Forecasts Company produces four products with a mixed model assembly line. Operates 12 hours per day for 250 days/yr. Products (Year) Z 1000 Y 3000 X 7000 . Determine mix schedule for a day. W 12000 Determine the mixed model MPS for a daily and hourly batch. Z Y W Year Forecast 1000 3000 7000 12000 Daily Batch divide by ? Hourly Batch divide by ? Minimum Batch MPS Relationship of smallest to others Instructions: 1) Replace the "?" above in cells D9 and D10 with the correct number. 2) Complete table for products Z-W (E9:W11). swer the following questions. Put answer in the green cells in column E. What is the Minimum Batch MPS? How often need to repeat the Minimum Batch MPS per day? EOQ Lead-time = 1 week 1 2 3 4 5 6 7 8 10 Gross requirements 80 110 80 20 140 60 80 40 0 40 Scheduled receipts Projected on hand 95 Net requirements Planned order receipts Planned order releases Instructions: Holding cost = $1.50/week; Setup cost = $75; 1) Calculate EOQ based on the following inputs, using formula shown at righ D = 65 units per week S = set-up cost H = holding cost =Q 2DS Q*= H total cost = 2) Fill in the table above (Net Requirements, Projected on-hand, Planned Order Receipts) using your calculated EOQ as the Lot Size --> Note: Projected On-Hand = amount of material left in inventory at the end of the period. --> Note: Must follow lead-time 3) Determine Total Cost for this lot size strategy and enter that in the Total Cost cell in L9. Lot-for-Lot Lead-time = 1 week 1 2 3 4 5 6 7 8 9 10 Gross requirements 80 110 80 80 20 140 60 80 40 0 40 Scheduled receipts Projected on hand 95 Net requirements Planned order receipts Planned order releases Instructions: Holding cost = $1.50/week; Setup cost = $75; total cost = 1) Fill in the table above (Net Requirements, Projected on-hand, Planned Order Receipts) using "Lot-for-Lot" lot size strategy. --> Note: Projected On-Hand = amount of material left in inventory at the end of the period. Note: Must follow lead-time 2) Determine Total Cost for this lot size strategy and enter that in the Total Cost cell in L9. Instructions: Complete all empty cells in the MRP tables below for all components shown in the product tree for Product Z (highlighted in green at right). Assume that lead-time is strictly followed, and you are not able to get or build material inside of lead-time. Planning Data: Product Z Gross Requirements Scheduled Receipts Projected Available 300 Net Requirements Planned Order Receipts Planned Order Releases MRP Final Lot Size = 1 Lot for Lot LT=1 2 3 4 Sfty Stk = 5 0 6 7 8 co Z 300 325 400 350 300 350 400 400 A (x1) B (x2) D (x3) C (x0.5) Planning Data: Assembly B Lot Size = 1 150 LT=2 2 3 4 Sfty Stk = 5 0 6 7 8 Gross Requirements Scheduled Receipts 400 600 300 Projected Available Net Requirements Planned Order Receipts Planned Order Releases Planning Data: Component A Gross Requirements Scheduled Receipts Projected Available 500 Net Requirements Planned Order Receipts Planned Order Releases Lot Size = 1 300 LT=2 2 3 4 Sfty Stk= 5 100 6 7 8 300 Planning Data: Component C Lot Size = 1 125 LT=3 2 3 4 Sfty Stk= 5 250 6 7 8 Gross Requirements Scheduled Receipts Projected Available 375 125 0 375 Net Requirements Planned Order Receipts Planned Order Releases Planning Data: Component D Lot Size = 1 250 LT=1 2 3 4 Sfty Stk= 5 150 6 7 8 Gross Requirements Scheduled Receipts Projected Available 500 0 500 650 Net Requirements Planned Order Receipts Planned Order Releases Planning Data: Component E Gross Requirements Scheduled Receipts Projected Available Net Requirements Planned Order Receipts Planned Order Releases Lot Size = 1 100 LT=1 2 3 4 Sfty Stk= 5 100 6 7 8 1100 350 E (x1)