Gaither/Frazier 9e
Chapter 15
Chapter 15
15.4
a. Construct a product structure tree for Product A.
Level
Code
A
0
1
B
2
F(2)
3
H(3)
C(3)
G
D(2)
H
I(2)
H(4)
G(3)
H
Note: low-level-coded product structure tree will require dropping
occurrences of item H in level codes 1 and 2 to level code 3.
b. Prepare an indented bill of materials for Product A.
0
A
1
Level
2
3
B
F
H
C
G
H
D
I
G
H
H
15 - 1
Quantity
1
1
2
3
3
1
1
2
2
3
1
4
Gaither/Frazier 9e
15.6
Chapter 15
Complete the MRP schedule for the part below.
Lot size = 2,000+
Lead time = 1 weeks
On hand = 1,300
Safety stock = 400
Allocated = 300
1
2
Week
3
Gross requirements
1100
700
1500
900
1850
1400
Scheduled Receipts
2000
Available
2600
1500
800
1300
400
550
4
5
6
Net requirements
700
1450
850
Planned order receipts
2000
2000
2000
Planned order releases
2000
15 - 2
2000
2000
Gaither/Frazier 9e
15.8
Chapter 15
Complete an MRP schedule for the E subassembly and all of its components.
Week
ITEM
E
Lot size =
Lead time =
On hand =
Safety stock =
Allocated =
1
900+
1
500
200
500
Gross Requirements
Scheduled Receipts
Available
Net Requirements
Planned Order Receipts
Planned Order Releases
G
Lot size =
Lead time =
On hand =
Safety stock =
Allocated =
1500+
1
400
Gross Requirements
Scheduled Receipts
Available
Net Requirements
Planned Order Receipts
Planned Order Releases
H
Lot size =
Lead time =
On hand =
Safety stock =
Allocated =
1500+
1
800
600
Gross Requirements
Scheduled Receipts
Available
Net Requirements
Planned Order Receipts
Planned Order Releases
I
Lot size =
Lead time =
On hand =
Safety stock =
Allocated =
2000+
2
800
500
500
Gross Requirements
Scheduled Receipts
Available
Net Requirements
Planned Order Receipts
Planned Order Releases
1000
800
2
1000
3
700
4
900
5
800
800
200
900
700
800
900
900
900
900
900
2
3
1800
4
1800
5
800
800
1000
1500
1500
500
1300
1500
200
2
3
900
4
900
5
300
300
600
1500
900
2
3
900
4
900
900
900
900
1
1800
700
1100
700
1500
1500*
1
900
1000
1200
1500
1500
1
900
2000
1800
5
1100
900
2000
2000
* This order for 1500 units needs to be expedited
to be available within the same week.
15 - 3
Gaither/Frazier 9e
15.9
Chapter 15
a. Prepare an MRP schedule for all the items to cover a six-week planning horizon.
Product B353
Lot size = LFL Gross requirements
Lead time =
1
Scheduled Receipts
On hand = 340 Available
Safety stock = 100 Net requirements
Allocated = 50 Planned order receipts
Planned order releases
1
2
750
190
190
560
560
560
1
Product R25
Lot size = LFL Gross requirements
2240
Lead time =
1
Scheduled Receipts
On hand = 2500 Available
2300
Safety stock = 200 Net requirements
Allocated =
0
Planned order receipts
Planned order releases
1
Product N35
Lot size = LFL Gross requirements
1120
Lead time =
1
Scheduled Receipts
On hand = 1500 Available
1285
Safety stock = 200 Net requirements
Allocated = 15 Planned order receipts
Planned order releases
1
Product K45
Lot size = LFL Gross requirements
1680
Lead time =
1
Scheduled Receipts
On hand = 2000 Available
1720
Safety stock = 200 Net requirements
Allocated = 80 Planned order receipts
Planned order releases
1
Product B5
Lot size = 10000+ Gross requirements
Lead time =
1
Scheduled Receipts
On hand = 750 Available
200
Safety stock = 300 Net requirements
Allocated = 250 Planned order receipts
Planned order releases 14080
15 - 4
Week
3
0
4
1800
5
6
1500
0
1800
1800
0
0
1500
1500
1800
1500
2
3
7200
4
5
6000
6
60
60
7140
7140
0
0
6000
6000
0
7140
6000
2
3
3600
4
5
3000
6
165
165
3435
3435
0
0
3000
3000
0
3435
3000
2
3
5400
4
5
4500
6
40
40
5360
5360
0
0
4500
4500
0
5360
4500
2
14280
3
4
12000
5
6
200
14080
14080
0
0
12000
12000
0
0
12000
Gaither/Frazier 9e
15.9
Chapter 15
Continued
Product F3
Lot size = 8000+ Gross requirements
Lead time =
1
Scheduled Receipts
On hand = 7600 Available
Safety stock = 300 Net requirements
Allocated = 100 Planned order receipts
Planned order releases
Product L7
Lot size =
Lead time =
On hand =
Safety stock =
Allocated =
Product D9
Lot size =
Lead time =
On hand =
Safety stock =
Allocated =
1000+
2
11000
1000
175
1
2
14010
7200
7200
6810
8000
8000
1
Gross requirements
Scheduled Receipts
Available
9825
Net requirements
Planned order receipts
Planned order releases 1000*
(Need to expedite)
1
2000+
2
25000
1000
200
Gross requirements
Scheduled Receipts
Available
23800
Net requirements
Planned order receipts
Planned order releases 3000*
(Need to expedite)
Week
3
1190
4
12000
5
6
1190
10810
10810
0
0
10810
2
10305
3
4
9000
5
6
9825
480
1000
8480
520
520
8480
8480
0
0
2
26800
3
4
22500
5
6
23800
3000
3000
22500
0
0
22500
22500
0
0
b. Are the MRP schedules for all items feasible from a material supply perspective?
If not, what might be done?
The MRP schedules for items L7 and D9 are not feasible. For item L7 it may be
possible to use safety stock to resolve the problem. However, using safety stock
will not resolve the problem for item D9. 3000 units of D9 must be expedited to
meet the MPS for product B353, or else the MPS must be changed.
15 - 5