Question

Recently, Phil Harris, the production control manager at Brunswick, read an article on time phased requirements planning. He was curious about how this technique might work in scheduling Brunswick's engine assembly operations and decided to prepare an example to illustrate the use of time-phased requirements planning. Phil's first step was to prepare a master schedule for one of the engine types produced by Brunswick: the Model 1000 engine. This schedule indicates the number of units of the Model 1000 engine to be assembled each week during the last 12 weeks and is shown on the next page. Next, Phil decided to simplify his requirements planning example by considering only two of the many components that are needed to complete the assembly of the Model 1000 engine. These two components, the gear box and the input shaft, are shown in the product structure diagram below. Phil noted that the gear box is assembled by the Subassembly Department and subsequently is sent to the main engine assembly line. The input shaft is one of several component parts manufactured by Brunswick that are needed to produce a gear box subassembly. Thus, levels 0. 1, and 2 are included in the product structure diagram to indicate the three manufacturing stages that are involved in producing an engine: the Engine Assembly Department, the Subassembly Department, and the Machine Shop The manufacturing lead times required to produce the gear box and input shaft components are also indicated in the product structure diagram. Note that two weeks are required to produce a batch of gear boxes and that all the gear boxes must be delivered to the assembly line parts stockroom before Monday morning of the week in which they are to be used. Likewise, it takes three weeks to produce a lot of input shafts, and all the shafts that are needed for the production of gear boxes in a given week must be delivered to the Subassembly Department stockroom before Monday morning of that week. In preparing the MRP example Phil planned to use the worksheets shown and to make the following assumptions: 1. Twenty two gear boxes are on hand at the beginning of Week 1, and eight gear boxes are currently on order to be delivered at the start of Week 2. 2. Forty five input shafts are on hand at the start of Week 1, and 25 are scheduled for delivery at the beginning of Week 2. Model 1000 master schedule

Answer 1

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week	1	2	3	4	5	6	7	8	9	10	11	12
demand	18	5	12	10		17	22	10		9	5	20
Gear Box
week	1	2	3	4	5	6	7	8	9	10	11	12
Gross Required	18	5	12	10	0	17	22	10	0	9	5	20
Scheduled Receipts	0	8	0	0	0	0	0	0	0	0	0	0
Proj. Avail. Bal. (on hand=22)	22	4	7	0	0	0	0	0	0	0	0	0
net requirements	0	0	5	10	0	17	22	10	0	9	5	20
Planned order Receipt	0	0	5	10	0	17	22	10	0	9	5	20
Planned order release	5	10	0	17	22	10	0	9	5	20	0	0
Input shafts
week	1	2	3	4	5	6	7	8	9	10	11	12
Gross Required	10	20	0	34	44	20	0	18	10	40	0	0
Scheduled Receipts	0	25	0	0	0	0	0	0	0	0	0	0
Proj. Avail. Bal. (on hand=45)	45	35	40	40	6	0	0	0	0	0	0	0
net requirements	0	0	0	0	38	20	0	18	10	40	0	0
Planned order Receipt	0	0	0	0	38	20	0	18	10	40	0	0
Planned order release	0	38	20	0	18	10	40	0	0	0	0	0

LK M 22 10 0 -B10+B9-B8 -C10+C9-08 -D8-D10 -D11 F12 -C11 E12 E8-E10 -E11 G12 -F8-F10 -F11 -H12 G8-610H8-H10-18-110-18-10 G11 -H11 -111 -11 -112 -12 -K12 -L12 K8 K10 -K11 M12 L8-L10-M8 M10 L11 -M11 N12 0 12 6 Gear Box 7 week 8 Gross Required 18 9 Scheduled Receipts 0 10 Proj. Avail. Bal. (on har 22 11 net requirements 0 12 Planned order Receipt -B11 13 Planned order release -012 14 15 Input shafts 16 week 17 Gross Required -B132 18 Scheduled Receipts 0 19 Proj. Avail. Bal. (on har 45 20 net requirements 0 21 Planned order Receipt B20 22 Planned order release =E21 23 -C132 25 -B19+B18-B17 o 10 11 12 -D132 -E132 -F132 G13-2 -H132 -113-2 -313*2 -K13-2 -L13*2 -M13*2 0 -C19+C18-C17 -019+D18-D17 - 19+E18-E17 0 -F17-F19 G17-619 -H17-H19 -117-119 =)17-19 -K17-K19 -L17-L19 -M17-M19 -D20 -E20 -F20 -H20 -120 ho 120 J20 K20 -L20 -M20 =G21 -H21 =121 =J21 -K21 -L21 M21 N21 -021 =P21 G20 C20 =F21