1. 15 – 1 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Resource Planning 15 For Operations Management, 9e by Krajewski/Ritzman/Malhotra © 2010 Pearson Education PowerPoint Slides by Jeff Heyl

2. 15 – 2 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Resource Planning At the heart of any organization Starts with sales and operations plans and plans the input requirements A process relative to the firm’s competitive priorities and an important part of managing supply chains

3. 15 – 3 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Enterprise Resource Planning What an ERP system does  Integrating the firm’s functional areas  Used by many different types of organizations How ERP systems are designed  Single comprehensive database  Managers to monitor all of the company’s products at all locations and at all times  Information is automatically updated in the all applications when transactions occur  Streamlines the data flows throughout the organization  Requires a careful analysis of major processes  Significant changes in ERP systems - interoperability

4. 15 – 4 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Back-Office ProcessesFront-Office Processes Human Resources Benefits Payroll Data Analysis Product costing Job costs Sales and Marketing Sales orders Pricing system Customer Service Field service Quality Supply-Chain Management Forecasting Purchasing Distribution Accounting and Finance Accounts payable and receivable General ledgers Asset management Manufacturing Material requirements planning Scheduling ERP System Enterprise Resource Planning Figure 15.1 – ERP Application Modules

5. 15 – 5 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. MRP is a computerized information system to manage dependent demand inventory and schedule orders Translates the master production schedule into requirements for all subassemblies, components, and raw materials through the MRP explosion Materials Requirements Planning Dependent demand  Quantity required varies with the production plans of other items  Component  Parent

6. 15 – 6 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Inventory transactions Inventory records Bills of materials Engineering and process designs Other sources of demand Authorized master production schedule Material requirements plan MRP explosion MRP Inputs Figure 15.2 – Material Requirements Plan Inputs

7. 15 – 7 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Demand Patterns |||||||||| 1510 Day 2000 – 1500 – 1000 – 500 – 0 Bicycles (a) Parent inventory Reorder point Order 1000 on day 3 Order 1000 on day 8 (b) Component demand 2000 – 1500 – 1000 – 500 – 0 Rims |||||||||| 1510 Day Figure 15.3 – Lumpy Dependent Demand Resulting from Continuous Independent Demand

8. 15 – 8 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. A record of all components of an item Shows the parent-component relationship The usage quantities are derived from engineering and process design Bill of Materials Five common terms  End items  Intermediate items  Subassemblies  Purchased items Part commonality (sometimes called standardization of parts or modularity)

9. 15 – 9 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Seat cushion Seat-frame boards Front legs A Ladder-back chair Back legs Leg supports Back slats Bill of Materials Figure 15.4 –BOM for a Ladder-Back Chair

10. 15 – 10 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. J (4) Seat-frame boards Bill of Materials G (4) Back slats F (2) Back legs I (1) Seat cushion H (1) Seat frame C (1) Seat subassembly D (2) Front legs B (1) Ladder-back subassembly E (4) Leg supports A Ladder-back chair Figure 15.4 –BOM for a Ladder-Back Chair

11. 15 – 11 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Details how many end items will be produced within specified periods of time  It breaks the sales and operations plan into specific product schedules  Create a prospective MPS and test whether it meets the schedule with available resources Master Production Schedule (MPS) Sums of quantities must equal sales and operational plan Production must be allocated efficiently over time Capacity limitations and bottlenecks may be determined

12. 15 – 12 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Master Production Schedule (MPS) AprilMay 12345678 Ladder-back chair Kitchen chair Desk chair Aggregate production plans for chair family Figure 15.5 – MPS for a Family of Chairs 150 120 200 670

13. 15 – 13 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. No Material requirements planning Yes Authorized master production schedule Master Production Schedule (MPS) Are resources available? Prospective master production schedule Authorized production plan Figure 15.6 – Master Production Scheduling Process

14. 15 – 14 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Developing a MPS Step 1:Calculate projected on-hand inventories =+– Projected on-hand inventory at end of this week On-hand inventory at end of last week MPS quantity due at start of this week Projected requirements this week where: Projected requirements = max(Forecast, Customer orders booked) = Inventory + 55 chairs currently in stock – MPS quantity (0 for week 1) 38 chairs already promised for delivery in week 1 = 17 chairs

