Answer to the Question No: 3

A mapping for the production of end item is shown below:

End
Item Lead Time: 1 week
(1)

Lead Time: 3 weeks Lead Time: 3 weeks

Lead Time: 2 weeks

L (2) C (1) K (3)

B (2) J (3) G (2) B (2) H (4) B (2)

Lead Time: Lead Time: Lead Time:

2 weeks 2 weeks 2 weeks
Lead Time: Lead Time: Lead Time:
3 weeks 3 weeks 2 weeks

(a)
For 40 units of end item, 80 units of L are needed, 40 units of C are needed and 120 units of K
are needed.
10 units of L, 15 units of C, 20 units of K are already on hand.
So, units of L needed = (80-10) units = 70 units
Units of C needed = (40-15) units = 25 units
Units of K needed = (120-20) units = 100 units
For 70 units of L, Amount of B needed = (2 x 70) = 140 units
For 25 units of C, Amount of B needed = (2 x 25) = 50 units
For 100 units of K, Amount of B needed = (2 x 100) = 200 units
Total amount of B needed = (140 + 50 + 200) units = 390 units
Units already in hand are 30.
Additional units of B needed = (390-30) units = 360 units

(b)
Lead time for end item is 1 week. So, order must be placed at a start of 7 th week considering only
this level.
Lead time for L is 2 weeks, lead time for C is 3 weeks and Lead time for K is 3 weeks. So,
considering this level orders must be placed at latest at the start of week 4.
Lead time for B is 2 weeks, G is 3 weeks, J is 3 weeks and H is 2 weeks. So, here orders must be
placed at latest at the start of week 1 to ensure timely production of L and C since their direct
components take a lead time of 3 weeks.
So, the order must be placed at the start of Week 1 in order to ship end item at the start of
Week 8.

Answer to the Question no: 5

(a)

Given,
Required units = Z = 120 units at the beginning of week Z
On hand, Z= 40 units, A= 70 units, B= 100 units, C= 30 units.
20 units of scheduled receipt of C should be there in week 4.
MRP chart for Z
ITEM Z Beginning 1 2 3 4 5 6 7
inventory
Gross 120
Requirement
On hand- 40

Scheduled
receipt
Balance 40 40 40 40 40 40 40 -

Net 80
requirements
Planned order 80
receipt
Planned order 80
release

MRP chart for A

ITEM A Beginning 1 2 3 4 5 6 7
inventory
Gross 160
Requirement
On hand- 70

Scheduled
receipt
Balance 70 70 70 70 70 70 0 0

Net 90
requirements
Planned 90
order receipt
Planned 90
order release
MRP chart for B
ITEM B Beginning 1 2 3 4 5 6 7
inventory
Gross 320
Requirement
On hand-
100
Scheduled
receipt
Balance 100 100 100 100 100 100 0 0

Net 220
requirements
Planned 220
order receipt
Planned 220
order release

MRP chart for C

ITEM C Beginning 1 2 3 4 5 6 7
inventory
Gross 440 270
Requirement
On hand- 30
Scheduled 20
receipt
Balance 30 30 30 30 20

Net 410 250

requirement
s
Planned 410 250
order receipt
Planned 410 250
order release

Answer of the Question no 5

(b)

Given,
Required units = E = 95 units at the beginning of week 7
On hand, E= 5 units, B= 50 units, C=100 units, D=80 units.
30 units of C have been outsourced and should arrive in week four.

MRP chart for E

ITEM E Beginning 1 2 3 4 5 6 7
inventory
Gross 95
Requirement
On hand-5
Scheduled
receipt
Balance 5 5 5 5 5 5 5 5 -
Net 90
requirements
Planned 90
order receipt
Planned 90
order release

MRP chart for B

ITEM B Beginning 1 2 3 4 5 6 7
inventory
Gross 270
requirement
On hand-50
Scheduled
receipt
Balance 50 50 50 50 50 50 0 0
Net 220
requirements
Planned 220
order receipt
Planned 220
order release

MRP chart for C

ITEM C Beginning 1 2 3 4 5 6 7
inventory
Gross 180
requirement
On hand-100
Schedule 30
receipt
Balance 100 100 100 100 130 130 0 0
Net 50
requirement
s
Planned 50
order receipt
Planned 50
order release

