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Psycho Sports Ltd

Nadia Febianita
Shinta Dwi Wahyuni
Yohanes Febryanto

Background
Key Person : Peter Townsend
Psycho Sports Sports Goods
Manufacturing
Over the last two years had grown
rapidly
Including : Tennis Balls,
Table Tennis
Product
Bats

Specialist Sport
Customers
Shops

Darts, Protective
Equipment for various
games

Included some of major


sports retail chain

Background
Problem
Manufacturing Control

Would soon to install some


systematic procedures and
routines to manage the
business
Take as examples High-Resolution Bat (5654)
Peter set six exercise too understand fully basics of
MRP

Given Data
Sales Forecasts
Weeks

Quantity

13-21

100 per week

22-29

150 per week

30-35

200 per week

Given Data

Given Data

Questions
1. Why did Peter have such
problems getting to the
relevant information?
2. Perform all the exercises which
Peter set for himself. Do you
think he should now fully
understand MRP?

Exercises
Exercise 1
Draw up:
(a) the single-level bill of materials for each level of
assembly,
(b) a complete indented bill of materials for all levels of
assembly
Exercise 2
(c) Create the materials requirements planning records for
each part and sub-assembly in the bat
(d) List any problems that the completed MRP records
identify
(e) What alternatives are there that the company could take
to solve any problems? What are their relative merits?

Exercises
Exercise 3
Based on the first two exercises, create another set
of MRP records, this time allowing one weeks safety
lead time for each time: that is, ensuring the items
are in stock the week prior to when they are
required
Exercise 4
Over the time period of the exercise, what effect
would the imposition of a safety lead time have on
average inventory value?

Exercises
Exercise 5
If we decided that our first task was to reduce
inventory cost by 15 per cent, what action would be
recommend? What are the implications of our
action?
Exercise 6
How might production in our business be smoothed?

Question 1
Data mengenai
Inventori tidak
tersimpan secara
centralized dan tidak
ada komunikasi antar
departemen
Beberapa informasi
tidak tercatat dengan
baik

Exercise 1
a. The single-level bill of materials
for each level
Part No
Description
Level

Level
1
1
1
1
1
1

5654
Bat
0
Part
Number
0499
7754
0955
9110
8744
0772

Description Quantity
Handle Assy
1
Shaft
1
Connector
1
Nail
4
Rivet
4
Face Assy
1

Exercise 1
Part No
Description
Level

Level
2
2
Part No
Description
Level

Level
2
2
2

0499
Handle
Assy
1
Part
Number
1821
9110
0772

Quantit
Description
y
Handle
1
Nail
2

Face Assy
1
Part
Number
6511
2547
8561

Quantit
Description
y
Rubber Face
2
Wooden inner
1
Foam Panel
2

Exercise 1
b. Complete idented bill of materials
for all levels of assembly
Level
0
1
2
2
1
1
1
1
1
2
2
2

Part
Number
5654
0499
1821
9110
7754
0955
9110
8744
0772
6511
2547
8561

Desription Quantity
Bat
1
Handle Assy
1
Handle
1
Nail
2
Shaft
1
Connector
1
Nail
4
Rivet
4
Face Assy
1
Rubber Face
2
Wooden inner
1
Foam Panel
2

Exercise 2
a. Material Requirement Planning (MRP)
Record

Part Number

5654

EQ

50
0

LT
Week Number
Gross
Requirement
Schedule
Receipts
Part
Number
On Hand
Inventory
Planned Order
EQ
Release

LT
Week Number
Gross
Requirement
Schedule
Receipts
Part
Number
On Hand
Inventory
Planned Order
EQ
Release

0499
0 0
40
0

775
4

0
80
0

100
0

LT
5
Week Number
1
2
3
4
5
6
7
Gross Requirement

Schedule Receipts

On Hand Inventory 095


15 15 15 15 15 15 15
Planned
Order
100
Part
Number
5
Release

EQ

LT
Week Number
Gross Requirement

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
10 10
10 10 10 10 10 10 15 15 15 15 15 15 15 15 20 20 20 20 20 20
Unit
Avrg
Avrg

