Part Name: Side: Level 2 for Cabinet (2) Safety Stock = 0 Lead-time 1 week Order Lot for lot Quantity Week Week Week Week Week Week Week Week 1 2 3 4 5 6 7 8 Gross Requirements 160 180 120 160 160 140 Scheduled Receipts On Hand Inventory 200 40 Net Requirements 140 120 160 160 140 Planned Order Receipts 140 120 160 160 140 Planned Order Releases 140 120 160 160 140 Part Name: End : Level 2 for Cabinet (2) Safety Stock = 0 Lead-time 1 week Order Lot for lot Quantity Week Week Week Week Week Week Week Week 1 2 3 4 5 6 7 8 Gross Requirements 160 180 120 160 160 140 Scheduled Receipts On Hand Inventory 200 40 Net Requirements 140 120 160 160 140 Planned Order Receipts 140 120 160 160 140 Planned Order Releases 140 120 160 160 140 Part Name: Oak Sheet: Level 3 (1) (Back, Side, End, Shell) Safety Stock = 30 Lead-time 2 Weeks Order FOQ: 1000 I uanti Sheets Week Week Week Week Week 1 2 8 Gross Requirements 850 300 Scheduled Receipts 1000 On Hand Inventory 500 650 350 Net Requirements Planned Order Receipts 1000 1000 Planned Order Releases 1000 1000 The Casual Furniture Company The Casual Furniture Company (CFC) makes a variety of bookshelves for homes and businesses. The shelves come in various heights, widths, materials, and finishes. Effective requirements planning is essential for CFC's performance, and it uses MRP for planning. The MPS and MRP records are shown for one of CFC's products, part number 4 x 3-01, a four-foot-high and three-foot- wide standard depth oak bookshelf. The BOM as a product structure diagram is shown in & Figure 14-18. FIGURE 14-18 Bookshelf 4 x 3-01 BOM 4x3-01 Bookshelf Cabinet (1) Shelf (3) Bracket (4) Back (1) Side (2) End (2) Oak Sheet (1) Oak Sheet (1) Oak Sheet (1) Oak Sheet (1) CFC uses one-week time buckets and a planning horizon of eight weeks. The MPS for the 4 x 3-01 Bookshelf is shown in 2 Figure 14-19. FIGURE 14-19 MPS Bookshelf 4 x 3-01 Part Name: Bookshelf 4 x 3-01 Week Week Week Week Week Week Week Week 1 2 3 4 5 6 7 8 MPS 70 70 80 90 60 80 80 70 The cabinets are built in the cabinet assembly department and the shelves, backs, sides, and ends are made in the cutting department. The component lot size, lead time, available inventory and safety stock are shown in &I Figure 14-20. Two associates work in the cutting department, making the available capacity 80 hours per week, without overtime. The processing time for each component in the cutting department is shown in & Figure 14-21. FIGURE 14-20 Component Lot Size and Inventory Information Page 515 Bookshelf Oak Sheet Item 4 x 3-01 Cabinet Back Side End Shelf Bracket Lot size rule LAL LAL LAL LAL L4L FOO = 500 FOO = 600 FOO = 1,000 Lead time 2 weeks 1 week 1 week 1 week 1 week 1 week 2 weeks Available 0 100 200 300 500 120 200 inventory Safety stock 0 O 0 0 30 FIGURE 14-21 Cutting Department Processing Time Component Processing Time (minutes/part) Back 10 minutes Side 8 minutes End 5 minutes Shelf 7 minutes Questions 1. Develop the MRP for all of the components.Part Name: Bookshelf 4X3-01 : Level 0 Lead-time 0 Order Lot for lot Quantity Week Week Week Week Week Week Week Week 2 3 4 5 6 7 8 Gross Requirements 70 70 80 90 60 80 80 70 Scheduled Receipts On Hand Inventory 0 Net Requirements 70 70 80 90 60 80 80 70 Planned Order Receipts 70 70 80 90 60 80 80 70 Planned Order Releases 70 70 80 90 60 80 80 70 Part Name: Cabinet: Level 1 (1) Safety Stock = 0 Lead-time 2 weeks Order Lot for lot Quantity Week Week Week Week Week Week Week Week I 2 3 4 5 6 7 8 Gross Requirements 70 70 80 90 60 80 80 70 Scheduled Receipts 20 On Hand Inventory 120 50 Net Requirements 90 60 80 80 70 Planned Order Receipts 80 90 60 80 80 70 Planned Order Releases 80 90 60 80 80 70 Part Name: Shelf: Level 1 (3) Safety Stock = 0 Lead-time 1 Week Order FOQ: 500 Quantity Week Week Week Week Week Week Week Week 1 2 3 4 5 6 7 8 Gross Requirements 210 210 240 270 180 240 240 210 Scheduled Receipts On Hand Inventory 300 90 380 140 370 190 450 210 Net Requirements 120 130 50 Planned Order Receipts 500 500 500 Planned Order Releases 500 500 500Part Name: Bracket: Level 1 (4) Safety Stock = 0 Lead-time 1 week Order FOQ: 600 Quantity Week Week Week Week Week Week Week Week 1 2 3 4 5 6 7 8 Gross Requirements 280 280 320 360 240 320 320 280 Scheduled Receipts 600 On Hand Inventory 0 320 40 320 560 320 0 280 0 Net Requirements 280 40 320 Planned Order Receipts 600 600 600 Planned Order Releases 600 600 600Part Name: Back: Level 2 for Cabinet (1) Safety Stock = 0 Lead-time 1 week Order Lot for lot Quantity Week Week Week Week Week Week Week Week 1 2 3 4 5 6 7 8 Gross Requirements 80 90 60 80 80 70 Scheduled Receipts On Hand Inventory 100 20 Net Requirements 70 60 80 80 70 Planned Order Receipts 70 60 80 80 70 Planned Order Releases 70 60 80 80 70 O