Bluewave panel is one of the leading manufacturers of residential solar panels. Production at the bluewave panel factory are scheduled by an ERP system using MRP logic. There are two models tripod and quadpod, both of which are assembled from the same base unit PolyCell, which is not used in the production of any other solar panels. The lead time to assemble a solar panel is one week, and PolyCell production also requires one week.

The current gross requirements for the two watch models in a future 8 week period are: 

WEEK           5       6       7     8      9    10    11    12      

tripod         58    85    75    43    33    68    48    74

quadpod    30    50    39    31    32    45    38    37

 

The tripod inventory at the end of week 4 is 12 units while that for quadpod is 18 units. For tripod there are scheduled receipts of 15 in week 5 and 20 in week 7. For quadpod there are scheduled receipts of 12 in week 5 and 16 in week 6. 

 

Solve in the attached worksheet.

(i) Production of tripod is to occur in lot size multiples (LSM) of 30 units, while that quadpod occurs in minimum lot sizes (LMIN) of 60 units. Derive the MRP tableau corresponding to weeks 5 to 12 for the solar panels.

(ii) Derive the planned receipts for PolyCell using the part period balancing algorithm. The inventory at the end of week 3 is zero units and there are scheduled receipts of 42 in week 5 and 31 in week 6 and 80 in week 10. The BOM of tripod requires 3 PolyCells while quadpod requires 4. The order cost is $1050 and the holding cost is $2.30 per housing/week.