15. 15 – 15 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Item: Ladder-back chair Quantity on Hand: Forecast Customer orders (booked) Projected on-hand inventory MPS quantity MPS start April 12 Developing a MPS 55 30 3827 17–13 00 Explanation: Forecast is less than booked orders in week 1; projected on-hand inventory balance = 55 + 0 – 38 = 17. Explanation: Forecast exceeds booked orders in week 2; projected on-hand inventory balance = 17 + 0 – 30 = –13. The shortage signals a need to schedule an MPS quantity for completion in week 2. Figure 15.7 –Master Production Schedule for Weeks 1 and 2

16. 15 – 16 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Developing a MPS The goal is to maintain a nonnegative projected on-hand inventory balance As shortages are detected, MPS quantities should be scheduled to cover them Step 2:Determine the timing and size of MPS quantities = Inventory 17 chairs in inventory at the end of week 1 + MPS quantity of 150 chairs – Forecast of 30 chairs = 137 chairs

17. 15 – 17 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Application 15.1 Determine the MPS for Product A that has a 50-unit policy and 5 units on hand. The demand forecast and booked orders are shown in the partially completed plan given in the Student Notes. The lead time is one week. Here is the completed plan. You might want to ask a question or two on how they would respond to a customer request for a specific week and order quantity.

18. 15 – 18 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Application 15.1 Item: Product AOrder Policy: 50 units Lead Time: 1 week Quantity on Hand 512345678910 Forecast201040100030204020 Customer orders (booked) 302058020000 Projected on-hand inventory MPS quantity MPS start Available-to- promise (ATP) inventory SOLUTION

19. 15 – 19 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Application 15.1 Item: Product AOrder Policy: 50 units Lead Time: 1 week Quantity on Hand 512345678910 Forecast201040100030204020 Customer orders (booked) 302058020000 Projected on-hand inventory MPS quantity MPS start Available-to- promise (ATP) inventory SOLUTION 255 50 5 5532331343 50 3550 15 50

20. 15 – 20 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Master Production Schedule (MPS) Available-to-promise (ATP) inventory  The quantity of an end item that marketing can promise to deliver on specific dates  It is the difference between customer orders already booked and the quantity that operations is planning to produce Freezing the MPS Reconciling the MPS with sales and operations plans

21. 15 – 21 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Figure 15.8 –Master Production Schedule for Weeks 1–8 Item: Ladder-back chair Order Policy: 150 units Lead Time: 1 week 12345678 April Forecast Customer orders booked Projected on-hand inventory MPS quantity MPS start Quantity on Hand: 30 38 30 27 30 24 30 80 35 0 00 55 May 171371077742712287 01500000 0 0000 00 Master Production Schedule (MPS) Explanation: On-hand inventory balance = 17 + 150 – 30 = 137. The MPS quantity is needed to avoid a shortage of 30 – 17 = 13 chairs in week 2. Explanation: The time needed to assemble 150 chairs is 1 week. The assembly department must start assembling chairs in week 1 to have them ready by week 2.

22. 15 – 22 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Figure 15.9 – MPS Record with an ATP Row Item: Ladder-back chair Order Policy: 150 units Lead Time: 1 week 12345678 April Forecast Customer orders booked Projected on-hand inventory MPS quantity MPS start Quantity on Hand: 30 38 30 27 30 24 30 80 35 0 00 55 May 171371077742712287 01500000 0 0000 00 Available-to- promise (ATP) inventory 1791150 Master Production Schedule (MPS) Explanation: The total of customer orders booked until the next MPS receipt is 38 units. The ATP = 55 (on-hand) + 0 (MPS quantity) – 38 = 17. Explanation: The total of customer orders booked until the next MPS receipt is 27 + 24 + 8 = 59 units. The ATP = 150 (MPS quantity) – 59 = 91 units..

