MEM671

ASSIGNMENT - TUTORIAL

Prepared for

PROF. MADYA IR. DR. SALINA BINTI BUDIN

MEM671 - MANUFACTURING MANAGEMENT

Universiti Teknologi MARA Cawangan Pulau Pinang

Name Student ID

AIMAN ASYRAAF BIN ROSLAN 2021492486

PEM2455B1/2

FACULTY OF MECHANICAL ENGINEERING

DATE OF SUBMISSION: 7/7/2023

QUESTION 1

Sejati Perabut produces a variety of furniture products. Mr Alan, the production manager has
developed an aggregate forecast as shown in Table Q1a. Using information given in Table Q1b,

1. Develop an aggregate planning using a level strategy with a combination of overtime,

subcontracting and inventory. The backlogs are allowed by the customer.
2. Develop an aggregate planning using regular production capacity and support the
shortage by using overtime, subcontracting and inventory. The backlogs are not allowed
by the customer.
QUESTION 2

One unit of A is made of two units of B, three units of C and two units of D. B is composed of
one unit of E and two units of F. Item A, C, D and F have one week lead time while item B and E
have lead time of two weeks. Lot-for-lot (LFL) lot sizing is used for item A, B, C and D. Item E
required fixed order quantity (FOQ) of 50 units whereas for item F, the FOQ is 220. Item D has
an inventory of 50 units while the other items have zero inventory. There is a schedule receipt of
item E on WW2 with the quantity of 20 units. The schedule shipment until WW10 is
summarized in Table Q2. Draw a product structure and prepare material requirement planning
for all items.
QUESTION 3

Golden Coin Sdn Bhd is planning a new product project which consist of ten activities. The time
required for each activity and immediate predecessor are summarized in Table Q3.

1. Draw a network diagram and list the available path including duration for each path.
2. Identify the critical path and project duration.
3. Determine the slack for each activity.
4. Elucidate what will happen to project duration if activity G and H are delays for 3 days.
QUESTION 1 (i)

Period 1 2 3 4 5 6 Total
Forecasted
Demand (D) 50 45 55 60 50 40 300
Regular
Output (O) 40 40 40 40 40 40 240
Overtime 8 8 8 8 8 4 44
Subcontract 4 12 16
Hire/Layoff
(O)-(D) -2 3 -3 0 -2 4
Inventory
Begin 0 0 1 0 0 0
End 0 1 0 0 0 0
Average 0 0.5 0.5 0 0 0 1
Backlog 2 0 2 2 4 0 10
Costs
Reg
prodn-normal
(80$/unit) 3200 3200 3200 3200 3200 3200 19200
OT
(120$/unit) 960 960 960 960 960 480 5280
Backorders
(20$/unit) 40 0 40 40 80 0 200
Subcontracting
(RM 140/unit) 0 0 560 1680 0 0 2240
Hire
(RM b/wkr)
Layoff
(RM c/wkr)
Inventory
(RM 10/unit) 0 5 5 0 0 0 10
TOTAL 26930
QUESTION 01 (ii)

Period 1 2 3 4 5 6 Total
Forecasted
Demand (D) 50 45 55 60 50 40 300
Regular
Output (O) 40 40 40 40 40 40 240
Overtime 8 8 8 8 8
Subcontract 2 4 12 2
Hire/Layoff
(O)-(D) 0 3 -3 0 0 0 0
Inventory
Begin 0 0 3 0 0 0
End 0 3 0 0 0 0
Average 0 1.5 1.5 0 0 0
Backlog
Costs
Reg
prodn-normal
(80$/unit) 3200 3200 3200 3200 3200 3200 19200
OT
(120$/unit) 960 960 960 960 960 0 4800
Backorders
(20$/unit)
Subcontracting
(RM 140/unit) 280 0 560 1680 280 0 2800
Hire
(RM b/wkr)
Layoff
(RM c/wkr)
Inventory
(RM 10/unit) 0 15 15 0 0 0 30
TOTAL 26830
QUESTION 02 (i)
QUESTION 02 (ii)

Begin
Week number inv 1 2 3 4 5 6 7 8 9 10
Quantity 0 100 50 200

Item : A Gross requirement 100 50 200

LT : 1
week Scheduled receipt
Projected on hand
Net requirement 100 50 200
Planned order
receipts 100 50 200
Planned order
releases 100 50 200

Begin
Week number inv 1 2 3 4 5 6 7 8 9 10
(2)10 (2)20
Quantity 0 0 (2)50 0

Item : B Gross requirement 200 100 400

LT : 2
weeks Scheduled receipt
Projected on hand
Net requirement 200 100 400
Planned order
receipts 200 100 400
Planned order
releases 200 100 400

Begin
Week number inv 1 2 3 4 5 6 7 8 9 10
(3)10 (3)20
Quantity 0 0 (3)50 0

Item : C Gross requirement 300 150 600

LT : 1
weeks Scheduled receipt
Projected on hand
Net requirement 300 150 600
Planned order
receipts 300 150 600
Planned order
releases 300 150 600
 Begin
Week number inv 1 2 3 4 5 6 7 8 9 10
(2)10 (2)20
Quantity 50 0 (2)50 0

Item : D Gross requirement 200 100 400

LT : 1
week Scheduled receipt
Projected on hand 50 50 50 50 50 50
Net requirement 150 100 400
Planned order
receipts 150 100 400
Planned order
releases 150 100 400

Begin
Week number inv 1 2 3 4 5 6 7 8 9 10
(2)10 (2)20
Quantity 0 0 (2)50 0

Item : E Gross requirement 200 100 400

LT : 2
weeks Scheduled receipt 20 20
Projected on hand 20 20 20 20 20 20 20
Net requirement 180 80 380
Planned order
receipts 200 100 400
Planned order
releases 200 100 400

Begin
Week number inv 1 2 3 4 5 6 7 8 9 10
(4)10 (4)20
Quantity 0 0 (4)50 0

Item : F Gross requirement 400 200 800

LT : 1
weeks Scheduled receipt
Projected on hand 40 40 60 60 60 140 140 140
Net requirement 400 160 740
Planned order
receipts 440 220 880
Planned order
releases 440 220 880
QUESTION 03

i) The network diagram

The available path including the duration for each path.

No Path Duration
1 A,B,D,G,J 18
2 A,B,E,G,J 17
3 A,B,F,H,J 26
4 A,B,F,I,J 25
5 A,C,F,H,J 27
6 A,C,F,I,J 26

ii) Critical Path and Project Duration

A,C,F,H,J
Project Duration = 2+5+8+5+7=27
iii. The slack for each activity.

Earliest Start Earliest Finish Latest Finish On Critical

Activity ES EF Latest Start LS LF Slack (LS-ES) Path
A 0 2 0 2 0 Yes
B 2 6 3 7 1 No
C 2 7 2 7 0 Yes
D 6 8 15 17 9 No
E 6 7 16 17 10 No
F 7 15 7 15 0 Yes
G 8 11 17 20 9 No
H 15 20 15 20 0 Yes
I 15 19 16 20 1 No
J 20 27 20 27 0 Yes

iv. What will happen to project duration if activities G and H are delayed for 3 days?

The following task after G and H, which is J, will also be delayed. Due to tasks H and J being on the
critical path, the project duration will increase. The project duration will increase from 27 to 30