MRP chart for D

ITEM D Beginning 1 2 3 4 5 6 7
 inventory
Gross 100 440
requirement
On hand- 80
Scheduled
receipt
Balance 80 80 80 80 20 20 20 20
Net 20 420
requirement
s
Planned 40 440
order receipt
Planned 40 440
order release

Answer to the Question no 6

Given that,
Master 1 2 3 4 5 6 7
Schedule/Da
y
Quantity 0 0 0 100 150 0 200

Table/ week 1 2 3 4 5 6 7
Gross 100 150 200
Requirements
Scheduled
receipt
On hand
inventory
Net 100 150 200
requirements
Planned 100 150 200
order receipts
Planned 100 150 200
order release
(lot for lot)

Planned order release for wood sections calculations from MPS of table are below
Wood 1 2 3 4 5 6 7
section/week
Gross 200 300 400
Requirements
Scheduled 100
receipts
On hand 100 100
inventory
Net 100 300 400
requirements
(LOL)
Planned order 100 300 400
recipts

Planned order 400 400

release (lot for
lot)

Planned order release for braces calculations from MPS of table are below
Braces/week 1 2 3 4 5 6 7
Gross 300 450 600
requirements
Scheduled
receipts
On hand 60 60 60 60
inventory-60
Net 240 450 600
requirements
(LOL
Planned order 240 450 600
receipts
Planned order 240 450 600
release (lot for
lot)

Calculation process of the planned order release for component legs are below:
Step 1: Calculate the gross requirements for legs from the table's MPS (master production
schedule) by multiplying the table's production schedule by a (since four quantities of legs are
required to make one end item).
Step 2: now. Subtract on-hand inventory and any scheduled receipts from gross requirements to
arrive at net requirements. Legs are available in quantities of 120. In week 3, 10% of safety stock
will be 26 units added as safety stock.
Step 3: Phase back the net requirements for two periods for orders above 201-550 (lead time is
two weeks) and three weeks for orders over 550 units (lead time is three weeks) in order to
acquire the time phased net requirements and production schedule.

Planned order release for braces calculations from MPS of table are below
Braces/week 1 2 3 4 5 6 7
Gross 400 600 800
requirements
Scheduled
receipts
On hand 120 120 120 120
inventory-120
Net 280 600 800
requirements
(LOL)+10%
Planned order 280 600 800
receipts
Planned order 880 800
release (lot for
lot)

7 No Question Answer
Here is MPS for end item X –

Item X 1 2 3 4 5 6 7 8

Gross 80 30
requirements

Scheduled
receipts

On hand
inventory

Net 80 30
requirements

Planned 80 30
order
receipts

Planned 80 30
order release

Here is planned order release for B –

Component 1 2 3 4 5 6 7 8
B

Gross 160 60
requirements

Scheduled
receipts

On hand 30 30 30 30 30
inventory
(30)

Net 130 60
requirements
Planned 130 60
order
receipts

Planned 130 60
order release

Here is planned order release of D –

Component 1 2 3 4 5 6 7 8
D

Gross 260 240 120 90

requirement
s

Scheduled 50 50 50 50
receipts

On hand 70 70 120 10 60 20 50 10
inventory
(20)

Net 140 180 100 40

requirement
s

Planned 150 200 100 50

order
receipts

Planned 150 200 100 50

order release

Therefore, planned order release for component D is –

For week 1 – 150 orders
For week 3 – 200 orders
For week 5 – 100 orders
For week 6 – 50 orders
 8 No Question Answer

Here is MRP for item A –

Item A 1 2 3 4 5 6
(LT: 1 week)

Gross 40
requirement
s

Scheduled
receipts

On hand
inventory

Net 40
requirement
s

Planned 40
order
receipts

Planned 40
order release

Here is MRP for item B –

Item B (LT: 1 1 2 3 4 5 6
week)

Gross 60
requirements

Scheduled
receipts

On hand 10 10 10 10 10
inventory (10)

Net 50
requirements

Planned order 50
receipts

Planned order 50
release

Here is MRP for item C –

Item C (LT: 1 2 3 4 5 6
2 weeks)

Gross 30
requirements

Scheduled
receipts

On hand 10 10 10 10 10 10
inventory
(10)

Net 20
requirements

Planned 20
order
receipts

Planned 20
order release

Here is MRP for item D –

Item D (LT: 1 2 3 4 5 6
1 week)

