Question

Analytics Exercise 9-1

Recently, Phil Harris, the production control manager at Brunswick, read an article on time-phased requirements planning. He was curious about how this technique might work in scheduling Brunswick's engine assembly operations and decided to prepare an example to illustrate the use of time phased requirements planning.

     Phil's first step was to prepare a master schedule for one of the engine types produced by Brunswick: the Model 1000 engine. This schedule indicates the number of units of the Model 1000 engine to be assembled each week during the last 12 weeks and is shown on the next page. Next, Phil decided to simplify his requirements planning example by considering only two of the many components that are needed to complete the assembly of the Model 1000 engine. These two components, the gear box and the input shaft, are shown in the product structure diagram shown below. Phil noted that the gear box is assembled by the Subassembly Department and subsequently is sent to the main engine assembly line. The input shaft is one of several component parts manufactured by Brunswick that are needed to produce a gear box subassembly. Thus, levels 0, 1, and 2 are included in the product structure diagram to indicate the three manufacturing stages that are involved in producing an engine: the Engine Assembly Department, the Subassembly Department, and the Machine Shop.

     The manufacturing lead times required to produce the gear box and input shaft components are also indicated in the bill-of-material diagram. Note that two weeks are required to produce a batch of gear boxes and that all the gear boxes must be delivered to the assembly line parts stockroom before Monday morning of the week in which they are to be used. Likewise, it takes three weeks to produce a lot of input shafts, and all the shafts that are needed for the production of gear boxes in a given week must be delivered to the Subassembly Department stockroom before Monday morning of that week.

     In preparing the MRP example Phil planned to use the worksheets shown below and to make the following assumptions:

1 Twenty five gear boxes are on hand at the beginning of Week 1, and seven gear boxes are currently on order to be delivered at the start of Week 2.

2 Fifty input shafts are on hand at the start of Week 1, and 26 are scheduled for delivery at the beginning of Week 2.

Model 1000 master schedule Week 1 2 3 45 67 8 9 10 11 12 Demand 18 5 12 10 20 25 13 4 13 Model 1000 bill-of-material Engine assembly Gear box Lead time 2 weeks Used: 1 per engine Crankcase Input shaft Lead time 3 weeks Used: 2 per gear box

a. Initially, assume that Phil wants to minimize his inventory requirements. Assume that each order will be only for what is required for a single period. Calculate the net requirements and planned order releases for the gear boxes and input shafts. Assume that lot sizing is done using lot-for-lot.

Gear Box Requirements

Week:	1	2	3	4	5	6	7	8	9	10	11	12
Gross Requirements	18	5	12	10	0	20	25	13	0	6	4	13
Scheduled Receipts
Projected Available Balance
Net Requirements
Planned Order Receipt
Planned Order Release

Input Shaft Requirements

Week:	1	2	3	4	5	6	7	8	9	10	11	12
Gross Requirements
Scheduled Receipts
Projected Available Balance
Net Requirements
Planned Order Receipt
Planned Order Release

Answer 1

Below is the screenshot of formula applied to get the result -

Gear Boc MRP Excel Abhishek Rai -O × File Home Insert Page Layout Formulas Data Review View Help Tell me what you want to do Share 018 1 Gear Bor s Projected avalable bala 25 ESF7.F4.F 4G4-33 H341744-13 r Flaeed Orde 8 Fla m Input sShaft 3 Gross EISF17-F14 T Planed Order Receipt:S Sheet1 Display Settings ®凹- +60% Type here to search ENG 8:34 PM US 22-Mar-19

Below is the required table -

Gear Boc MRP Excel Abhishek Rai X File Home Insert Page Layout Formulas Data Review View Help Tell me what you want to do f1 Lt: 2 weeks On Hand 1 Gear Box 2 Week 3 Gross Requirement 4 Scheduled Receipt 10 12 25 ected available balance 6 Net Requirement Planned Order Recei Planned Order Releases 25 7 8 25 10 13 13 10 t Shaft Lt: 3 weeks On Hand 12 Week 13 Gross Requirement 14 Scheduled Recei 10 12 2б 26 ected available balance 16 Net Requirement 17 Planned Order Recei 18 Planned Order Releases 19 26 2б 2б 24 Sheet1 Display Settings - + 100% Type here to search ENG 8:35 PM US 22-Mar-19