23. 15 – 23 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Inventory Record Inventory transactions are the basic building blocks of up-to-date records Transactions include releasing new orders, receiving scheduled receipts, adjusting due dates for scheduled receipts, withdrawing inventory, canceling orders, correcting inventory errors, rejecting shipments, and verifying losses and stock returns Inventory records divide the future into time periods called time buckets Keep track of inventory levels and component replenishment needs

24. 15 – 24 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Inventory Record The time-phase information contained in the inventory record consists of:  Gross requirements  Scheduled receipts  Projected on-hand inventory  Planned receipts  Planned order releases =+– Projected on-hand inventory balance at end of week t Inventory on hand at end of week t –1 Scheduled or planned receipts in week t Gross requirements in week t

25. 15 – 25 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Inventory Record Weeks 2 and 3:117 + 0 – 0 = 117 The on-hand inventory calculations for each week in Figure 15.10 are as follows Week 4:117 + 0 – 120 = –3 Week 5:–3 + 0 – 0 = –3 Week 6:–3 + 0 – 150 = –153 Week 7:–153 + 0 – 120 = –273 Week 8:–273 + 0 – 0 = –273 Week 1:37 + 230 – 150 = 117

26. 15 – 26 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Inventory Record Item: C Description: Seat subassembly Lot Size: 230 units Lead Time: 2 weeks Week 12345678 Gross requirements 0000 Scheduled receipts 0000000 Projected on-hand inventory 117 –3 –153–273 Planned receipts Planned order releases Explanation: Gross requirements are the total demand for the two chairs. Projected on-hand inventory in week 1 is 37 + 230 – 150 = 117 units. Figure 15.10 –MRP Record for the Seat Subassembly 37 120 150 117 230

27. 15 – 27 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Inventory Record Item: C Description: Seat subassembly Lot Size: 230 units Lead Time: 2 weeks Week 12345678 Gross requirements 15000 Scheduled receipts 23000 Projected on-hand inventory 117 Planned receipts Planned order releases 37 Without a planned receipt in week 4, a shortage of 3 units will occur: 117 + 0 + 0 – 120 = –3 units. Adding the planned receipt brings the balance to 117 + 0 + 230 – 120 = 227 units. Offsetting for a 2-week lead time puts the corresponding planned order release back to week 2. The first planned receipt lasts until week 7, when projected inventory would drop to 77 + 0 + 0 – 120 = –43 units. Adding the second planned receipt brings the balance to 77 + 0 + 230 – 120 = 187 units. The corresponding planned order release is for week 5 (or week 7 minus 2 weeks). 120 0 227 230 187 120 0 77 0150 00 227 0 0 187 Figure 15.11 –Completed Inventory Record for the Seat Subassembly

28. 15 – 28 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Planning lead time For purchased items planning lead time is the time allowed for receiving a shipment from the supplier Planning Factors For manufactured the planning lead time consists of estimates for  Setup time  Processing time  Materials handling time between operations  Waiting time

29. 15 – 29 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Lot-sizing rules Fixed order quantity (FQO) rule maintains the same order quantity each time an order is issued Could be determined by quantity discounts, truckload capacity, minimum purchases, or EOQ Planning Factors

30. 15 – 30 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Periodic order quantity (POQ) rule allows a different order quantity for each order issue but tends to issue the order at predetermined time intervals Planning Factors = – POQ lot size to arrive in week t Total gross requirements for P week, including week t Projected on-hand inventory balance at end of week t –1 Figure 15.12 shows the application of the POQ rule for P = 3

31. 15 – 31 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Planning Factors = – (POQ lot size) Gross requirements for weeks 4, 5, and 6 Inventory at end of week 3 The first order using P = 3 is (POQ lot size) = (120 + 0 + 150) – 117 = 153 units

32. 15 – 32 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Planning Factors Figure 15.12 –The POQ ( P = 3) Rule for the Seat Subassembly

