APIX Polybob Case Q1. What are the key issues brought about in the conversation? What are the key symptoms, and what are the underlying problems? Be specific in your answers Ans – According to the given information we can make out that there is a great difference between Materials Requirements Planning and Master Production Schedule. Moreover, there is inventory issue as well in the organization. These issues lead to more inventory, high carrying costs, premium freight costs and reduced efficiency. Q2. Use the product information to develop an MRP approach to the problems. Would MRP solve the problems? If so, show specifically how MRP would avoid the problems discussed by Ken and Jack. Ans – Yes, MRP can solve the problems since it is used to determine components needed, quantity and time frame when they are required. This way items in MPS are made on time. Also, MRP has various components such as safety stock, lead times and gross requirements which make it a reliable option to avoid such problems. Q3. Do any conditions bother you about the ability of MRP to deal with the problems? What specifically are those conditions? Ans- Following conditions might reduce the ability of MRP to deal with the problems – Changes in order quantities Delays in releasing components Safety stock not maintained properly. Underutilization of capacity available. Q4. Suppose it was discovered that only 250 of components E were in stock instead of the 300 listed on the inventory record. What problems would this cause and what are some ways these problems could be addressed? How would MRP help you when other methods might not? Ans – This situation would affect the final goods and organization might need to get them arranged immediately for which supplier might charge a premium. To avoid this they can add a safety stock which would eliminate or avoid such situations. Q5. Suppose that the design engineer advises that he has a new design for components, but it won’t be ready until sometime after week 2, but he wants you to give a date for the first supplier shipment to come in, and you should be ready to tell the supplier how many to ship. Since the change is transparent to the customer, the design engineer advises you to go ahead and use up any existing material of the model. How will MRP help you to deal with this issue. Ans – If there is a design change the component should have a new part number. Accordingly, product tree, level code and other necessary details should be updated. MRP can help in making these changes easily. Q6. Can you think of any other “what if” questions that might be more easily addressed by a systematic approach such as MRP?