Gross 40 180
requirements

Scheduled 100
receipts
On hand 25 125 125 85 5 5
inventory
(25)

Net 95
requirements

Planned 100
order
receipts

Planned 100
order release

Answer to the question no. 9

(a)

Product structure of provided data is given below:

Saw

A (2) B(1) C(4)

E(3) D(1) D(2) F(3) E(2) D(2)

Master schedule

Beginnin 1 2 3 4 5 6 7 8
g
Week
Number
 Inventory

Quantity 50

Item Saw Beginning

LT= 2 weeks Inventory

Week 1 2 3 4 5 6 7 8

Gross 50
Requirements

Scheduled
Receipts

Projects On 15 15 15 15 15 15 15 0
Hand

Net 35
requirements

Planned 35
order receipts

Planned 35
order releases

Item A (2) Beginning

Inventory
LT = 1 week

Week 1 2 3 4 5 6 7 8

Gross 70
Requirements
Scheduled
Receipts

Projects On 10 10 10 10 10 10 0
Hand

Net 60
requirements

Planned 60
order receipts

Planned 60
order releases

Item C (4) Beginning

Inventory
LT = 2 weeks

Week 1 2 3 4 5 6 7 8

Gross 140
Requirement
s

Scheduled
Receipts

Projects On 65 65 65 65 65 65 0
Hand

Net 75
requirements

Planned 75
order receipts

Planned 75
order releases

b. MRP chart for component E by using lot for ordering

Item E(3) & Beginning

E (2) Inventory
LT = 1 weeks

Week 1 2 3 4 5 6 7 8

Gross 150 180

Requirement
s

Scheduled
Receipts

Projects On 10 10 10 0 0
Hand

Net 140 180

requirements

Planned 140 180

order receipts

Planned 140 180

order releases

Answer to the question no 10

Product R

B (1) G (1) C (3)

E F G (2) H

Gross requirements = 40 units

Lead time = 2 weeks
Calculation of the MRP is given below:

Product
R

Week 1 2 3 4 5 6 7

Lead Gross 40
Time
Requirement
=2
s

On Scheduled
hand = Receipts
10

SS= 0 Projects On 10 10 10 10 10 10 0
Hand

Q= L4L Net 30
requirements

Planned 30
order receipts

Planned 30
order releases

The gross requirement of C is 3 times the planned order release of as R. The output is mentioned
below:-

Product
C

Week 1 2 3 4 5 6 7

Lead Gross 90
Time
Requirements
=2

On Scheduled
hand = Receipts
10
SS= 0 Projects On 20 20 20 20 20
Hand

Q= L4L Net 70
requirements

Planned 70
order receipts

Planned 70
order releases

The gross requirements for G are 2 times the planned order release of C and 1 time the planned
order release of R. The on hand inventory for G is 15 units & G is ordered in multiples of 80
units. –

Product
G

Lead Week 1 2 3 4 5 6 7
Time
=2

On Gross 140 30
hand =
requirements
10

SS= 0 Scheduled
Receipts

Q=L4L Projects On 15 15 15 15 35 5 5
Hand

Net 125
requirements

Planned 160
order
receipts

Planned 160
order
releases
So, we can say that, in order to fulfill the orders of 40 units 160 units of subassembly G should
be ordered in week 2.

Answer to the question no 11

M(3) I (2)

R(2) P(1) N(4)

V(1)

(a)

Here, at the beginning of week 3,

We have,
100 Ns,
40 Is,
10 ns, but at the start of week 5, we need 120Es on hand.

Es needed at the start of week 5

Master Week 1 2 3 4 5 6 7 8
schedule

Quantity 120

To prepare the master schedule,

Create MEP for N and V using a lot-for lot as shown below,

Item-e: There is no inventory on hand, the net and gross requirements are equal, item E has a
lead time of one week, and the product must arrive the week before the requirement week.
 Time=1 1 2 3 4 5 6 7 8

Gross requirement 120

Item- Scheduled receipts

E

Projected on hand

Net requirement 120

Planned receipts 120

Planned release 120

Item-I: Gross requirement I is twice E because each E uses two I. these must be available at the
start of week 4. The net requirement is 200 since there is an on-hand inventory of 40 units due to
schedule receipts for week 3. The lead time is one week.
Lead time=1 1 2 3 4 5 6 7 8

Gross requirement 240

Projected on hand 40 40

Item 2 Net requirement 200

Planed receipts 200

Planned order 200

releases

Scheduled receipts 40

Item-n: Since I have four times as many Ns as I have, the gross need for N is 200*4=800. These
have to be accessible at the start of week three. Due to the schedule for week three and the lead
time of week one, the net requirement is 700 and there is an inventory of 100 units on hand.