33. 15 – 33 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Lot-for-lot (L4L) rule where the lot size covers the gross requirements of a single week Planning Factors = – L4L lot size to arrive in week t Gross requirements for week t Projected on-hand inventory balance at end of week t –1 Figure 15.13 shows the application of the L4L = – (L4L lot size) Gross requirements in week 4 Inventory balance at end of week 3 (L4L lot size) = 120 – 117 = 3 units

34. 15 – 34 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Planning Factors Figure 15.13 –The L4L Rule for the Seat Subassembly

35. 15 – 35 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Application 15.2 Item H10-A is a produced item (not purchased) with an order quantity of 80 units. Complete the rest of its MRP record using the fixed order quantity (FOQ) rule SOLUTION Item: H10-A Description: Chair seat assembly Lot Size: FOQ = 80 units Lead Time: 4 weeks Week 31323334353637383940 Gross requirements 60354560 Scheduled receipts 80 Projected on-hand inventory Planned receipts Planned order releases 20

36. 15 – 36 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Application 15.2 Item H10-A is a produced item (not purchased) with an order quantity of 80 units. Complete the rest of its MRP record using the fixed order quantity (FOQ) rule SOLUTION Item: H10-A Description: Chair seat assembly Lot Size: FOQ = 80 units Lead Time: 4 weeks Week 31323334353637383940 Gross requirements 60354560 Scheduled receipts 80 Projected on-hand inventory Planned receipts Planned order releases 20 80 4060 80 2040 55

37. 15 – 37 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Application 15.3 Now complete the H10-A record using a POQ rule. The P should give an average lot size of 80 units. Assume the average weekly requirements are 20 units. P = = 4 weeks 80 20

38. 15 – 38 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Application 15.3 SOLUTION Item: H10-A Description: Chair seat assembly Lot Size: POQ = 4 Lead Time: 4 weeks Week 31323334353637383940 Gross requirements 60354560 Scheduled receipts 80 Projected on-hand inventory Planned receipts Planned order releases 20

39. 15 – 39 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Application 15.3 SOLUTION Item: H10-A Description: Chair seat assembly Lot Size: POQ = 4 Lead Time: 4 weeks Week 31323334353637383940 Gross requirements 60354560 Scheduled receipts 80 Projected on-hand inventory Planned receipts Planned order releases 20 40 5560 0 100

40. 15 – 40 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Application 15.4 Revise the H10-A record using the lot-for-lot (L4L) Rule. (Complete the highlighted section) SOLUTION Item: H10-A Description: Chair seat assembly Lot Size: FOQ = 80 units Lead Time: 4 weeks Week 31323334353637383940 Gross requirements 60354560 Scheduled receipts 80 Projected on-hand inventory Planned receipts Planned order releases 20

41. 15 – 41 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Application 15.4 Revise the H10-A record using the lot-for-lot (L4L) Rule. (Complete the highlighted section) SOLUTION Item: H10-A Description: Chair seat assembly Lot Size: FOQ = 80 units Lead Time: 4 weeks Week 31323334353637383940 Gross requirements 60354560 Scheduled receipts 80 Projected on-hand inventory Planned receipts Planned order releases 20 40 550 00 60 40

42. 15 – 42 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Comparing lot-sizing rules Planning Factors FOQ:= 181 units 227 + 227 + 77 + 187 + 187 5 POQ:= 60 units 150 + 150 + 0 + 0 + 0 5 L4L:= 0 units 0 + 0 + 0 + 0 + 0 5

43. 15 – 43 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Lot sizes affect inventory costs and setup and ordering costs The FOQ rule generates a high level of average inventory because it creates inventory remnants The POQ rule reduces the amount of average on- hand inventory because it does a better job of matching order quantity to requirements The L4L rule minimizes inventory investment, but it also maximizes the number of orders placed Planning Factors

44. 15 – 44 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Planning Factors Safety stock for dependent demand items with lumpy demand (gross requirements) is helpful only when future gross requirements, the timing or size of scheduled receipts, and the amount of scrap that will be produced are certain Safety stock is used for end items and purchased items to protect against fluctuating customer orders and unreliable suppliers

45. 15 – 45 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Planning Factors Figure 15.14 –Inventory Record for the Seat Subassembly Showing the Application of a Safety Stock

