Recall from Chapter 6 that Myer Wine Racking and Cel- lar Company is a small but growing carpentry job shop specializing in natural-finish redwood racking systems for storage and display of wine bottles. In addition to building customized wine cellars, Myer offers two sizes of standard box rack set, or preassembled wine racks roughly the size of book cases. Box rack sets hold wine bottles in precise 20-bottle high columns, with the smaller box rack set storing 10 columns for a total capacity of 200 bottles, while the larger set stores 20 columns. These products are popular purchases for retail stores and res- taurants, and are marketed through catalogs and websites as beginner's kits for private wine collections. Myer Wine Racking refers to the two sizes as BOX2010 for the smaller and BOX2020 for the larger set, assembling them both as described in the illustration below:

Myer has just received an order for this popular product line from one of its retail dis- tributors, who is requesting that 10 units of BOX2010 and 10 units of BOX2020 be shipped out as soon as possible. This order arrives at an awkward time, in that the employees in Myer's job shop are busy working on a large custom wine cellar and none of the pieces or subassemblies that might speed the assembly of a BOX2010 or BOX2020 are currently in stock. Nonetheless, this retail distributor has been a valuable supply chain partner in the past, so Myer Wine Racking would like to fill this unexpected order for BOX2010 and BOX2020 as quickly as possible. Lead time on any item varies with how many of the item is needed, as Myer produces all items within its job shop:

Questions 

1. Draw standard product structure diagrams for the two finished goods discussed here, BOX2010 and BOX2020. Be certain to note the correct parent-to-child ratio required between each of the items in the diagram. 2. Draw time-phased product structure diagrams for a single BOX2010 and a single BOX2020, using the production rate information to estimate lead times for each item in the structure. Under the assumption of material requirements planning, that work on a parent item cannot begin until all work on all child items is finished, how long does your diagram suggest Myer needs to produce one BOX2010 from nothing in stock? How long to produce one BOX2020? 3. How many labor-hours will be required in total to fill the retail distributor's order? 4. Myer Wine Racking and Cellar Company is willing to reassign three employees to build this order, which it wishes to ship within three 8-hour days. Work out a sched- ule for these three employees to accomplish this goal, outlining the timing of the production of all the items in the bill of materials. State any assumptions you make concerning how the Myer job shop works.

Third: The freestanding box rack set is created by attaching 6 horizontal trim pieces across the front edges of a set of middles and ends, and another 6 horizontal trim pieces across the back edges of those same subassemblies. The number of middles and the length of the horizontal trim determine the size of the box rack set. Each BOX2010 consists of 9 middles and 2 ends, while each BOX2020 consists of 19 middles and 2 ends. This illustration shows four complete columns. First: Horizontal and vertical pieces are cut to precise lengths. 3 Second: Horizontal and vertical pieces are assembled into ladder-shaped subassemblies called middles and ends. Each middle requires 2 vertical pieces and 42 horizontal pieces. Each end also requires 2 vertical pieces but only 21 horizontal pieces, because ends only have horizontal pieces on one side.