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Semans is a manufacturer that produces bracket assemblies. Demand for bracket assemblies (X) is 130 units. The following is the BOM in indented form:

ITEMS

DESCRIPTION

USAGE

X

Bracket assembly

1

A

Wall board

4

B

Hanger sub-assembly

2

D

Hanger casting

3

E

Ceramic knob

1

C

Rivet Head screw

3

F

Metal tong

4

G

Plastic cap

2

Below is a table indicating current inventory levels:

ITEMS

X

A

B

C

D

E

F

G

Inventory

25

16

60

20

180

160

1000

100

a.Using Excel, create the MRP using the information provided.

Short Answer

Expert verified

Items

Net requirement

X

105

A

114

B

70

D

110

E

50

C

30

F

870

G

30

Step by step solution

01

MRP

Material requirements planning(MRP)is a method that assists producers in scheduling, budgeting, and managing their inventories during production. It is a software-based platform.

02

 Calculation of demand, inventory and net requirement

Demand for X = 130

Inventory = 25

Net requirement,

X = demand - inventory

= 105

Every bracket assembly requires (4 of A), (2 of B), and (3 of C).

Demand for A = 4 x 105

= 420

Inventory = 16

Net requirement = 420 – 16

= 404

Demand for B = 2 x 105

= 210

Inventory for B = 60

B Net requirement = 210 – 60

=150

Same for (3 of D) and (1 of E)

Demand for D = 3 x Net requirement of B

= 3 x 250

= 750

Inventory for D = 180

D, net requirement = 750 – 180

= 570

Demand for E = 1 x Net requirement of B

= 1 x 250

= 250

Inventory for E = 160

E, net requirement = 250 – 160

=90

Demand for C = 3 x 250

= 750

Inventory = 20

C, net requirement = 750 – 20

= 730

Rivet head screw, C requires (4 of F) and (2 of G)

Demand of F = 4 x 730

=2920

Inventory of F = 1000

F, net requirement = 2920 – 1000

= 1920

Demand of G = 2 x 730

=1460

Inventory = 100

G, net requirement = 1460 – 100

=1360

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Most popular questions from this chapter

Palin’s Muffler Shop has one standard muffler that fits a large variety of cars. The shop wishes to establish a periodic review system to manage the inventory of this standard muffler. Use the information in the following table to determine the optimal inventory target level (or order-up-to level).

Annual demand

3,000 mufflers

Ordering cost

\(50 per order

The standard deviation of daily demand

6 mufflers per working day

Service probability

90%

Item cost

\)30 per muffler

Lead time

2 working days

Annual holding cost

25% of the item value

Working days

300 per year

Review period

15 working days

a. What is the optimal target level (order-up-to level)?

b. If the service probability requirement is 95 percent, the optimal target level [your answer in part (a)] will (select one):

I. Increase.

II. Decrease.

III. Stay the same.

Question: After using your forecasting model for six months, you decide to test it using MAD and a tracking signal. Here are the forecast and actual demands for the six months;

Period

Forecast

Actual

May

450

500

June

500

550

July

550

400

August

600

500

September

650

675

October

700

600

a. Find the tracking signal.

b. Decide whether your forecasting routine is acceptable.

Visit the vendors’ websites to read up on both SAP and Microsoft Dynamics ERP systems. Provide a list of four ways in which the two differ in their approach to implementing ERP

Your manager is trying to determine what forecasting method to use. Based upon the following historical data, calculate the following forecast and specify what procedure you would utilize.

Month

Actual demand

1

62

2

65

3

67

4

68

5

71

6

73

7

76

8

78

9

78

10

80

11

84

12

85

a. Calculate the simple three-month moving average forecast for periods 4–12.

b. Calculate the weighted three-month moving average using weights of 0.50, 0.30, and 0.20 for periods 4–12.

c. Calculate the single exponential smoothing forecast for periods 2–12 using an initial (F1) of 61 and anαof 0.30.

d. Calculate the exponential smoothing with trend component forecast for periods 2– 12 using an initial trend forecast (T1) of 1.8, an initial exponential smoothing forecast (F1) of 60, and αof 0.30 andδof 0.30.

e. Calculate the mean absolute deviation (MAD) for the forecasts made by each technique in periods 4–12. Which forecasting method do you prefer?

Questions: How many steps are there in collaborative planning, forecasting, and replenishment (CPFR)?

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