Analytics Exercise $9\mathrm{.}2($Algo$)$

Recently, Phil Harris, the production control manager at Brunswick, read an article on time$-$phased requirements planning. He was

curious about how this technique might work in scheduling Brunswick's engine assembly operations and decided to prepare an

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 $1000$ engine. This

schedule indicates the number of units of the Model $1000$ engine to be assembled each week during the last $12$ weeks and is shown

on the next page. Next, Phil decided to simplify his requirements planning example by considering only two of the many components

that are needed to complete the assembly of the Model $1000$ engine. These two components, the gear box and the input shaft, are

shown in the product structure diagram shown below. Fhil noted that the gear box is assembled by the Subassembly Department and

subsequently is sent to the main engine assembly line. The input shaft is one of several component parts manufactured by Brunswick

that are needed to produce a gear box subsssembly. Thus, levels $0,1,$ and $2$ are included in the product structure diagram to indicste

the three manufacturing stages that are involved in producing an engine: the Engine Assembly Department, the Subsssembly

Department, and the Machine Shop.

The manufacturing lead times required to produce the gear box and input shaft components are also indicated in the bill$-$of$-$msterials

diagram. Note that two weeks are required to produce a batch of gear boxes and that all the gear boxes must be delivered to the

assembly$-$line parts stockroom before Monday morning of the week in which they ore to be used. Likewise, it takes three weeks to

produce a lot of input shafts, and all the shafts needed for the production of gear boxes in a given week must be delivered to the

Subossembly Department stockroom before Mondsy morning of that week.

In preparing the MRP example, Phil planned to use the worksheets shown the below and to make the following assumptions:

Seventeen gear boxes are on hand at the beginning of Week $1,$ and six gear boxes are currently on order to be delivered at the start

of Week $2.$

Forty$-$six input shafts are on hand at the start of Week $1,$ and $18$ 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 required for

a single period. Calculate the net requirements and planned order releases for the gear boxes and input shafts. Assume that lot

sizing is done using lot$-$for$-$lot.

Gear Box Requirements

Input Shaft Requirements