MRP Assignment

Requirements
Sidelamp
100 week 13
80 week 15
110 week 16
Headlamp
120 week 14
90 week 15
75 week 16
BOM for Sidelamp

Week 13
C206P
SL111P
SL112A
SL113P
Week 15
C206P
SL111P
SL112A
SL113P
Week 16
C206P
SL111P
SL112A
SL113P
BOM for Headlamp

Week 14
100
200
100
100
100
40
80
160
80
80
80
110
220
110
110
110
120
C310P
SL121F
SL122A
SL123A
100
100
100
100
SL131F
SL132P
100
100
C310P
SL121F
SL122A
SL123A
80
80
80
80
SL131F
SL132P
80
80
C310P
SL121F
SL122A
SL123A
110
110
110
110
SL131F
SL132P
110
110
35
C206P
HL211A
HL212P
480
120
120
Week 15
C206P
HL211A
HL212P
90
360
90
90
Week 16
C206P
HL211A
HL212P
75
300
75
75
C206P
C310P
HL222P
HL223F
240
120
120
120
C206P
C310P
HL222P
HL223F
180
90
90
90
C206P
C310P
HL222P
HL223F
150
75
75
75
SL133F
SL134P
100
100
SL133F
SL134P
80
80
SL133F
SL134P
110
110
Exploded MRP for each assembly, subassembly component and subcomponent level for the sidelamp.
C206P
FOQ Rule
Lot Size
Lead Time
Safety Stock
5
6
Gross Requirements
200
160
220
Scheduled Receipts
150
150
2450
2450
2290
2070
Planned Receipts
2500
Planned Order Releases
2500
Lot Size
Lead Time
Safety Stock
5
6
Projected On-
150
SL111P
FOQ Rule
Gross Requirements
140
80
145
Scheduled Receipts
15
15
225
225
145
350
350
Lead Time
Safety Stock
5
6
Projected On-
15
Planned Receipts
SL112A
L4L Rule
Quantity on Hand
Gross Requirements
100
80
110
Scheduled Receipts
100
20
20
20
20
Projected On-
20
Planned Receipts
60
110
60
110
Lot Size
Lead Time
Safety Stock
5
6
SL113P
FOQ Rule
Gross Requirements
100
80
110
Scheduled Receipts
20
20
20
20
40
30
Planned Receipts
100
100
100
100
100
100
Projected On-
SL112A
20
Subassembly level planned order release becomes gross requirements for the component level
C310P
FOQ Rule
Lot Size
Lead Time
Safety Stock
5
6
Gross Requirements
60
110
Scheduled Receipts
180
30
150
40
40
40
40
Planned Receipts
Projected On-
30
SL121F
L4L Rule
Lead Time
Safety Stock
Quantity on Hand
Gross Requirements
60
110
Scheduled Receipts
70
70
70
70
70
Planned Receipts
60
110
Projected On-
SL122A
L4L Rule
Quantity on Hand
Lead Time
Safety Stock
5
6
Gross Requirements
60
110
Scheduled Receipts
50
10
Planned Receipts
110
110
Projected On-
10
SL123A
L4L Rule
Quantity on Hand
Lead Time
Safety Stock
5
6
Gross Requirements
60
110
Scheduled Receipts
60
110
60
110
Projected OnPlanned Receipts

SL122A Planned order release becomes the gross requirements for the sub sub component level
SL131F
POQ Rule
Quantity on Hand
Period (P)
Lead Time
Safety Stock
5
6
Gross Requirements
110
Scheduled Receipts
Planned Receipts
110
Projected On-
SL132P
FOQ Rule
Lot Size
Lead Time
Safety Stock
5
6
Gross Requirements
110
Scheduled Receipts
100
35
25
25
25
25
25
Planned Receipts
Projected On-
35
SL123A Planned order release becomes gross requirements for sub sub component level
SL133F
POQ Rule
Quantity on Hand
Period (P)
Lead Time
Safety Stock
5
6
Gross Requirements
60
110
Scheduled Receipts
180
110
180
180
180
180
180
170
Projected On-
Planned Receipts
SL134P
FOQ Rule
Lot Size
Lead Time
Safety Stock
5
6
Gross Requirements
60
110
Scheduled Receipts
100
60
50
50
50
50
50
100
Projected On-
20
Planned Receipts
he sidelamp.
2500
1
30
8
2070
2070
350
2
0
8
3
0
8
Action Notices:
Action Notices:
1. Action notice to release planned order of 350 units
Action Notices:
100
1
20
8
30
30
180
1
20
8
40
40
Action Notices:
e component level
3
0
Action Notices:
Action Notices:
70
70
1
0
8
1
0
8
1. Here wecan expedite the open order by 11 week to take care of

