Documente Academic
Documente Profesional
Documente Cultură
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
Background
Problem
Manufacturing Control
Given Data
Sales Forecasts
Weeks
Quantity
13-21
22-29
30-35
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
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
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
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
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
0
0
0
Release
Gross Requirement
Schedule Receipts
EQ
17.9
Avrg
Value
29.9
250
LT
4
Week Number
1
Gross Requirement
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
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
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
0
0
100
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
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
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
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
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
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
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
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
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
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
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
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