Must use capacity bills methodology

Manufacturing Lead times Level O leadtime = 0 (that is, these operations occur in the same period as gross requirements) Level 1 Leadtime = 1 (these operations occur one week prior to level O operations) Level 2 leadtime=1 (i.e. these operations occur 1 week prior to level 1 operations) 800 A company makes 2 products (Backboard post set and Volleyball post set) which is manufactured in house. Given the following information, prepare a rough-cut analysis of capacity (using CPOF and capacity bills) for next 4 weeks based on the MPS, and determine when and which areas are out of capacity. A. Products Backboard post set + F. Routings and time Standards (hours/unit) Volleyball post set Package backboard post set hrs/unit Assembly 0.1 B. Plant Work Centers Capacities (in terms of employees and hrs) Manufacture upright 001- Sawing 12 @ 40 hrs 002- Bending 20 @ 40 hrs Bending 0.2 003- Drilling 5 @ 40 hrs Welding 0.1 004- Milling 5 @ 40 hrs Manufacture Crossbar 005- Welding 10 @ 40 hrs Welding 0.1 006- Assembly 5 @ 40 hours Manufacturing shaft C. Master Production Schedule Sawing 0.1 Product WK1 WK 2 WK 3 WK4 Bending 0.2 Backboard post sets 1000 1200 800 Welding 0.1 Volleyball post sets 800 600 600 1000 Sawing 0.2 D. Historical Work Center Percentage Manufacture plate next to post 001- Sawing 20% Sawing 002- Bending Drilling 0.1 003- Drilling 10% Manufacture plate next to backboard 004- Milling 10% Sawing 0.1 005- Welding 20% 006- Assembly 10% Milling 0.2 Package backboard post hardware E. Manufacturing Bill of Materials (excluding raw materials) Assembly 0.05 **Standard hours per blackboard 1.6 hours ** Backboard post set (package) Package volleyball post set Upright (manufacture) Assembly 0.1 Crossbar (weld on plates) Manufacture posts (each package requires two posts) Shaft (manufacture) Bending 0.2 Plate next to post (manufacture) Welding 0.1 Manufacture plate next to backboard Hardware package (package) Drilling 0.05 Package volleyball post hardware Volleyball post set (package) Assembly 0.05 Posts (manufacture) **Standard hours per volleyball post set 0.85 hours** Hardware package (package) 0.05 30% Package backboard post set Assembly hrs/unit 0.1 0.2 0.1 Package volleyball post set Assembly 0.1 Manufacture posts (each package requires two posts) Bending 0.2 Welding 0.1 Drilling 0.05 Package volleyball post hardware Assembly 0.05 **Standard hours per volleyball post set 0.85 hours Step 1: Capacity Requirements Computations Work Center Backboard Volleyball post sets post sets Sawing Bending Drilling Milling Welding Assembly (Std Time) Total 0.1 Manufacture upright Bending Welding Manufacture Crossbar Welding Manufacturing shaft Sawing Bending Welding Sawing Manufacture plate next to post Sawing Drilling Manufacture plate next to backboard Sawing Milling Package backboard post hardware Assembly **Standard hours per blackboard 0.1 0.2 0.1 0.2 WK 3 WK4 Product Backboard post sets Volleyball post sets WK1 1000 800 WK 2 1200 600 800 800 0.05 600 1000 0.1 Total 0.1 0.2 WK4 0.05 1.6 hours ** Step 2: Allocation using Routings and Manufacturing Bill of Materials (BOM) Work Center WK1 WK 3 Sawing Bending Drilling Milling Welding Assembly check Answer to question - determine when and which areas are out of capacity? Work Center Task Capacity per week 1 2 3 Sawing Bending Drilling Milling Welding Assembly 4 5 6 Manufacturing Lead times Level O leadtime = 0 (that is, these operations occur in the same period as gross requirements) Level 1 Leadtime = 1 (these operations occur one week prior to level O operations) Level 2 leadtime=1 (i.e. these operations occur 1 week prior to level 1 operations) 800 A company makes 2 products (Backboard post set and Volleyball post set) which is manufactured in house. Given the following information, prepare a rough-cut analysis of capacity (using CPOF and capacity bills) for next 4 weeks based on the MPS, and determine when and which areas are out of capacity. A. Products Backboard post set + F. Routings and time Standards (hours/unit) Volleyball post set Package backboard post set hrs/unit Assembly 0.1 B. Plant Work Centers Capacities (in terms of employees and hrs) Manufacture upright 001- Sawing 12 @ 40 hrs 002- Bending 20 @ 40 hrs Bending 0.2 003- Drilling 5 @ 40 hrs Welding 0.1 004- Milling 5 @ 40 hrs Manufacture Crossbar 005- Welding 10 @ 40 hrs Welding 0.1 006- Assembly 5 @ 40 hours Manufacturing shaft C. Master Production Schedule Sawing 0.1 Product WK1 WK 2 WK 3 WK4 Bending 0.2 Backboard post sets 1000 1200 800 Welding 0.1 Volleyball post sets 800 600 600 1000 Sawing 0.2 D. Historical Work Center Percentage Manufacture plate next to post 001- Sawing 20% Sawing 002- Bending Drilling 0.1 003- Drilling 10% Manufacture plate next to backboard 004- Milling 10% Sawing 0.1 005- Welding 20% 006- Assembly 10% Milling 0.2 Package backboard post hardware E. Manufacturing Bill of Materials (excluding raw materials) Assembly 0.05 **Standard hours per blackboard 1.6 hours ** Backboard post set (package) Package volleyball post set Upright (manufacture) Assembly 0.1 Crossbar (weld on plates) Manufacture posts (each package requires two posts) Shaft (manufacture) Bending 0.2 Plate next to post (manufacture) Welding 0.1 Manufacture plate next to backboard Hardware package (package) Drilling 0.05 Package volleyball post hardware Volleyball post set (package) Assembly 0.05 Posts (manufacture) **Standard hours per volleyball post set 0.85 hours** Hardware package (package) 0.05 30% Package backboard post set Assembly hrs/unit 0.1 0.2 0.1 Package volleyball post set Assembly 0.1 Manufacture posts (each package requires two posts) Bending 0.2 Welding 0.1 Drilling 0.05 Package volleyball post hardware Assembly 0.05 **Standard hours per volleyball post set 0.85 hours Step 1: Capacity Requirements Computations Work Center Backboard Volleyball post sets post sets Sawing Bending Drilling Milling Welding Assembly (Std Time) Total 0.1 Manufacture upright Bending Welding Manufacture Crossbar Welding Manufacturing shaft Sawing Bending Welding Sawing Manufacture plate next to post Sawing Drilling Manufacture plate next to backboard Sawing Milling Package backboard post hardware Assembly **Standard hours per blackboard 0.1 0.2 0.1 0.2 WK 3 WK4 Product Backboard post sets Volleyball post sets WK1 1000 800 WK 2 1200 600 800 800 0.05 600 1000 0.1 Total 0.1 0.2 WK4 0.05 1.6 hours ** Step 2: Allocation using Routings and Manufacturing Bill of Materials (BOM) Work Center WK1 WK 3 Sawing Bending Drilling Milling Welding Assembly check Answer to question - determine when and which areas are out of capacity? Work Center Task Capacity per week 1 2 3 Sawing Bending Drilling Milling Welding Assembly 4 5 6