requirements in week 12 but still we will not be able to meet
requirements in week 13 and the shortfall of 100 units has to be
ordered in week 10
2. Because of the above method the inventory carried subsequently will
be lower
Action Notices:
Action Notices:
1. Action notice for planned order release of 60 units
2
2
0
8
100
1
25
8
25
25
2
2
0
8
Action Notices:
Action Notices:
Action Notices:
1. Here we can expedite the open order to reach on week 11
as aresult we do not have to take the planned receipt in week 11
and we can manage with the scheduled receipt of 180 and the subsequent
180
180
100
1
25
8
50
50
inventory will also be less i.e 10
Action Notices:
1. Here if the open order would have been expedited then we would have
placed a planned order on the week 11 which we would have received on week 12
2. Because of the above action we could have released an action order on week 11
to release 100 units.
ubsequently will
nd the subsequent
en we would have
have received on week 12
an action order on week 11
Exploded MRP for each assembly, subassembly component and subcomponent level for the Headlamp
C206P
FOQ Rule
Lot Size
Lead Time
Safety Stock
5
6
Gross Requirements
480
360
300
Scheduled Receipts
150
150
150
2170
1810
1510
Planned Receipts
2500
2500
Lead Time
Safety Stock
5
6
Projected On-
150
HL211A
L4L Rule
Quantity on Hand
Gross Requirements
120
90
75
Scheduled Receipts
50
10
60
60
Planned Receipts
60
90
75
60
90
75
Projected On-
10
HL212P
FOQ Rule
Lot Size
Lead Time
Safety Stock
5
6
Gross Requirements
120
90
75
Scheduled Receipts
Projected On-
15
15
15
15
245
155
80
Planned Receipts
350
350
HL211A Planned order release becomes gross requirements at component level

C206P
FOQ Rule
Lot Size
Lead Time
Safety Stock
5
6
Gross Requirements
120
180
150
Scheduled Receipts
150
30
2350
2200
2200
2200
Planned Receipts
2500
2500
Lot Size
Lead Time
Safety Stock
5
6
Projected On-
150
C310P
FOQ Rule
Gross Requirements
60
90
75
Scheduled Receipts
180
150
270
180
105
105
105
Planned Receipts
Projected On-
HL222P
150
POQ Rule
Period (P)
Lead Time
Safety Stock
5
6
Quantity on Hand
Gross Requirements
60
90
75
Scheduled Receipts
110
50
175
85
120
120
120
Planned Receipts
185
Lead Time
Safety Stock
5
6
Projected On-
50
HL223F
L4L Rule
Quantity on Hand
Gross Requirements
60
90
75
Scheduled Receipts
70
10
Planned Receipts
80
75
80
75
Projected On-
70
he Headlamp
2500
1
30
8
1510
1510
2
0
8
350
2
15
8
Action Notices:
Action Notices:
1. We could have delayed the open receipt from week 12 to week 14
This would have reduced the average inventory carried in those weeks
Action Notices:
80
80
2500
1
30
8
2200
2200
180
1
20
8
105
105
Action Notices:
Action Notices:
4
4
10
8
120
120
1
0
8
Action Notices:
1. Here expediting the open order would not have helped because
if we would have received the order on week 12 we would have been
safe in week 12 and week 13 but again problem would have been
in week 14 but even if we would have planned order release on week 11
we would not have received ithe order until week 15 as lead time is
4 weeks, so the above exercise will not yield results
Action Notices:
2 to week 14
n those weeks
ld have been
ease on week 11
ead time is

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Requirements

BOM for Sidelamp

BOM for Headlamp

Planned Order Releases

Planned Order Releases

Planned Order Releases

Planned Order Releases

Planned Order Releases

Planned Order Releases

Projected OnPlanned Receipts

Planned Order Releases

Planned Order Releases

1. Here wecan expedite the open order by 11 week to take care of

inventory will also be less i.e 10

Planned Order Releases

Planned Order Releases

Planned Order Releases

HL211A Planned order release becomes gross requirements at component level

Planned Order Releases

Planned Order Releases

Planned Order Releases

Planned Order Releases

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