Finance-AW592

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Assignment 3

 

Anne Carroll, your boss, storms into your office—obviously very upset.  “Allen (Hayes, Director of Purchasing) is pushing hard for a change to something called MRP.  I remember studying MRP in college, but we tried it at my previous job and it didn’t work for us.  He is taking a hard line on this and Cooper is backing him.”   She stops for a moment and seems to regain some composure.  “I’m sorry.  These political issues don’t concern you.”

 

“Look.  I’ve got the Master Production Schedule (MPS) for the Premium Prestige 400-101 that Allen is using to do his pilot testing.  I’d like you to bone up on MRP and develop a materials plan so that I can compare it to Allen’s plan to be sure he knows what he is talking about.  Don’t worry about the packaging.  Allen says we have enough of it to last at least a year because of some sort of purchasing foul-up.  He gave me some information you might need (in Appendix).  I need to know if this MRP thing indicates whether the Master Schedule is feasible from a materials lead time standpoint.  I would also like you to review the data he has collected and let me know how ready you think we are for MRP.  Get back with me as soon as possible.”

 

With that, Anne turned and left your office.  You grabbed your old POM text, silently thanking your old professor for saying you would regret selling it at the end of the semester.  The few dollars you would have gotten then wouldn’t have made much difference, and having the text now could make all the difference.  You make a mental note to send a contribution to the Alumni Association.

 

Since this is just a trial study, you figure it would save time to do the MRP tables by hand, in POM for Windows, or on Excel rather than setting it up in an actual MRP program.  So you set up a master MRP matrix in Excel (available for download from the MGT 560 web site) and start to work.

 

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MASTER PRODUCTION SCHEDULE (MPS)      Part Number 400-101

 

WEEK 1 2 3 4 5 6 7 8
REQ. 0 0 0 0 20,000 0 0 0

 

 

 

Appendix to Assignment 3

 

PART NO. LEAD TIME (weeks) PROJECTED ON HAND in WEEK 1 LOT SIZE (multiples) Scheduled Receipts
400-101 1 0 L-4-L 0
SA-304 1 2,000 100 0
S-901 1 10,000 10,000 0
SG-333 2 3,000 1,000 0
SA-506 1 55,000 10,000 0
Cotton String 2 1,000,000 1,000,000 0
Bees Wax 3 5,000 1,000 0
Dowel Rod 3 500,000 12,000 0
AL Bar Stock 5 1,600 1,600 1,600 in Wk 3

 

 

Anne,

 

For this simulation, I am assuming that the 400-101 is the only product using these materials.  Obviously, this is not really true—all our products use dowel, string and glue—but it makes the pilot study feasible.

 

I also collected some sample data on our processes.  Here’s what I found

 

Average lead time variation from suppliers:  ± 10% from committed due date.

Average % shipments rejected at incoming inspection:  0.05%.

Proportion of BOMs without error:  97%.

Proportion of inventory records without error:  81%.

Average change in MPS quantities within 1 week of due date:  ± 1%.

Average change in MPS quantities within 1 month of due date:  ± 5%.

 

I think that you will like and appreciate the benefits of MRP if you only give it a chance.

 

Allen

 

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