46. 15 – 46 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Manufacturing resources plan Performance reports Outputs from MRP Material requirements plan Action notices  Releasing new orders  Adjusting due dates Priority reports  Dispatch lists  Supplier schedules Capacity reports  Capacity requirements planning  Finite capacity scheduling  Input-output control Cost and price data MRP explosion Routings and time standards Figure 15.15 –MRP Outputs

47. 15 – 47 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. MRP Explosion Translates the MPS and other sources of demand into the requirements needed for all of the subassemblies, components, and raw materials the firm needs to produce parent items An item’s gross requirements are derived from three sources  The MPS for immediate parents that are end items  The planned order releases for parents below the MPS level  Any other requirements not originating in the MPS, such as the demand for replacement parts

48. 15 – 48 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. MRP Explosion J(4) Seat-frame boards C(1) Seat subassembly H(1) Seat frame I(1) Seat cushion Figure 15.16 –BOM for the Seat Subassembly

49. 15 – 49 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Item: Seat subassembly Lot size: 230 units Lead time: 2 weeks Gross requirements 150 1 230 117 23 120 45 150 6 120 78 Scheduled receipts Projected on-hand inventory Planned receipts Planned order releases 37 Week 117 0000 000 0000 227 77187 230 MRP Explosion Figure 15.17 –MRP Explosion of Seat Assembly Components

50. 15 – 50 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Item: Seat subassembly Lot size: 230 units Lead time: 2 weeks Gross requirements 150 123 120 45 150 6 120 78 Planned receipts Planned order releases Week 0000 230 MRP Explosion Figure 15.17 –MRP Explosion of Seat Assembly Components

51. 15 – 51 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Item: Seat frames Lot size: 300 units Lead time: 1 week Gross requirements 1 0 2345678 Scheduled receipts Projected on-hand inventory Planned receipts Planned order releases 40 Week 000 300000 Item: Seat cushion Lot size: L4L Lead time: 1 week Gross requirements 1 0 2345678 Scheduled receipts Projected on-hand inventory Planned receipts Planned order releases 0 Week 000 0000 MRP Explosion Item: Seat subassembly Lot size: 230 units Lead time: 2 weeks Gross requirements 150 123 120 45 150 6 120 78 Planned receipts Planned order releases Week 0000 230 Figure 15.17 –MRP Explosion of Seat Assembly Components

52. 15 – 52 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Item: Seat frames Lot size: 300 units Lead time: 1 week Gross requirements 1 0 2345678 Scheduled receipts Projected on-hand inventory Planned receipts Planned order releases 40 Week 000 300000 Item: Seat cushion Lot size: L4L Lead time: 1 week Gross requirements 1 0 2345678 Scheduled receipts Projected on-hand inventory Planned receipts Planned order releases 0 Week 000 0000 MRP Explosion Item: Seat subassembly Lot size: 230 units Lead time: 2 weeks Gross requirements 150 123 120 45 150 6 120 78 Planned receipts Planned order releases Week 0000 230 Usage quantity: 1 0 230 0 Figure 15.17 –MRP Explosion of Seat Assembly Components

53. 15 – 53 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Item: Seat frames Lot size: 300 units Lead time: 1 week Gross requirements 1 0 2345678 Scheduled receipts Projected on-hand inventory Planned receipts Planned order releases 40 Week 000 300000 Item: Seat cushion Lot size: L4L Lead time: 1 week Gross requirements 1 0 2345678 Scheduled receipts Projected on-hand inventory Planned receipts Planned order releases 0 Week 000 0000 MRP Explosion Item: Seat subassembly Lot size: 230 units Lead time: 2 weeks Gross requirements 150 123 120 45 150 6 120 78 Planned receipts Planned order releases Week 0000 230 Usage quantity: 1 0 230 0 0 0 0 0 Figure 15.17 –MRP Explosion of Seat Assembly Components

