Analytics Exercise $21-3($Algo$)$

Recently, Phil Harris, the production control manager at Brunswick, read an article on time$-$phased requirements plannin curious about how this technique might work in scheduling Brunswick's engine assembly operations and decided to pre 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 $1000$ el schedule indicates the number of units of the Model $1000$ engine to be assembled each week during the last $12$ weeks a on the next page. Next, Phil decided to simplify his requirements planning example by considering only two of the many that are needed to complete the assembly of the Model $1000$ engine. These two components, the gear box and the inpl shown in the product structure diagram below. Phil noted that the gear box is assembled by the Subassembly Departme subsequently is sent to the main engine assembly line. The input shaft is one of several component parts manufactured that are needed to produce a gear box subassembly. Thus, levels $0,1,$ and $2$ are included in the product structure diagra the three manufacturing stages that are involved in producing an engine: the Engine Assembly Department, the Subasse Department, and the Machine Shop.

The manufacturing lead times required to produce the gear box and input shaft components are also indicated in the prc diagram. Note that two weeks are required to produce a batch of gear boxes and that all the gear boxes must be deliver assembly line parts stockroom before Monday morning of the week in which they are to be used. Likewise, it takes three 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 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:

Twenty five gear boxes are on hand at the beginning of Week $1,$ and seven gear boxes are currently on order to be d start of Week $2.$

Fifty input shafts are on hand at the start of Week $1,$ and $26$ are scheduled for delivery at the beginning of Week $2.$

a$.$ Initially, assume that Phil wants to minimize his inventory requirements. Assume that each order will be only for what is $r$ single period. Calculate the net requirements and planned order releases for the gear boxes and input shafts. Assume that done using lot$-$for$-$lot $($ L $4$ L $).($Leave no cells blank $-$ be certain to enter $"0"$ wherever required.$)$

Gear Box Requirements