0 0 100 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Cos
level
Value
t

40 30
10
40 30 20 10 45 30 15
35 20
40 20
30 10 40 20
0 0 0 0 0 200 0 0 0 0 0 0 0 0 0 0 0 0 50 0 0 0 0 0 0 0
145.7 12 1748.6
50
50
50
50
50
50
50
0

0
0

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
50
50
50
50
50
50
50
0

0
0

30 30 30 30
20 20 20 20 10 10 10 10
0 0 0 0 300 0 0 0 0 0 0 0 0 0
40
40
40
80

Avrg Unit Avrg


level Cost Value

30 30 30 20 20 10 10 10 10
0 0 0 0 0 0 0 0 0 125.7
40
40
0
0

502.8

8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Avrg Unit Avrg

500

500

500

500
500
500 500

level
Cost Value

15 15 15 515 515 515 515 515 15 15 15 15 515 515 515 515 15 15 15 515 515 515 15 15 515 515 515 515 243.6
1
243.6
100
100
100

500
0

4
1

10 11 12 13 14
500

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
500

500

500
500
500 500

Avrg Unit Avrg


level Cost Value

Exercise 2
a. Material Requirement Planning (MRP)
Record

Part Number

911
0

EQ

5000

LT
Week Number

Gross Requirement
Schedule Receipts

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35

Avrg Unit
160
200
200
200
280
200
200

800

800

800
3600

800

0
0
0
0
0
0
0
level Cost

352 352 352 152 152


372 292 292 292
152 152 372 372 292
392 392 392 392
120 120 120 120 120 120 120
720 720 720
920 120 120 120 1520
920 920
1794.3 0.01
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
500
500
500
500
500

0
0
0
0
0

On Hand Inventory
Planned Order
Release
Part Number
8744

EQ

5000

LT
Week Number

4
1

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Avrg Unit
200
200
200
200
200
200
200

0
0
0
0
0
0
0
level Cost

354 354 354 354 354 354


354 354 354 154 154 154 154
454 454 454 454 254 254 254 254
354 354 354 154 154 454 454 454 454
077
3540
1540
540 540 540
2997.1 0.01
On Hand
Inventory 2 0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Part
Number
Planned Order
500
500
500

0
0
0
Release
Gross Requirement
Schedule Receipts

EQ

17.9

Avrg
Value
29.9

250

LT
4
Week Number
1
Gross Requirement

Schedule Receipts 182

On
Inventory 1 0
PartHand
Number
Planned Order

Release
EQ

Avrg
Value

500

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
500

500

500

500
500
500 500

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

500

500

500

500

500

500

Avrg Unit Avrg


level Cost Value
0

500

LT
4
Week Number
1
Gross Requirement

Schedule Receipts

On Hand Inventory
0

8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Avrg Unit Avrg
800

400

400

400
800
400 400

level Cost Value

200 200 200 200 200 300 300 300 300 400 400 400 400 0
0
0 200 200 200 300 300 400 400 400 400 400 400 400 222.9
2
445.7

Exercise 2
a. Material Requirement Planning (MRP)
Record
Part Number

651
1

EQ

2000

LT
Week Number

10
1

1000

200
0

Gross Requirement
Schedule Receipts
On Hand Inventory
Planned Order
Release

200
0

Part Number

2547

EQ

300

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

100
neg neg neg neg
0

100
0

200
0

100
100

0
0

100 100 100 100


0
0
0
0
0
200

100
100

0
0

100 100 100


0
0
0
0

100

100 100 100 100 100 100 100 100


0
0
0
0
0
0
0
0

Avrg Unit Avrg


level Cost Value
516.1

0.5

258.1

LT
7
Week Number
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Avrg Unit Avrg
Gross Requirement

500

500

500

500
500
500 500

level Cost Value


Schedule Receipts

On Hand Inventory 10 10 10 10 10 10 neg 110 110 110 110 210 210 210 210 10 10 10 10 110 110 110 210 210 210 10 10 110 110 110 110 110 110 110 110 95.3
1.5 142.9
Planned Order
600