Lead time =2 week Beg. 1 2 3 4 5 6 7 8

iv

Gross 800
requirement

Item - Projected on hand 100 100 100 100

N4
 Net requirements 700

Planned receipts 700

Planned release 700

Schedule receipts

Item-v: Because each I only utilize one V, the gross need for V is equal to I. things need to be
accessible at the beginning of week three. Since 10 units are expected to be received in week
three, there is no requirement of 190 units. There is a two-week lead time.

Lead time =2 week 1 2 3 4 5 6 7 8

Gross requirement 200

Item-V Scheduled receipts 10

Project on hand

Net requirements 190

Planned order receipts 190

Planned release 190

(b)

First, need to create a master production schedule using the following information at the bottom
was given

Master schedule: for 100 Es needed at start week 5 and 55 at start of Es

start of week 7
Master Week 1 2 3 4 5 6 7 8
schedule

quantit 100 55
y
Item- E: Gross requirement to the master production schedule. Because there is no on-hand
inventory, yet requirement is also equal to the gross requirement. Lead time for item E is one-
week order has to be released before one week from the requirement week.

Lead time = 1 week 1 2 3 4 5 6 7 8

Gross requirement 100 55

Item- Net requirement 100 55

E

Planned order receipt

Scheduled receipts 100

Projected on hand

Planned order releases 100 55

Item -I: gross requirement for I is twice E because each E uses two I. these must be the start of
week-4 and week-6. No requirement is 160 since there is an on-hand inventory of 40 units due to
schedule receipts in week-3. Lead time is 1 week.
Lead time= 1 week 1 2 3 4 5 6 7 8

Gross requirement 200 110

Item-I Schedule receipts 40

Project on hand 40 40

Net requirement 160 110

Planned receipts 160 110

Planned release 160 110

Item-N: gross requirement for N is for the time of that (160*4=640) because each I uses four Ns.
These must be available at the start of week-3. Not a requirement of 540 units because there has
an on-hand inventory of 100 units due to schedule receipts in week 3. The lead time is one week.
The order size has to be multiplied by 800, carry unused supply as inventory to next week as
shown in the below table
Lead time= 2 week Beg. 1 2 3 4 5 6 7 8
iv

Gross requirement 640 440

Item- Projected on hand 100 100 100 100 260 260 620 620 620
N

Net requirement 540 180

Schedule receipts

Planned receipts 800 160

Planned release 800 800

Item -v: gross re requirement for V is equal to me because each I uses only one V. these must be
available at the start of week-3. No requirement in the unit because there is a schedule of 10 units
in week-3. The order size should be multiplied by 200. Carry used inventory to show next week
as shown below
Lead time =2 week 1 2 3 4 5 6 7 8

Gross requirement 160 110

Item- Project on hand 100 10 50 50 140 140 140

v

Schedule receipts 10

Net requirement 150 60

Planned receipts 200 200

Planned order 200 200

releases

(C)
The MRP plan will remain unchanged because it has been presented and the master production
schedule is also changing. (Considering week-1 as elapsed and delivery in week -9 under the
former scheduled)

Answer to the question no 12

(a)

Here now we will construct a product the tree diagram for a lot chart has a top-level. The next
level is level-1 and the top base level. Level -2 as well gives components of the top and base.
Under the base level there has level-3 and in level 3 we have the body, frame, control, wheel
assemblies and body.
 Electronic golf chart

Base

cover supporter (4) motor body seats (2)

assembly wheel

(b)

The assembly time chart indicates when production should be carried out based on lead times
from different components as specified in the BOM. This procedure makes sure that the
assembly is in place and that everything goes according to plan.
The horizontal line begins during the week that the lead time-aware procurement or manufacture
should start, and the line connects during the week that the components are assembled at the
following higher level of commerce. For instance, because chairs need to be procured in week 6
in order to be supplied in week 8 for assembling the electronic golf chart,
Week

Item 1 2 3 4 5 6 7 8

Golf

Top

Supports

Cover

Base

Motor
Body

Frame

Control

Assembly

Seats

(c)
The following equation and the calculation are used to compute the MRP for all items:
Net requirements = gross requirement – on-hand inventory
Net requirement = 0 own on-hand inventory more than the gross requirement since the inventory
full fills the requirement.
Planned order release = would be equal to the plan order released in consideration of the lead
time.
Planned order release = is the plan amount that is to be ordered to meet the net requirement.

