The Green Thumb Water Sprinkler Company was founded in 1948 by Arthur Green, an entrepreneur with an avid interest in home gardening. Today the successful company, known as Arthur Green, Inc., is run by Arthurs descendants. Among other things Arthur Green produces a line of high-quality sprinklers targeted at upper-income hobbyists. The companys products are considered very retro in design and are seen by customers as unique and harkening back to an earlier time. To reinforce this image company catalogs and websites feature photos of the late Arthur Green working in his garden and wearing a pith helmet, popular in the past with some gardeners. A stylized drawing of Arthurss pith helmet appears on the companys logo, and one of the real Arthurian headgear is lovingly displayed behind glass at the companys headquarters in Oconomowoc, Wisconsin.

One product made by Arthur Green is the Model #984 Basic Lawn Sprinkler, a mainstay of the companys product line and little-changed since first introduced in 1953.

The #984 Sprinkler is very basic in design and easy to assemble. A product structure tree is given later in this problem as well as basic information about each item in the tree. Capacity is limited in that a maximum of 250,000 sprinklers may be shipped in any given week. Note especially the items Raw Aluminum Tubing and Bulk Paint. The tubing in diameter and is purchased in 18-foot lengths. 2000 of these 18-foot tubes can be shipped on a single semi flatbed trailer. The lengths of tubing are then cut to form the Frame Tube and the Sprinkler Tube. The Bulk Paint is purchased in semi tanker loads of 8500 gallons each.

Considering the Master Production Schedule and other information given on the following page:

1. Develop MRP reports for each of the ten items of interest in the #984 problem. For Raw Aluminum Tubing and Bulk Paint your report should show the number of truck/tanker loads to be ordered in each time bucket.

2. For the planning scenario in part a above you also need an estimate of scrap aluminum tubing to be sold for recycling on a weekly basis. Determine on a week-by-week basis the revenue that can come from selling scrap aluminum assuming:

• One foot of aluminum tubing weighs .17 pounds.
• The market price for scrap aluminum of this type is $0.42 per pound.

3. Mall-Mart Stores, In, a very good customer, has suddenly asked whether Arthur Green can ship an additional 150,000 #984 sprinklers in Week 4. This is on top of other orders reflected in the Master Production Schedule. Modify the Master Production Schedule such that Arthur Green can:

• Meet the new quantity from Mall-Mart as quickly as possible.
• Fulfill all other existing orders in the MPS.
• Incur no more than a 10% change in MPS quantities week-to-week

Master Production Schedule
Week	4	5	6	7	8	9	10	11	12
Shipment Quantity	125,000	100,000	145,000	175,000	200,000	220,000	220,000	230,000	250,000

Item	Ordering Policy	Beginning Inventory	Scheduled Receipts
Sprinkler	Lot = 800	5,000
Water Motor Assembly	Any Batch Size	0
Hose Receptacle Assembly	Lot = 10,000	0
Frame Assembly	Any Batch Size	0
Sprinkler Tube	Any Batch Size	10,000
Metal Screw	Lot = 100,000	50,000
Water Motor	Lot = 50,000	50,000
Frame Tube	Lot for Lot	0
Plastic Cap	Lot = 10,000	50,000	10,000 in Week 2
End Plate	Lot = 1,000,000	350,000
Bulk Paint	Lot = 8500 gallons	3200 gallons
Raw Aluminum Tubing	Lot = 3500 sections	25,000 sections	10 Truckloads in Week 1

Additional Information

The End Plate has a 2-week lead time. All other items have a lead time of 1 week.

The grade and gauge of aluminum tubing used here weighs .17 pounds per linear foot.

The current market price for scrap aluminum tubing is $0.42 per pound.

M-Water Motor Assembly #699 Hose Recept. Assembly Frame Assembly Lawn Sprinkler Water Motor Assembly Hose Recept. Assembly Frame Assembly Paint (3.8 fl. oz.) Sprinkler Tube (17.9 inches) Metal Screw (3 units) Water Motor (1 unit) Frame Tube (29.7 inches) Plastic Cap (3 units) Metal Screw (3 units) End Plate (1 unit) Bulk Paint Raw Aluminum Tubing Raw Aluminum Tubing