600

300

600
600
300 600

Release
Part Number

8561

EQ

1000

LT
Week Number

Gross Requirement
Schedule Receipts
On Hand Inventory
Planned Order
Release

1000

0
100
0

0
100
0

neg neg
100

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

100
0

100
0

100
0

100
0

100
0

100
0

Avrg Unit Avrg


level Cost Value

0.5

1000

0
100
0

0
100
0

0
100
0

Total

3441.8

Exercise 2
b. Problems from MRP Records
Terdapat masalah pada inventory yaitu pada item Rubber Face
(6511), Wooden Inner (2547) dan Foam Panel (8561).
Perusahaan tidak dapat memenuhi demand tepat waktu
dikarenakan 3 item tsb tidak tersedia pada saat dibutuhkan
(delay).

c. Alternative Solutions
a. Menekan supplier untuk memproduksi lebih cepat.
Dengan resiko: membayar lebih mahal dan kualitas menurun.
b. Mencari supplier lain yang bersedia untuk memproduksi material
yang
sama lebih cepat
Dengan resiko: belum mengetahui kualitas dari supplier baru

Exercise 3
a. Material Requirement Planning (MRP) Record
+ 1 safety week
Part Number

5654

EQ

500

LT
2+1
Week Number
1
2
Gross Requirement

Schedule Receipts

On Hand Inventory 0
0
Planned
Order
Part Number
0499

Release
EQ

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Avrg Unit Avrg

100 100 100 100 100 100 100 100 100 150 150 150 150 150 150 150 150 200 200 200 200 200 200

level Cost Value


0
0 500 400 300 200 100 500 400 300 200 600 450 300 150 500 350 200 550 400 200 500 300 600 400 200 245.7 12 2948.6

8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Avrg Unit Avrg

500

500

500

500
500
500 500

level
Cost Value

0 800 300 300 300 300 700 200 200 200 600 100 100 100 500 0
0 800 300 300 700 200 600 100 100 100 100 100 231.4 4
925.7

800

15

15

15

15

15

100
0

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

500

500

500

500

500

500

500

500

400

400

400

800

400

400

1000

LT
5+1
Week Number
1
2

Gross Requirement

Schedule Receipts
On Hand Inventory 15 15
Part
Number
0955
Planned
Order

Release
EQ

400

LT
3+1
Week Number
1
2
Gross Requirement

Schedule Receipts

On Hand Inventory 0
0
Part
Number
7754
Planned Order

Release
EQ

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

500

500

101
15
515 515 515 515 515 15 15
5
100

Avrg Unit Avrg


Cost Value

500

500
500
500 500

level

101
101
101
15
515 515 515 515 15 15
515 515 515 15
515 515 515 515 515 372.1
5
5
5
100
100

0
0

372.1

5000

LT
4+1
Week Number
1
2

Gross Requirement

Schedule Receipts

500

500

500

500

500

500

Avrg Unit Avrg


level Cost Value

Exercise 3
a. Material Requirement Planning (MRP) Record
+ 1 safety week
Part Number

911
0

EQ

5000

LT
Week Number

4+1
1
2

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Avrg Unit
160
200
280
160 200
200
200
200

800

2800

800
800

Gross Requirement
0
0
0
0
0
0
0
0
level Cost

Schedule Receipts
512 352
352 352 152
572
292 292 292
512 352 152 152 572 372 292 292
592 392 392 392 392 392
Part Number
8744
3520
720 720 720
2920
120 120
920
2697.1 0.01
On Hand Inventory 120 120 120 120 0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Planned Order
500
500
500
500
500

0
0
0
0
0
Release

EQ

5000

LT
Week Number

4+1
1
2

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Avrg Unit
200
200
200
200
200
200

2000

Gross Requirement
0
0
0
0
0
0
level Cost

Schedule Receipts
354 354 354 354 354 354
354 354 154 154 154 154 654
454 454 454 254 254 254 254
554 354 354 354 154 654 454 454 454 454 454
Part Number
0772
3540
4540
540 540
3454.3 0.01
On Hand Inventory
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Planned Order
500
500
500