54. 15 – 54 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. MRP Explosion Item: Seat subassembly Lot size: 230 units Lead time: 2 weeks Gross requirements 150 123 120 45 150 6 120 78 Planned receipts Planned order releases Week 0000 230 Item: Seat frames Lot size: 300 units Lead time: 1 week Gross requirements 1 0 2345678 Scheduled receipts Projected on-hand inventory Planned receipts Planned order releases 40 Week 000 300000 Item: Seat cushion Lot size: L4L Lead time: 1 week Gross requirements 1 0 2345678 Scheduled receipts Projected on-hand inventory Planned receipts Planned order releases 0 Week 000 0000 0 230 0 0 0 0 0 00 0 40110110 110180 300 00 0 000 00000 230 Figure 15.17 –MRP Explosion of Seat Assembly Components

55. 15 – 55 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. MRP Explosion Item: Seat frames Lot size: 300 units Lead time: 1 week Gross requirements 12345678 Planned receipts Planned order releases Week 300 Item: Seat cushion Lot size: L4L Lead time: 1 week Gross requirements 12345678 Planned receipts Planned order releases Week 230 0000 00 0000 00 Gross requirements 1 0 2345678 Scheduled receipts Planned receipts Planned order releases 200 Week 000 0000 Projected on-hand inventory Item: Seat-frame boards Lot size: 1500 units Lead time: 1 week Figure 15.17 –MRP Explosion of Seat Assembly Components

56. 15 – 56 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Gross requirements 1 0 2345678 Scheduled receipts Planned receipts Planned order releases 200 Week 000 0000 Projected on-hand inventory Item: Seat-frame boards Lot size: 1500 units Lead time: 1 week 0120000 0000 MRP Explosion Item: Seat frames Lot size: 300 units Lead time: 1 week Gross requirements 12345678 Planned receipts Planned order releases Week 300 Item: Seat cushion Lot size: L4L Lead time: 1 week Gross requirements 12345678 Planned receipts Planned order releases Week 230 0000 00 0000 00 Usage quantity: 4 Figure 15.17 –MRP Explosion of Seat Assembly Components

57. 15 – 57 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. MRP Explosion Item: Seat frames Lot size: 300 units Lead time: 1 week Gross requirements 12345678 Planned receipts Planned order releases Week 300 Item: Seat cushion Lot size: L4L Lead time: 1 week Gross requirements 12345678 Planned receipts Planned order releases Week 230 0000 00 0000 00 Gross requirements 1 0 2345678 Scheduled receipts Planned receipts Planned order releases 200 Week 000 0000 Projected on-hand inventory Item: Seat-frame boards Lot size: 1500 units Lead time: 1 week 0120000 0000 200 500 1500 Figure 15.17 –MRP Explosion of Seat Assembly Components

58. 15 – 58 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Other Important Reports Action notice Capacity requirements planning (CRP) Theory of constraints principles can be applied to keep bottleneck operations fed by adjusting some lot sizing rules or occasionally overriding planned order releases Priority reports Manufacturing resource planning (MRP II)

59. 15 – 59 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. MRP and the Environment Consumer and government concern about the deterioration of the natural environment has driven manufacturers to reengineer their processes to become more environmentally friendly Companies can modify their MRP systems to help track these waste and plans for their disposal

60. 15 – 60 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Application 15.5 A firm makes a product (Item A) from three components (intermediate Items B and D, and purchased item C). The latest MPS for product A calls for completion of a 250-unit order in week 8, and its lead time is 2 weeks. The master schedule and bill of material for Product A are given below. Item: End Item ALead Time: 2 wks Week 12345678 MPS quantity250 MPS start250

61. 15 – 61 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. C(2) B(1) Application 15.5 Develop a material requirements plan for items B, C, and D, given the following inventory data. Blank MRP records are provided in the Student Notes, and the completed records are shown on the next slide. B(1)C(1)D(2) A Data Category Item BCD Lot-sizing rulePOQ (P = 5)FOQ = 1000L4L Lead time2 weeks1 week3 weeks Scheduled receipts None1000 (week 1)None Beginning inventory 08000

