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GIANT is a bicycle manufacturer that offers its products to stores in China and Hong Kong. One of the most popular bicycle models is "Flying" (Figure 1), which is built according to the bill of materials (BOM) diagram (Figure 2) shown below. The quantity is also displayed at each component, as seen below. Wheel (2u) denotes that two units are required to produce one bicycle (1u), while Tire (1u) denotes that one unit is required to produce one wheel.

Figure 2: BOM of model Flying

70 units of model Flying are needed in week 3, 150 units in week 5, and 100 units in week 7. The lead time for assembly of Model Flying is one week and there is no on-hand inventory.

Additional information regarding the major components Wheel, Tire, and Spokes can be found in the table below.

Tires are sold to a retailer who requires 500 units in week 7, while for Spokes are also sold to a retailer who requires 50 units in week 2, 100 units in week 4 and 80 units in week 7. The minimum production quantity of Spokes is 500 units.

Question:

1(b)

Calculate the total expenses (consider the setup cost + holding cost only) of Wheel, Tire, and Spokes based on the projected order released and inventory level (referred to as Projected on Hand) over an 8-week period if the Holding cost is $2/unit/week and the Setup cost is $400. Your holding cost calculation should exclude the first week's inventory units.

Because of bad economic environment under COVID-19, the retailer has asked GIANT for discounts on the price of model Flying. After negotiation, GIANT offered the following discount schedule for the retailer:

Quantity ordered per order	Discount on unit price
Less than 120 units	0%
120 199 units	10%
200 units or above	20%

Seat Brakes Handlebar Grips Frame Seat post Fork Sprockets Spokes Tire Chainrings Reflector Rim Pedals Chain Valve Figure 1: Model "Flying" Bill of materials for a bicycle Level o (Finished product) Level 1 (Components) Level 2 (Subcomponents) Rim (1u) Tire Wheel (10) (2u) Spokes (36) Reflector (1u) Valves (1u) Pedals (2u) Bicycle (lu) Chainrings (3u) Frame (lu) Sprockets (5u) Chain (lu) Brakes (2u) Handlebar (lu) Grips (2u) Seat (lu) Seat post (lu) Wheel Tire Spokes Lot size (unit) Lot-for-lot (L4L) 300 Lot-for-lot (L4L) 2 1 1 0 0 50 Lead-time (week) Safety stock (unit) Beginning inventory (unit) Scheduled receipts 0 40 80 none 150 units in week 250 units in week 3 2 Based on the given data, calculate the missing values in the MRP worksheets below, al to a 20. (10 marks) MPS Data Product: Model "Flying", Lead time: 1 week, On-hand inventory: 0 Week number 1 2 3 4 5 6 7 8 Required date 70 150 100 Order release date 70 150 100 Item: Wheel Lot size: units units Lead time: weeks Minimum order quantity: Immediate Parent(s); As BOM Safety stock: units Week number 1 2 3 4 5 6 7 8 Gross Requirements 140 (a2) 200 Scheduled Receipts (al) Projected on hand 0 0 0 10 10 000 0 0 290 200 Net Requirements Planned order receipts 290 200 Planned order releases 290 200 Item: Tire Lot size: units Minimum order quantity: units Lead time: week Immediate Parent(s): As BOM Safety stock: units Week number 1 2. 3 4 5 6 7 8 Gross Requirements 290 200 (29) Scheduled Receipts (a6) Projected on hand 40 40 40 (a7) (as) 100 100 100 200 (a3) 400 Net Requirements Planned order receipts (a4) (a 10) Planned order releases (25) 600 Lot size: units Item: Spokes Minimum order quantity: Immediate Parent(s); units week Lead time: Safety stock: As BOM units Week number 1 2 3 3 4 5 6 7 8 Gross Requirements (all) (a16) 80 Scheduled Receipts Projected on hand 80 80 80 (a15) 50 50 50 50 (20) Net Requirements (a12) (a17) 80 Planned order receipts (a13) (a18) 500 Planned order releases (a14) (a 19) 500