Question

One unit of A is made of one unit of B and one unit of C. B is made of four units of C and one unit each of E and F. C is made of two units of D and one unit of E. E is made of three units of F. Item C has a lead time of one week; Items A, B, E, and F have two-week lead times; and Item D has a lead time of three weeks. Lot-for-lot lot sizing is used for Items A, D, and E; lots of size 50, 100, and 48 are used for Items B, C, and F, respectively. Items A, C, D, and E have on-hand (beginning) inventories of 20, 50, 100, and 20, respectively; all other items have zero beginning inventory. We are scheduled to receive 10 units of A in Week 1, 100 units of C in Week 1, and 100 units of D in Week 3; there are no other scheduled receipts.

If 40 units of A are required in Week 10, use the low-level-coded bill-of-materials (product structure tree) to find the necessary planned order releases for all components. (Leave no cells blank - be certain to enter "0" wherever required.)

  

	Period	1	2	3	4	5	6	7	8	9	10
Item A OH = 20 LT = 2 SS = 0 Q = L4L	Gross requirements
	Scheduled receipts
	Projected available balance
	Net requirements
	Planned order receipts
	Planned order releases
Item B OH = 0 LT = 2 SS = 0 Q = 50	Gross requirements
	Scheduled receipts
	Projected available balance
	Net requirements
	Planned order receipts
	Planned order releases
Item C OH = 50 LT = 1 SS = 0 Q = 100	Gross requirements
	Scheduled receipts
	Projected available balance
	Net requirements
	Planned order receipts
	Planned order releases
Item D OH = 100 LT = 3 SS = 0 Q = L4L	Gross requirements
	Scheduled receipts
	Projected available balance
	Net requirements
	Planned order receipts
	Planned order releases
Item E OH = 20 LT = 2 SS = 0 Q = L4L	Gross requirements
	Scheduled receipts
	Projected available balance
	Net requirements
	Planned order receipts
	Planned order releases
Item F OH = 0 LT = 2 SS = 0 Q = 48	Gross requirements
	Scheduled receipts
	Projected available balance
	Net requirements
	Planned order receipts
	Planned order releases

Answer 1

Below is the required MRP schedule -

A LT 2 Q = L4L		On Hand	1	2	3	4	5	6	7	8	9	10
	Gross Requirement		0	0	0	0	0	0	0	0	0	40
	Scheduled Receipts		10	0	0	0	0	0	0	0	0	0
	Projected on Hand	20	30	30	30	30	30	30	30	30	30	0
	Net Requirements		0	0	0	0	0	0	0	0	0	10
	Planned Order Receipts		0	0	0	0	0	0	0	0	0	10
	Planned Order Releases		0	0	0	0	0	0	0	10	0	0
B LT 2 Q = 50	Gross Requirement		0	0	0	0	0	0	0	10	0	0
	Scheduled Receipts		0	0	0	0	0	0	0	0	0	0
	Projected on Hand	0	0	0	0	0	0	0	0	40	40	40
	Net Requirements		0	0	0	0	0	0	0	10	0	0
	Planned Order Receipts		0	0	0	0	0	0	0	50	0	0
	Planned Order Releases		0	0	0	0	0	50	0	0	0	0
C LT 1 Q = 100	Gross Requirement		0	0	0	0	0	200	0	10	0	0
	Scheduled Receipts		100	0	0	0	0	0	0	0	0	0
	Projected on Hand	50	150	150	150	150	150	50	50	40	40	40
	Net Requirements		0	0	0	0	0	50	0	0	0	0
	Planned Order Receipts		0	0	0	0	0	100	0	0	0	0
	Planned Order Releases		0	0	0	0	100	0	0	0	0	0
D LT 3 Q = L4L	Gross Requirement		0	0	0	0	200	0	0	0	0	0
	Scheduled Receipts		0	0	100	0	0	0	0	0	0	0
	Projected on Hand	100	100	100	200	200	0	0	0	0	0	0
	Net Requirements		0	0	0	0	0	0	0	0	0	0
	Planned Order Receipts		0	0	0	0	0	0	0	0	0	0
	Planned Order Releases		0	0	0	0	0	0	0	0	0	0
E LT 2 Q = L4L	Gross Requirement		0	0	0	0	100	50	0	0	0	0
	Scheduled Receipts		0	0	0	0	0	0	0	0	0	0
	Projected on Hand	20	20	20	20	20	0	0	0	0	0	0
	Net Requirements		0	0	0	0	80	50	0	0	0	0
	Planned Order Receipts		0	0	0	0	80	50	0	0	0	0
	Planned Order Releases		0	0	80	50	0	0	0	0	0	0
F LT 2 Q = 48	Gross Requirement		0	0	240	150	0	50	0	0	0	0
	Scheduled Receipts		0	0	0	0	0	0	0	0	0	0
	Projected on Hand	0	0	0	0	42	42	40	40	40	40	40
	Net Requirements		0	0	240	150	0	8	0	0	0	0
	Planned Order Receipts		0	0	240	192	0	48	0	0	0	0
	Planned Order Releases		240	192	0	48	0	0	0	0	0	0