Case study: Develop the MRP and MRP II for the following case and answer the questions that are asked: A lamp consists of a structural frame and a shade plus several screws as shown in the figure. The frame is made from a base, two screws, a neck and a socket which are assembled together from the purchased parts. The semiconical screen is added and screwed to get the product. Apart from screens, the company imports plugs that it distributes to hardware stores.

The data for the master production plan are: The plan must be developed for 8 months. The lamps must be produced in the following order: In the seventh month the production will be 1,000 units and in the eighth month 1,500 units. To meet the market demand for plugs, the company must have 2,500 units available in the first month and 500 units in the second month.

For the lamps you will need: 1 shade, 2 screws and a structural frame. For the structural frame you will need: 1 aluminum tube 1.8 meters long and 3 cm in diameter for the support, 1 plug, two screws and 1 base.

In the case of screws, they must be ordered from the importer where each order costs Bs25 and each screw is stored at 0.02Bs / u per week. The plugs have a cost of 1000 Bs / order and to store them costs 0.50 Bs / u per week. a) Prepare the BOM (Bill of Materials). 2 points.

b) Report of MRP I outputs: b1) Define what type of batch is most convenient for sockets and screws, choose LxL or FOQ. Explain the reason for your decision. 2 points b2) Availabilities (D). 4 points b3) Issuance of Orders (EP). 4 points.

c) Report of MRP II outputs: c1) Purchase budget. 2 points. c2) Manufacturing budget. 2 points c3) Storage budget. 2 points d) Assembling the frames consumes man-hour and assembling the lamp consumes man-hour. Calculate the total man-hours required to make the assemblies of: I. The bases. 1 point. ii. The lamps. 1 point.

Fill in the solution in this excel table.

REGISTRO DE INVENTARIOS Item Tipo de Stock de Disponi- Recepciones Lote seguridad bilidades programadas LXL 0 200 u LxL 30 u 400 u Tiempo de suministro semanas 1 sem 3 sem Se fabrica? Se compra? F F Costo fabricacin o precio del proveedor 30 Bs/u 10 Bs/u Lampara Pantalla Marco Est. LxL 0 100 u 2 sem F 7 Bs/u Cuello 0 0 25 u en t-2 3 sem 1 Bs/u Enchufe 300 u 50 u 1,80 Bs/u 60 u en t-4 2 sem FOQ 2000u ? 2 sem FOQ 1500 u ? Base 150 u 200 u 3 sem F 30 Bs/u Tornillo 100 u 160 u 1 sem 0,20 Bs/u Item: 0 1 2 3 4 5 6 7 8 T. Lote: Item Requerimientos Brutos RB Recepciones Programadas RPRO Inventario (Disponible) D Requerimiento Neto RN Recepciones Pedidos RP Emisin de pedidos EP SS: LTime: Item: 0 1 2 3 4 5 6 7 8 T. Lote: Item Requerimientos Brutos RB Recepciones Programadas RPRO Inventario (Disponible) D Requerimiento Neto RN Recepciones Pedidos RP Emision de pedidos EP SS: LTime: Item: 0 1 2 3 4 5 6 7 8 T. Lote: Item Requerimientos Brutos RB Recepciones Programadas RPRO Inventario (Disponible) D Requerimiento Neto RN Recepciones Pedidos RP Emisin de pedidos EP SS: LTime: Item: 0 1 2 3 4 5 6 7 8 T. Lote: Item Requerimientos Brutos RB Recepciones Programadas RPRO Inventario Disponible) D Requerimiento Neto RN Recepciones Pedidos RP Emisin de pedidos EP SS: LTime: REGISTRO DE INVENTARIOS Item Tipo de Stock de Disponi- Recepciones Lote seguridad bilidades programadas LXL 0 200 u LxL 30 u 400 u Tiempo de suministro semanas 1 sem 3 sem Se fabrica? Se compra? F F Costo fabricacin o precio del proveedor 30 Bs/u 10 Bs/u Lampara Pantalla Marco Est. LxL 0 100 u 2 sem F 7 Bs/u Cuello 0 0 25 u en t-2 3 sem 1 Bs/u Enchufe 300 u 50 u 1,80 Bs/u 60 u en t-4 2 sem FOQ 2000u ? 2 sem FOQ 1500 u ? Base 150 u 200 u 3 sem F 30 Bs/u Tornillo 100 u 160 u 1 sem 0,20 Bs/u Item: 0 1 2 3 4 5 6 7 8 T. Lote: Item Requerimientos Brutos RB Recepciones Programadas RPRO Inventario (Disponible) D Requerimiento Neto RN Recepciones Pedidos RP Emisin de pedidos EP SS: LTime: Item: 0 1 2 3 4 5 6 7 8 T. Lote: Item Requerimientos Brutos RB Recepciones Programadas RPRO Inventario (Disponible) D Requerimiento Neto RN Recepciones Pedidos RP Emision de pedidos EP SS: LTime: Item: 0 1 2 3 4 5 6 7 8 T. Lote: Item Requerimientos Brutos RB Recepciones Programadas RPRO Inventario (Disponible) D Requerimiento Neto RN Recepciones Pedidos RP Emisin de pedidos EP SS: LTime: Item: 0 1 2 3 4 5 6 7 8 T. Lote: Item Requerimientos Brutos RB Recepciones Programadas RPRO Inventario Disponible) D Requerimiento Neto RN Recepciones Pedidos RP Emisin de pedidos EP SS: LTime