50 Ultimasteppers Case Analysis

Homework 6
A production manager for an exercise equipment manufacturing company needs to schedule an order for 50 UltimaSteppers, which are to be shipped in week 8. Using the following table and product structure for the UltimaSteppers:

Item | Lead Time | On-Hand Inventory | Components | Stepper | 2 | 20 | A(1), B(3),C(2) | A | 1 | 10 | D(1),F(2) | B | 2 | 30 | E(1),F(3) | C | 3 | 10 | D(2),E(3) | D | 1 | 15 | | E | 2 | 5 | | F | 2 | 20 | |
Level
0

1

2

Q1: construct the Bill of Material (BOM)
Q3: Develop a Gross Requirements Plan for the UltimaSteppers
Q2: Develop a net material requirements plan for the UltimaSteppers

Q1:
The requirements for an order of 50 UltimaSteppers:
Part A: 1 x number of Stepper's = (1)(50) = 50
Part B:
3 x number of Stepper's = (3)(50) = 150
Part C: 2 x number of Stepper's = (2)(50) = 100
Part D: 1 x number of As + 2 x number of Cs = (1)(50) + (2)(100) =250
Part E: 1 x number of Bs + 3 x number of Cs = (1)(150) + (3)(100) = 450
Part F: 2 x number of As + 3 x number of Bs = (2)(50) + (3)(150) = 550

Q2: | | Week | Lead time | | | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | | | Stepper | Required date | | | | | | | | 50 | | 2 | | Order release date | | | | | | 50 | | | | | A | Required date | | | | | | 50 | | | | 1 | | Order release date | | | | | 50 | | | | | | B | Required date | | | | | | 150 | | | | 2 | | Order release date | | | | 150 | | | | | | | C | Required date | | | | | | 100 | | | | 3 | | Order release date | | | 100 | | | | | | | | D | Required date | | | 200 | | 50 | | | | | 1 | | Order release date | | 200 | | 50 | | | | | | | E | Required date | | | 300 | 150 | | | | | | 2 | | Order release date | 300 | 150 | | | | | | | | | F | Required date | | | | 450 | 100 | | | | | 2 | | Order release date | | 450 | 100 | | | | | | | |

Q3: Stepper | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | Gross requirement | | | | | | | | 50 | On hand 20 | | | | | | | | 20 | Net | | | | | | | | 30 | P.O.
receipt | | | | | | | | 30 | P.O. release | | | | | | 30 | | | | | | | | | | |
| A | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | Gross requirement | | | | | | 30 | | | On hand 10 | | | | | | 10 | | | Net | | | | | | 20 | | | P.O. receipt | | | | | | 20 | | | P.O. release | | | | | 20 | | | |

B | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | Gross requirement | | | | | | 90 | | | On hand 30 | | | | | | 30 | | | Net | | | | | | 60 | | | P.O. receipt | | | | | | 60 | | | P.O. release | | | | 60 | | | | | | | | | | | | | | C | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | Gross requirement | | | | | 60 | | | | On hand 10 | | | | | 10 | | | | Net | | | | | 50 | | | | P.O. receipt | | | | | 50 | | | | P.O. release | | 50 | | | | | | | | | | | | | | | | D | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | Gross requirement | | 100 | | 20 | | | | | On hand 15 | | 15 | | 0 | | | | | Net | | 85 | | 20 | | | | | P.O. receipt | | 85 | | 20 | | | | | P.O. release | 85 | | 20 | | | | | | | | | | | | | | | E | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | Gross requirement | | | 150 | 60 | | | | | On hand 5 | | | 5 | 0 | | | | | Net | | | 145 | 60 | | | | | P.O. receipt | | | 145 | 60 | | | | | P.O. release | 145 | 60 | | | | | | | | | | | | | | | | F | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | Gross requirement | | | | 180 | 40 | | | | On hand 20 | | | | 20 | 0 | | | | Net | | | | 160 | 40 | | | | P.O. receipt | | | | 160 | 40 | | | | P.O. release | | 160 | 40 | | | | | |