Master requirement for the golf cart for the top and base,
Golf cart 1 2 3 4 5 6 7 8

Gross 200
requirement

Scheduled
receipts

Projected on 0
hand

Net 200
requirements

Planned 200
order
receipts

Planned 200
order release

Top 1 2 3 4 5 6 7 8
Gross 200
requiremen
t

Net 160
requiremen
t

Project on 40 40 40 40 40 40 40 40
hand

Planned 160
order
receipts

Planned 160
order
releases

Scheduled
receipts

base 1 2 3 4 5 6 7 8

Gross 200
requiremen
t

Net 180
requiremen
t

Projected 20 20 20 20 20 20 20 20
on hand

Planned 180
order
receipts

Planned 180
order
releases

Answer to the question number 17

The planned-order release for component J27 is how we know the computer died.
We will go backwards, starting with component J27, to restore the master schedule for end item
565.
Here is a reversed tree diagram for the given structure:

J27(4)
X43
640/4= 160

X43 Y36 (2) N78

160+200=160
360/2= 180

565
(180)

Based on the tree diagram above, the MRP schedule for component J27 is as follows:

Lot Size: L4L

Lead Time: 2 weeks
Component: J27
Week
1 2 3 4 5 6
Gross Requirements 640
Scheduled Receipts
Projected on hand inventory
Planned receipts 640
Planned order releases 640

Based on the tree diagram above, the MRP schedule for component Y36 is as follows:

Component: Y36 Lot Size: L4L

 Lead Time: 1 week
Week
1 2 3 4 5 6
Gross Requirements 360
Scheduled Receipts
Projected on hand inventory
(200) 200 200 200 200 200
Planned receipts 160
Planned order releases 160

Based on the tree diagram above, the MRP schedule for end item 565 is as follows:

Lot Size: L4L

Lead Time: 1 week
End item: 565
Week
1 2 3 4 5 6
Gross Requirements 180
Scheduled Receipts
Projected on hand inventory
Planned receipts 180
Planned order releases 180

Using its MRP, we can now recreate the master schedule for end item 565:

Lead Time: 1 week

End item: 565 Week
1 2 3 4 5 6
MPS Quantity 180
MPS Start 180

In conclusion, 180 units of end item 565 are required at the start of Week 6 based on the updated
master schedule.

Answer to the Question No 18

Items Lead Time (Weeks) Inventory on Hand

A 1 -

B 3 15
C 1 -

D 1 -

E 1 130

H 1 -

K 1 -

Master production schedule for production of A:

Master Week 1 2 3 4 5 6 7 8
Schedule Quantity 60

Master Requirements Planning

Item B Lead Time: 3

weeks

Week

1 2 3 4 5 6 7 8

Gross 120
Requirements

Scheduled
Receipts

Projected on 15 15 15 15 15 15 15 0
hand Inventory
(15)

Net 105
Requirements

Planned Receipts 105

Planned order 105

releases
Item C Lead Time: 1
week

Week

1 2 3 4 5 6 7 8

Gross 60
Requirements

Scheduled
Receipts

Projected on 0 0 0 0 0 0 0 0
hand Inventory

Net 60
Requirements

Planned Receipts 60

Planned order 60
releases

Item E Lead Time: 1

week

Week

1 2 3 4 5 6 7 8

Gross 210 240

Requirements

Scheduled
Receipts

Projected on 130 130 130 130 0 0 0 0

hand Inventory
(130)

Net 80 240
Requirements

Planned Receipts 80 240

Planned order 80 240
releases

Item H Lead Time: 1

week

Week

1 2 3 4 5 6 7 8

Gross 240 720

Requirements

Scheduled
Receipts

Projected on 0 50 0 0 0 0 0 0
hand Inventory
(130)

Net 190 720

Requirements

Planned Receipts 190 720

Planned order 190 720

releases