Cairo University – Faculty of Engineering – Mechanical Design & Production Dept.
Production Planning and Control (MDP4340) – Spring 2026
Tutorial #7: Materials Requirement Planning
Problems to be solved by students in class with guidance by the TA and submitted as in-class assignment: 2
Problems to be solved by the TA in class: 1, 3
Problems to be solved by students and submitted next week: 4
1) Elnajjar Co. has gained a long-standing reputation of producing top quality office and school wooden furniture.
One of its product lines is the stool illustrated in the figure below. Based on confirmed customer orders received
from schools and universities along with forecasted demand, the following table summarizes the planned
production of stools for the next 12 months.
Month 1 2 3 4 5 6 7 8 9 10 11 12
Demand 210 340 380 450 520 840 720 315 222 120 98 55
Each component of the leg assembly (long rails, short rails and legs) is ordered from a local supplier with a lot size of
5000 and a lead time of one month. The leg assembly has a lot size of 1000 and lead time of one month. The seat is
produced at Elnaggar Co. to insure the quality of the surface and correct profile. The lot-sizing rule used for seats is lot-
for-lot and its lead time is 2 months. For the stool assembly, the management decided to use a fixed order period of 3
months. The lead time for the stool assembly is one month. The following table summarizes the current on-hand and
scheduled receipts for each item in the product structure.
Scheduled receipts
Item Current on-hand
Month Quantity
Stool 1000 --- ---
Seat 500 --- ---
Leg assembly 200 2 800
Long rails 2000 --- ---
Short rails 2000 --- ---
Legs 2000 --- ---
Construct the MRP sheets for Stool, Leg Assembly, Seat and Long rail.
2) The product structure trees for products A and F are shown below. Part of the master
production schedule showing when the company will complete production operations for
quantities of these products is shown in the table below. The lot-sizing rule for A and F is lot-
for-lot and there is no current on-hand inventory or scheduled receipts for both of them. There is
a scheduled receipt of 1000 units of item B in the first week and another 1000 units in the third
week. If the lot-for-lot lot-sizing rule is used for item B, find the net requirements for item B
throughout the first 12 weeks of the master schedule.
Week 1 2 3 4 5 6 7 8 9 10 11 12 13
Product A 200 150 250 160 250 300 325 300 225 180 150
Product F 80 180 125 200 210 100 180 150 250 200 260
A LT = 1 wk F LT = 2 wks
2B 3C 3B 2X 1Y
LT = 3 wks LT = 2 wks LT = 3 wks LT = 4 wks LT = 2 wks
3) Consider the following product structure trees.
Product A Product B
X (2) Y (1) Z (2) W (1)
X (3) V (2)
The master production schedule for the next 13 weeks is given as follows:
week 1 2 3 4 5 6 7 8 9 10 11 12 13
Product A 20 30 50 80 40 40 40 20 10
Product B 30 20 90 120 60 60 60 60
Furthermore, the following information regarding quantity on hand, scheduled receipts, lead time
and lot sizing rules are provided.
Part Current Scheduled receipts Lot-sizing Lead time
on-hand Due Quantity rule
Product A 60 4 200 FOP, 2 weeks 1 week
Product B 40 2 100 FOP, 4 weeks 2 weeks
X 120 -- -- Lot-for-lot 2 weeks
Y 150 2 100 Lot-for-lot 1 week
Z 540 -- -- Lot-for-lot 1 week
W 50 -- -- Lot-for-lot 2 weeks
V 120 -- -- Lot-for-lot 2 weeks
It is required to construct the MRP sheets of parts A, B, Z and X
4) Consider the following product structure tree for a single-stage helical gearbox. The quantity
required for each item in the product structure tree is shown between square brackets.
The following table represents the demand information for the next 10 weeks for the single-stage
helical gearbox.
Week 1 2 3 4 5 6 7 8 9 10
Demand 20 10 30 50 100 80 40 40 40 20
Furthermore, the following information regarding quantity on hand, scheduled receipts, lead time
and lot sizing rules are provided.
Part Current Scheduled receipts Lot-sizing Lead time
on-hand Due Quantity rule (weeks)
Single-stage helical 40 4 80 FOP of 4 2
gearbox weeks
Case 10 -- -- Lot-for-lot 2
Gear-shaft 80 -- -- FOP of 3 1
subassembly weeks
Front/back cover 0 -- -- Lot-for-lot 1
subassembly
Top cover 10 -- -- Lot-for-lot 2
Gear 1 0 -- -- LUC 1
Shaft 1 0 -- -- LUC 1
Gear 2 100 -- -- FOQ of 400 2
Shaft 2 50 -- -- FOQ of 200 1
Front cover 0 -- -- Silver-Meal 3
Back cover 0 -- -- Silver-Meal 3
Bolt 220 -- -- FOQ of 5000 2
The cost of capital is 24%.
a) Construct the MRP sheet for the single-stage helical gearbox.
b) Construct the MRP sheet for the gear-shaft subassembly while making sure that there is a safety
stock of 50 items that should always be kept in inventory for this item.
c) Construct the MRP sheet for Gear 1, knowing that the setup cost for the machine that produces
Gear1 is LE 250.00 and the value of one unit of Gear1 is LE 30.00 (assume 50 weeks per year)
d) Construct the MRP sheet for Bolt.