A. (10 points) Product A has the product structure shown. MRP data is provided for items A-D. Orders for 300 units of item B and 500 units of item D have been placed and are scheduled for delivery in week 3. The master production schedule shows demand for 600 units of product A in week 6. Develop A B (1) C (2) D (1) D (3) Lead Time A 1 B 3 Lot Size Lot for Lot 100 On Hand MRP schedules for 50 100 C 1 500 minimum 200 items A-D. (number in parentheses is units required/unit of parent item, i.e., 3 D's required for 1 C) D 2 Lot for Lot 100 Product A Gross Requirements Scheduled Receipts Available Planned Order Release Part B Gross Requirements Scheduled Receipts Available Planned Order Release Part C Gross Requirements Scheduled Receipts Available Planned Order Release Part D Gross Requirements Scheduled Receipts Available Planned Order Release 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 B. (9 points) Demand for a part is as shown. The company purchases the item for $10/unit and has an order cost of $ 80/order. Holding costs for the part are $1/unit/period based on average period inventory. Period 1 2 3 4 5 6 Demand 30 20 30 40 60 30 a. Using the part period balancing method, how large should the first order be? b. Using the POQ method, how large should the second order be? (part b is independent of part a) C. (7 points) Part of the MRP schedule for component A is shown. Component A has a three week lead time (one operation in each week) and is produced on a lot for lot basis. Processing characteristics for the component are as indicated. Complete the MRP schedule and determine capacity requirements, by week, for workstations 100, 200, and 300? Operation Workstation Setup Time (hrs) 1 200 3 Run Time/ Unit (hrs) .1 2 300 1 .2 3 100 2 .25 Gross Requirements Scheduled Receipts Available (40) Planned Order Release 1 2 3 4 50 50 30 D. (8 points) Product A has the product structure diagram and processing characteristics shown. The master production schedule calls for 200 units of the product to be produced in week 8. Determine weekly capacity requirements at each workstation (for items B and D, each operation occurs in a different week). B (2) Item Operation Workstation Lead Time (wks) Hours/ C (2) D unit A 1 100 1 0.25 1 200 1 0.2 B 2 300 1 0.5 3 100 1 0.5 C 1 300 1 0.1 1 200 1 0.3 D 2 300 1 0.5 Week 1 2 3 4 5 6 7 8 Workstation 100 200 300 A E. (6 points) Three jobs, with characteristics as shown, are to be processed on four machines. Using vertical loading, determine machine loadings such that all jobs are completed in the shortest amount of time. Job Operation Workstation Hours A B C 432341234 1231231 23 2 1 3 3 2 3 4 3 1