Phil's first step was to prepare a master schedule for one of the engine types produced by Brunswick: the Model 1000 engine. Thisschedule indicates the number of units of the Model 1000 engine to be assembled each week during the last 12 weeks and is shownon the next page. Next, Phil decided to simplify his requirements planning example by considering only two of the many componentsthat are needed to complete the assembly of the Model 1000 engine. These two components, the gear box and the input shaft, areshown in the product structure diagram below. Phil noted that the gear box is assembled by the Subassembly Department andsubsequently is sent to the main engine assembly line. The input shaft is one of several component parts manufactured by Brunswickthat are needed to produce a gear box subassembly. Thus, levels 0, 1, and 2 are included in the product structure diagram to indicatethe three manufacturing stages that are involved in producing an engine: the Engine Assembly Department, the SubassemblyDepartment, and the Machine Shop.The manufacturing lead times required to produce the gear box and input shaft components are also indicated in the product structurediagram. Note that two weeks are required to produce a batch of gear boxes and that all the gear boxes must be delivered to theassembly line parts stockroom before Monday morning of the week in which they are to be used. Likewise, it takes three weeks toproduce a lot of input shafts, and all the shafts that are neededthe Subassembly Department stockroom before Monday morning of that week.the production of gear boxes in a given week must be delivered toIn preparing the MRP example Phil planned to use the worksheets shown and to make the following assumptions:1. Twenty five gear boxes are on hand at the beginning of Week 1, and seven gear boxes are currently on order to be delivered at thestart of Week 2.2. Fifty input shafts are on hand at the start of Week 1, and 26 are scheduled for delivery at the beginning of Week 2.Model 1000 master scheduleWeek123456789101112Demand 1812102025136413Model 1000 product structureEngine assemblyGear boxLead time = 2 weeksUsed: 1 per engineCrankcaseInput shaftLead time = 3 weeksUsed: 2 per gear box a. Initially, assume that Phil wants to minimize his inventory requirements. Assume that each order will be only for what is required for asingle period. Calculate the net requirements and planned order releases for the gear boxes and input shafts. Assume that lot sizing isdone using lot-for-lot (L4L). (Leave no cells blank - be certain to enter "0" wherever required.)Gear Box RequirementsWeek:134579101112Gross requirementsScheduled receiptsProjected available balanceNet requirementsPlanned order receiptPlanned order releaseInput Shaft RequirementsWeek:156891012Gross requirementsScheduled receiptsProjected available balanceNet requirementsPlanned order receiptPlanned order release113.2.

Instructions and formula used: Projected on hand = Planned order receipts + ending inventory…

Answered: a. Initially, assume that Phil wants to…

Practical Management Science

6th Edition

ISBN:9781337406659

Author:WINSTON, Wayne L.

Publisher:WINSTON, Wayne L.

Chapter4: Linear Programming Models

Section: Chapter Questions

Problem 111P

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From the perspective of the development of manufacturing support systems, the "Product Management Integration" phase includes all of the following systems EXCEPT: Question 19 options: MRP II (Manufacturing Resource Planning) MRP (Materials Requirements Planning) CL MRP (Closed Loop Material Requirements Planning) LIS (Logistics Information System) Previous PageNext Page

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