62. 15 – 62 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Application 15.5 SOLUTION An item’s gross requirements cannot be derived until all of its immediate parents are processed. Thus we must begin with Item D. Its only immediate parent is item A, and its planned “production plan” is shown by the MPS start row. Note the 2- for-1 usage quantity when deriving D’s gross requirements. Item: D Lot Size: L4L Description: Lead Time: 3 weeks Week 12345678 Gross requirements500 Scheduled receipts Projected on-hand inventory 000000000 Planned receipts500 Planned order releases500

63. 15 – 63 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Application 15.5 We can do item B next, because the planned “production quantities” for its two immediate parents (A and D) are known. Item C cannot be done yet, because one of its parents is item B, and its PORs are still unknown. Item: B Lot Size: POQ = 5 Description: Lead Time: 3 weeks Week 12345678 Gross requirements Scheduled receipts Projected on-hand inventory 00000000 Planned receipts Planned order releases

64. 15 – 64 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Application 15.5 We can do item B next, because the planned “production quantities” for its two immediate parents (A and D) are known. Item C cannot be done yet, because one of its parents is item B, and its PORs are still unknown. Item: B Lot Size: POQ = 5 Description: Lead Time: 3 weeks Week 12345678 Gross requirements 500 250 Scheduled receipts Projected on-hand inventory 000000000 Planned receipts 750 Planned order releases 750

65. 15 – 65 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Application 15.5 Finally we can do Item C, because we now know the planned “production quantities” of both of its immediate parents (A and B). Note that the usage quantity for its parent B is 2-for-1. Item: C Lot Size: 1000 Description: Lead Time: 1 week Week 12345678 Gross requirements 1500 250 Scheduled receipts 1000 Projected on-hand inventory 800300 1050 Planned receipts 1000 Planned order releases 1000

66. 15 – 66 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Solved Problem 1 Refer to the bill of materials for product A shown in Figure 15.19. If there is no existing inventory and no scheduled receipts, how many units of items G, E, and D must be purchased to produce 5 units of end item A? LT = 2LT = 3 B (3)C (1) G (1) LT = 3 D (1) LT = 3 D (1) LT = 6 E (2) LT = 1 F (1) LT = 1 A Figure 15.19 –BOM for Product A

67. 15 – 67 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Solved Problem 1 SOLUTION Five units of item G, 30 units of item E, and 20 units of item D must be purchased to make 5 units of A. The usage quantities shown in Figure 15.21 indicate that 2 units of E are needed to make 1 unit of B and that 3 units of B are needed to make 1 unit of A; therefore, 5 units of A require 30 units of E(2  3  5 = 30). One unit of D is consumed to make 1 unit of B, and 3 units of B per unit of A result in 15 units of D(1  3  5 = 15); 1 unit of D in each unit of C and 1 unit of C per unit of A result in another 5 units of D(1  1  5 = 5). The total requirements to make 5 units of A are 20 units of D(15 + 5). The calculation of requirements for G is simply 1  1  1  5 = 5 units.

68. 15 – 68 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Solved Problem 2 The order policy is to produce end item A in lots of 50 units. Using the data shown in Figure 15.20 and the FOQ lot-sizing rule, complete the projected on-hand inventory and MPS quantity rows. Then complete the MPS start row by offsetting the MPS quantities for the final assembly lead time. Finally, compute the available-to-promise inventory for item A. If in week 1 a customer requests a new order for 30 units of item A, when is the earliest date the entire order could be shipped?

69. 15 – 69 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Solved Problem 2 Item: A Order Policy: 50 units Lead Time: 1 week Week 12345678910 Forecast 201040100030204020 Customer orders (booked) 302058020000 Projected on-hand inventory 25 MPS quantity 50 MPS start Available-to- promise (ATP) inventory Figure 15.20 –MPS Record for End Item A

70. 15 – 70 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Solved Problem 2 SOLUTION The projected on-hand inventory for the second week is =+– Projected on-hand inventory at end of week 2 On-hand inventory in week 1 MPS quantity due in week 2 Requirements in week 2 = 25 + 0 – 20 = 5 units where requirements are the larger of the forecast or actual customer orders booked for shipment during this period. No MPS quantity is required. Without an MPS quantity in the third period, a shortage of item A will occur: 5 + 0 – 40 = –35. Therefore, an MPS quantity equal to the lot size of 50 must be scheduled for completion in the third period. Then the projected on-hand inventory for the third week will be 5 + 50 – 40 = 15.

