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National Institute of Technology Calicut Department of Mechanical Engineering

Typical MRP Problem


The following illustration shows how to assemble your own computer
Memory Board (M) Arithmetic Board (A)
Assemble 4 RAM chips (C) Assemble 1 integrated microprocessor (Z)
and 1 switch (S) onto a board type X with 2 ROM chips (R) and 1 switch (S)
C C onto a board type (Y)
R R
S Z
C C S

Processor unit (P)


S S S S
Working from back to front of the box casing (B),
assemble one switch (S) to the inside of each of the M
4 plug connections at the back of the box.
Then fit 3 memory boards (M) into M
the 3 identical rows of connectors. M
Finally, fit 2 arithmetic boards (A) into
the front connector rows. A

Final assembly
The video unit (V) and the keyboard
unit (K) have been preassembled (with
connecting cables). Simply connect
the sockets on the end of their cables
to the corresponding plugs at the rear
of the processor unit (P). Your
computer is now ready to use.

Fig. Details for computer assembly


(a) Draw the product structure tree corresponding to the assembly instructions.
(b) Determine the low level codes for the following items:(1) A-Arithmetic board, (2) B-Box
casing, (3) C-RAM chip, (4) K-Key board unit, (5) M-Memory board, (6) P-Processor
unit, (7) R-ROM chip, (8) S-Switch, (9) V-Video unit, (10) X-Board type X, (11) Y-
Board type Y and (12) Z-integrated micro processor.
(c) Assume no inventory of any item. How many of each part should be available to
assemble one completed unit?
(d) Determine the minimum planning horizon for production planning of computer. The
planning horizon determination method should be demonstrated with Gantt chart. Lead
time information is given in Table 1.

MRP 16 March 2011


National Institute of Technology Calicut Department of Mechanical Engineering

Table 1 Lead time Data

Item Computer V P K M A B C S X Z R Y
Lead time (Period) 1 2 1 2 3 2 1 1 2 1 2 2 1
(e) Develop the MRP records for items: P, M, A and S. Use the MPS given in Table 2, and
inventory status and other details given in Table 3.
Table 2 MPS for Computer
Period 1 2 3 4 5 6 7 8 9 10
Production quantity 20 20 40 30 30 30 20 20 40 30
Table 3 Inventory status and other details
Part Computer P M A S
Initial inventory -- 10 ------ ------ 300
balance
LT (Periods) 1 1 3 2 2
Lot size - Lot-for-lot Lot-for-lot Lot-for-lot 300
Schedule receipt 20 in period 1 80 in period 1 90 in period 3 ------ -----

Solution
(a).
Computer

V (1) P (1) K (1)

S (4) M (3) A (2) B (1)

(4) (1) (1) Z (1) R (2) S (1) Y (1)


C S X

Product Structure tree with quantity required to make one unit of parent item
(b).
Item Computer V P K M A B C S X Z R Y
Low level Code 0 1 1 1 2 2 2 3 3 3 3 3 3
Low level code
(c)
Item Computer V P K M A B C S X Z R Y
Number of parts required to 0 1 1 1 3 2 1 12 9 3 2 4 2
make 1 final assembly
Quantity of components and subassemblies required to make one unit of the final
assembly

MRP 17 March 2011


National Institute of Technology Calicut Department of Mechanical Engineering

(d) Minimum planning horizon = 7 periods

(Period)
Gantt of assembly sequence (Forward schedule)

(e) MRP Records


MPS of computer
Period 1 2 3 4 5 6 7 8 9 10
Production Quantity 20 20 40 30 30 30 20 20 40 30

ITEM.NO : computer Lead time = 1 day Lot-sizing procedure : Lot-


for-lot
Period 1 2 3 4 5 6 7 8 9 10
GROSS 20 20 40 30 30 30 20 20 40 30
REQUIREMENT
Scheduled receipts 20
Projected on hand
Planned order releases 20 40 30 30 30 20 20 40 30

ITEM.NO : P Lead time = 1 day, Quantity Lot-sizing procedure : Lot-


=1 for-lot
Period 1 2 3 4 5 6 7 8 9 10
GROSS 20 40 30 30 30 20 20 40 30
REQUIREMENT
Scheduled receipts 80
Projected on hand 10 70 30 0 0 0 0 0 0 0 0
Planned order releases 30 30 20 20 40 30

MRP 18 March 2011


National Institute of Technology Calicut Department of Mechanical Engineering

ITEM.NO : M Lead time = 3 days , Quantity Lot-sizing procedure : Lot-


=3 for-lot
Period 1 2 3 4 5 6 7 8 9 10
GROSS 3*30 3*30 3*20 3*20 3*40 3*30
REQUIREMENT
Scheduled receipts 90
Projected on hand 0 0 0 0 0 0 0 0
Planned order releases 90 60 60 120 90

ITEM.NO : A Lead time = 2 days , Quantity Lot-sizing procedure : Lot-


=2 for-lot
Period 1 2 3 4 5 6 7 8 9 10
GROSS 2*30 2*30 2*20 2*20 2*40 2*30
REQUIREMENT
Scheduled receipts
Projected on hand
Planned order releases 60 60 40 40 80 60

ITEM.NO : S Lead time = 2 days, Quantity = Lot-sizing procedure :


4P+M+A 300
Period 1 2 3 4 5 6 7 8 9 10
GROSS 150 120 220 280 250 140 160 120
REQUIREMENT
Scheduled receipts
Projected on hand---- 300 150 30 110 130 180 40 180 60
Planned order releases 300 300 300 300

MRP 19 March 2011

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