 0 0 0 95 95 100 La 0 100 0 0 0 1 LFL 0 95 0 0 0 0 Q= 0 0 0 0 0 1 2 3 4 5 6 7 8 9 30 0 100 0 0 0 0 0 Item Controls SOR = SS= 100 0 0 0 0 0 0 0 0 Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 0 Net Requirement Planned Order Receipt Planned Order Release 0 0 0 0 0 30 0 0 0 30 30 100 0 0 0 0 100 0 0 0 0 100 100 0 0 0 0 0 0 L = Q= 1 LFL 100 100 30 0 0 0 0 0 1 2 3 4 5 6 7 8 9 120 0 400 400 0 0 0 0 0 0 0 0 0 0 0 0 Item Beg. Inv. Wheel assembly Gross Requirement SOR= Scheduled Receipt SS= Projected on Hand 240 Net Requirement L = 1 Planned Order Receipt Q = LFL Planned Order Release 0 0 0 0 120 0 0 0 120 0 0 280 0 0 400 400 0 280 280 400 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

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Assume that equipment problems have resulted in the manufacturer being able to assemble supports in lots of 100 and seats in lots of 50. Revised material requirements plan for supports and seats is following:

Item 1 2 3 4 5 6 7 9 0 0 0 240 400 0 Support SOR = 400 0 0 0 0 0 0 0 Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 200 Net Requirement Planned Order Receipt Planned Order Release 0 0 60 0 0 0 60 0 SS= 200 60 200 0 200 0 60 0 60 40 100 0 60 340 400 0 LE 0 0 0 0 340 400 400 1 100 0 0 O 0 Q= 0 0 100 400

Item 1 2 3 4. 5 6 7 9 0 0 0 160 200 0 Seats SOR = 200 0 0 0 0 0 0 0 Beg. Inv. Gross Requirement Scheduled Receipt Projected on Hand 120 Net Requirement Planned Order Receipt Planned Order Release SS= 0 0 10 0 0 120 0 120 0 10 0 120 0 0 50 10 0 0 10 190 200 0 10 40 50 200 10 190 200 0 LE 0 0 0 0 0 2 50 Q = 0 0 200 0 0