71. 15 – 71 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Solved Problem 2 Figure 15.21 shows the projected on-hand inventories and MPS quantities that would result from completing the MPS calculations. The MPS start row is completed by simply shifting a copy of the MPS quantity row to the left by one column to account for the 1-week final assembly lead time. Also shown are the available-to-promise quantities. In week 1, the ATP is =+– Available-to- promise in week 1 On-hand quantity in week 1 MPS quantity in week 1 Orders booked up to week 3 when the next MPS arrives = 5 + 50 – (30 + 20) = 5 units

72. 15 – 72 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Solved Problem 2 The ATP for the MPS quantity in week 3 is =– Available-to- promise in week 3 MPS quantity in week 3 Orders booked up to week 7 when the next MPS arrives = 50 – (5 + 8 + 0 + 2) = 35 units The other ATPs equal their respective MPS quantities because no orders are booked for those weeks. As for the new order for 30 units in week 1, the earliest it can be shipped is week 3 because the ATP for week 1 is insufficient. If the customer accepts the delivery date of week 3, the ATP for week 1 will stay at 5 units and the ATP for week 3 will be reduced to 5 units. This acceptance allows the firm the flexibility to immediately satisfy an order for 5 units or less, if one comes in. When the MPS is updated next, the customer orders booked for week 3 would be increased to 35 to reflect the new order’s shipping date.

73. 15 – 73 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Solved Problem 2 Figure 15.21 –Completed MPS Record for End Item A

74. 15 – 74 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. A B (1)C (2) D (1) LT = 2 LT = 1LT = 2 LT = 3 Solved Problem 3 The MPS start quantities for product A calls for the assembly department to begin final assembly according to the following schedule: 100 units in week 2; 200 units in week 4; 120 units in week 6; 180 units in week 7; and 60 units in week 8. Develop a material requirements plan for the next 8 weeks for items B, C, and D. The BOM for A is shown in Figure 15.22, and data from the inventory records are shown in Table 15.1. Figure 15.21 –BOM for Product A

75. 15 – 75 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Solved Problem 3 TABLE 15.1 | INVENTORY RECORD DATA Item Data CategoryBCD Lot-sizing rulePOQ (P=3)L4LFOQ = 500 units Lead time1 week2 weeks3 weeks Scheduled receiptsNone200 (week 1)None Beginning (on-hand) inventory200 425 SOLUTION We begin with items B and C and develop their inventory records, as shown in Figure 15.23. The MPS for product A must be multiplied by 2 to derive the gross requirements for item C because of the usage quantity. Once the planned order releases for item C are found, the gross requirements for item D can be calculated.

76. 15 – 76 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Solved Problem 3 Item: B Lot Size: POQ ( P = 3) Lead Time: 1 week Week 12345678910 Gross requirements 10020012018060 Scheduled receipts Projected on-hand inventory 20200 0024060000 Planned receipts 280360 Planned order releases 280360 Figure 15.23 –Inventory Records for Items B, C, and D 20

77. 15 – 77 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Solved Problem 3 Item: C Lot Size: L4L Lead Time: 2 weeks Week 12345678910 Gross requirements 200400240360120 Scheduled receipts 200 Projected on-hand inventory 200000000000 Planned receipts 400240360120 Planned order releases 400240360120 Figure 15.23 –Inventory Records for Items B, C, and D 0

78. 15 – 78 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Solved Problem 3 Item: D Lot Size: FOQ =500 units Lead Time: 1 week Week 12345678910 Gross requirements 400240360120 Scheduled receipts Projected on-hand inventory 42525 285425305 Planned receipts 500 Planned order releases 500 Figure 15.23 –Inventory Records for Items B, C, and D 425

79. 15 – 79 Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall.