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Refer again to Problems 14.5 and 14.7. In addition to 100 units of S, there is also a demand for 20 units of U, which is a component of S. The 20 units of U are needed for maintenance purposes. These units are needed in week 6. Modify the net material requirements plan to reflect this change.

Problems 14.7

Using the information in Problem 14.5, construct a net material requirements plan using the following on-hand inventory.

Problem 14.5

The demand for subassembly S is 100 units in week 7. Each unit of S requires 1 unit of T and 2 units of U. Each unit of T requires 1 unit of V, 2 units of W, and 1 unit of X. Finally, each unit of U requires 2 units of Y and 3 units of Z. One firm manufactures all items. It takes 2 weeks to make S, 1 week to make T, 2 weeks to make U, 2 weeks to make V, 3 weeks to make W, 1 week to make X, 2 weeks to make Y, and 1 week to make Z.

a) Construct a product structure. Identify all levels, parents, and components.

b) Prepare a time-phased product structure.

 
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Your boss at Xiangling Hu Products, Inc., has just provided you with the schedule and lead times for the bracket in Problem 14.3. The unit is to be prepared in week 10. The lead times for the components are bracket (1  week), base (1 week), spring (1 week), clamp (1 week), housing (2 weeks), handle (1 week), casting (3 weeks), bearing (1 week), and shaft (1 week).

a) Prepare the time-phased product structure for the bracket.

b) In what week do you need to start the castings?

Problem 14.3

As the production planner for Xiangling Hu Products, Inc., you have been given a bill of material for a bracket that is made up of a base, two springs, and four clamps. The base is assembled from one clamp and two housings. Each clamp has one handle and one casting. Each housing has two bearings and one shaft. There is no inventory on hand.

a) Design a product structure noting the quantities for each item and show the low-level coding.

b) Determine the gross quantities needed of each item if you are to assemble 50 brackets.

c) Compute the net quantities needed if there are 25 of the base and 100 of the clamp in stock.

 
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You have just been notified via fax that the lead time for component G of product A (Problem 14.15 and Figure 14.14) has been increased to 4 weeks.

a) Which items have changed, and why?

b) What are the implications for the production plan?

c) As production planner, what can you do?

Problem 14.15 and Figure 14.14

You are product planner for product A (in Problem 14.14 and Figure 14.14). The field service manager, Al Trostel, has just called and told you that the requirements for B and F should each be increased by 10 units for his repair requirements in the field.

a) Prepare a list showing the quantity of each part required to produce the requirements for the service manager and the production request of 10 Bs and Fs.

b) Prepare a net requirement plan by date for the new requirements (for both production and field service), assuming that the field service manager wants his 10 units of B and F in week 6 and the 10 production units of A in week 8.

Problem 14.14 and Figure 14.14

A part structure, lead time (weeks), and on-hand quantities for product A are shown in Figure 14.14. From the information shown, generate:

a) An indented bill of material for product A (see Figure 5.9 in Chapter 5 as an example of a BOM).

b) Net requirements for each part to produce 10 As in week 8 using lot-for-lot.

Figure 14.14

Figure 5.9

 
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You are product planner for product A (in Problem 14.14 and Figure 14.14). The field service manager, Al Trostel, has just called and told you that the requirements for B and F should each be increased by 10 units for his repair requirements in the field.

a) Prepare a list showing the quantity of each part required to produce the requirements for the service manager and the production request of 10 Bs and Fs.

b) Prepare a net requirement plan by date for the new requirements (for both production and field service), assuming that the field service manager wants his 10 units of B and F in week 6 and the 10 production units of A in week 8.

Problem 14.14 and Figure 14.14

A part structure, lead time (weeks), and on-hand quantities for product A are shown in Figure 14.14. From the information shown, generate:

a) An indented bill of material for product A (see Figure 5.9 in Chapter 5 as an example of a BOM).

b) Net requirements for each part to produce 10 As in week 8 using lot-for-lot.

Figure 14.14

Figure 5.9

 
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