c$)$ Kayabars Sdn$.$ Bhd$.$ is a manufacturer of Front Car Absorbers for Proton S$70.$ The company has secured $10$ years of contract to supply the absorbers$.$ The absorber is made up one $(1)$ unit each of Knuckle, Struts and Strut Mount assemblies.

The Knuckle assembly comprises one $(1)$ unit of Lower Control Arm, one $(1)$ unit of Steering Link. The Lower Control Arm is attached to the Knuckle using one $(1)$ unit of Bolt and one $(1)$ unit of Nut. Then, the Steering Link is tightened to the Knuckle assembly using three $(3)$ units of Bolt and three $(3)$ units of Nut.

The Struts assembly comprises one $(1)$ unit of Lower Spring Insulator, one $(1)$ unit of Upper Spring Insulator and one $(1)$ unit of Spring Set. One $(1)$ unit of Jounce Bumper is jointed to Spring Set using a snap fit method.

Struts Mount Assembly is assembled using one $(1)$ unit Strut Mount Housing and is tightened using five $(5)$ units of Nut.

Front Car Absorbers will be delivered to the customer in week $40.$ The lead time and onhand inventory information are given in Table $1\mathrm{.}3.$

$4-$

SEMM$3813$

Table $1\mathrm{.}3$: Lead time and on$-$hand inventory data

$\backslash$table$[[$Item$,\backslash$table$[[$Lead time$],[($week$)]],\backslash$table$[[$On$-$hand$],[$inventory $($Unit$)]]],[$Front Car Absorber,$1,10],[$Knuckle

$\backslash$table$[[$Lower Arm$],[$Steering Link$],[$Bolt$]],1,5],[$Nut$,2,7],[,1,7],[$Strut$,2,30],[$Lower Spring Insulator,$2,30],[$Upper Spring Insulator,$2,10],[$Spring set,$1,10],[$Jounce Bumper,$1,20],[$Strut Mount,$2,7],[$Strut Mount Housing,$1,8],[$Nut$,1,5],[,,5]]$

i$.$ Design a product structure for the front car absorber unit based on low$-$level coding. $(2$ marks$)$

ii$.$ Construct a time$-$phased product structure for the front car absorber unit.

$(2$ marks$)$

iii. Determine the quantity of Bolt and Lower Spring Insulator that should be ordered to deliver $100$ units of front car absorber in week $40.$ Develop a net material requirement plan using the table provided in Appendix I. The ordering of items is based on lot$-$for$-$lot policy.

$(6$ marks$)$