MANAGEMENT DEVELOPMENT INSTITUTE OF SINGAPORE IN TASHKENT (MDIST)

ASSIGNMENT SUBMISSION COVER SHEET

Course Module Lecturer Assignment Type Due Date

: : : : :

Year 3 Manufacturing Management Mr. Abdulloh Individual 09.11.2012

S/N 1

Student Name Ikboljon Kasimov

ID Number B1000430

Student Signature

Submitted on Due Date (Yes/No) Word Count

: :

05.11.2012 3000

MANUFACTURING MANAGEMENT ASSIGNMENT

Management Development Institute of Singapore in Tashkent

FACULTY OF INDUSTRIAL MANAGEMENT

MANUFACTURING MANAGEMENT ASSIGNMENT

IKBOLJON KASIMOV
Group No. 407 ID: B1000430

November 9, 2012 Tashkent

MANUFACTURING MANAGEMENT ASSIGNMENT

Product A is made up of one unit of B and one unit of C. B is made up of 2 units D and 2 units of C. C is made up of 1 unit of E and 1 unit of F. (Assumption: Lot size for all items= Lot-for-Lot). 1. Develop the product tree diagram and label them accordingly.
A 0

D2

C2

E2

F2

2. If 10 units of Product A are needed, calculate all the parts necessary and show the low-level coding in the table as shown below.
Level (0) (1) (2) (2) (3) (3) Item A B C D E F Quantity per item 1 1 3 2 3 3 Total Requirements for 10 A 10 10 30 20 30 30

3. Given below is the lead time of each component and their on hand quantity and the Master Production Schedule for product A, develop the MRP in the table provided.
Item A B C D E F Lead Time (wk.) 1 2 3 1 1 1 On Hand Quantity 10 20 0 100 10 50

MANUFACTURING MANAGEMENT ASSIGNMENT

Master Production Schedule for Product A

Period Gross requirement 6 7 8 50 9 10 11 50 12 13 100

[250 - is when making 200 units for week 13 and 50 units for week 11.]
Week number Item: A Lot Size=L4L Lead Time= 1 Gross Requirements Scheduled Receipts Projected Available 10 Net Requirements Planned Order Receipts Planned Order Releases Item: B Lot Size=L4L Lead Time= 2 Gross Requirements Scheduled Receipts Projected Available 20 Net Requirements Planned Order Receipts Planned Order Releases Item: C Lot Size=L4L Lead Time= 3 Gross Requirements Scheduled Receipts Projected Available 0 Net Requirements Planned Order Receipts Planned Order Releases Item: D Lot Size=L4L Lead Time= 1 Gross Requirements Scheduled Receipts Projected Available 100 Net Requirements Planned Order Receipts Planned Order Releases 1 2 3 4 5 6 7 8 9 10 11 12 13

50 50 10 10 10 10 10 10 10 40 40 40 1 2 3 4 5 6 7 40 20 20 20 20 20 20 20 20 20 20 1 2 3 4 5 40 40 40 40 100 5 40 100 100 100 100 60 40 60 60 40 40 40 200 200 200 6 6 7 40 40 40 40 250 7 50 8 100 100 100 100 100 8 100 40 9 10 200 200 9 50 50 100 10 250 250 250 250 8 9 50 10 50 50

50 50 50 50 100 11 12 100 100 100 100

100 100 100 100

13

11

12 100 100 100 100

13

40 1 2 3

40 4

11

12

13

MANUFACTURING MANAGEMENT ASSIGNMENT

5 12 13

Item: E Lot Size=L4L Lead Time= 1 Gross Requirements Scheduled Receipts Projected Available 10 Net Requirements Planned Order Receipts Planned Order Releases Item: F Lot Size=L4L Lead Time= 1 Gross Requirements Scheduled Receipts Projected Available 50 Net Requirements Planned Order Receipts Planned Order Releases

2 40 30

4 40 40 40 40 100 4 40 40

5 100 100 100 100

7 250 250 250 250

9 100 100 100 100

10

11

10 30 30 30 1 2 40 50 10 40 10 30 30 100 100 100 250 250 250 100 100 100 40 3

250 5 100 100 6 7 250 250

100 8 9 100 100 10 11 12 13

30

[250 - is when making 200 units for week 13 and 50 units for week 11.]

Materials Requirements Planning for product A is developed from the given information on Master Production Schedule. When looking at MPS, it is clear that company is required to manufacture 50 units of A on week 8, and another 50 on week 11 and 100 units on week 13. Lead time is given in weeks and quantity on hand is in units. 50 units of A product should be made by week 8. 3 units of F, 3 units of E, 2 units of D, 3 units of C and 1 unit of B is required to produce 1 unit of product A. On week 8, gross requirement for product A is 50 and 10 units already available on hand, so net requirement of 40 units is required and because the lead time is 1 week, order is released on week 7. Forty units of B and C are necessary to make 40 units of A, but twenty units of B is already available on hand, so order released for only 20 units of B on week five as the lead time is 2, and 40 units of C order released on week four as the lead time is 3 weeks for C. One unit of E and F are required to get one unit of C, so 40 units of E and F orders released on week three. B consists of 2 units of D and 2 units of C, 100 units of D are already available on hand, so only 40 units of C order released on week 2. One unit of E and F are necessary to make C on the second level of product tree, so 40 units of E and 40 units F orders are released on week 1 as the lead time is one week. Total required units of product A manufactured on week 8 when all released orders received by the expected time. It applies to week 11 and week 13 on Master Production Schedule.