0
0
0
Release

EQ

27.0

Avrg
Value
34.5

250

LT
4+1
Week Number
1
2
Gross Requirement

Schedule Receipts

On Hand Inventory
0
0
Planned
Order
Part
Number
1821

Release
EQ

Avrg
Value

8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Avrg Unit Avrg

500

500

500

500
500
500 500

level
Cost Value

0 500 0
0
0
0 500 0
0
0 500 0
0
0 500 0
0 500 0
0 500 0 500 0
0
0
0
0 100.0
5
500.0

500

500

500

500

500

500

500

500

LT
4+1
Week Number
1
2

Gross Requirement

Schedule Receipts

800

100

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

400

400

400

800

100

400

400

Avrg Unit Avrg


level Cost Value

Exercise 3
a. Material Requirement Planning (MRP) Record
+ 1 safety week
Part Number

651
1

EQ

2000

LT
Week Number

10+1
1
2

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

100
0

0
0
On Hand Inventory
Part
Number
2547
Planned
Order
200

0
Release

neg neg neg neg neg neg

200
0

200
0

Gross Requirement
Schedule Receipts

EQ

100
0

100
100

0
0

200 100
100 100
1000
0
0
0
0
0

2000

Avrg
100
100
100

0
0
0
level

200 100 100 100


200 100 100 100 100 100 100 100 100 100 100
0
793.1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Unit Avrg
Cost Value
0.5

396.5

300

LT
7+1
Week Number
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Avrg Unit Avrg
Gross Requirement

500

500

500

500
500
500 500

Schedule Receipts

level Cost Value


On Hand Inventory 10 10 10 10 neg neg neg 110 710 210 210 210 510 10 10 10 610 110 110 710 210 210 510 10 610 110 110 110 110 110 110 110 110 110 110 194.4 1.5 291.6
Planned Order
600 600

300

600
600
300 600

Part
Number
8561
Release

EQ

1000

LT
Week Number

8+1
1
2

100
0

Gross Requirement
Schedule Receipts

100
0

On Hand Inventory
Planned Order
Release

neg neg neg neg

200
0

200
0

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
100
0

100
100

0
0

200 100
100 100
0
1000
0
0
0
0
0
100
100

1000

0
0

100
0

100
0

100
0

100
0

100
0

100
0

Avrg Unit Avrg


level Cost Value

322.6

0.5

161.3

Total 6433.2

Exercise 4
Inventory Value
3441.78
6433.20

Source
Exercise 2
Exercise 3

Increase: 86,92%

Exercise 5
a. Raw Materials
Mengurangi inventory level dengan prinsip
Just-In-Time (JIT)
Exercise 2 dan 3 menunjukkan dengan
one-week safety lead time, cost of
inventory meningkat 86.92%
Implikasi:
Order cost meningkat karena sedikitnya
order
Resiko stock-outs

Exercise 5
b. Finished Goods
Fleksibilitas dalam jumlah produksi
dengan menyesuaikan kuantitas
permintaan sehingga mengurangi
inventory
Implikasi:
Mengurangi produktivitas mesin dan
pekerja
Resiko stock-outs

Exercise 5
c. Work in Process
Untuk mengurangi unnecessary delays,
perusahaan harus meningkatkan kontrol
pada sistem produksi
Memaksimalkan kapasitas mesin dan
penggunaan JIT
Implikasi:
Butuh tambahan pekerja untuk
melakukan kontrol

Exercise 6
Dalam realita, ada beberapa
hambatan:
Fleksibilitas
Beberapa variabel MRP (lead time,
batch
size) bersifat fixed kurang reliable
Unexpected events (mesin rusak)
Perusahaan perlu memiliki kontrol
terhadap keseluruhan sistem dan
perencanaan yang matang

Question 2
Simulasi yang dilakukan dapat
membantu Peter memahami cara
kerja MRP dan mengerti keterkaitan
antar department dalam Pscycho
Sports Ltd.

Q & A session