Material Requirements Planning Exercises
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ScribdTranslationsMaterial Requirements Planning Exercises
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ScribdTranslationsSUPPLY CHAIN MANAGEMENT
MRP Exercises
EXERCISE 1 It is required to make the Material Requirements Plan (MRP) for the
production of product A54 for the next eight weeks.
Orders received:
Product Sem.1 Sem.2 Sem.3 Sem.4 Sem.5 Sem.6 Sem.7 Sem.8
A54 35 40 ----- 40 50 80 30 60
Master List of Product Materials:
A54
(3) (2) (1)
B11 C21 D33
(3) (2) (4) (2)
E23 F15 F15 E23
where the numbers in parentheses indicate how many units of a material are needed to
produce another of the higher level; for example, two (2) units of component F15 are needed
and three (3) of the E23 to produce one (1) of the B11.
Inventory and others:
The data on inventories, scheduled receptions, and delivery times are as follows:
Product Inventory Time of Scheduled receptions
o initial delivery
Component (weeks)
A54 100 --- ---------
B11 50 3 80 in weeks 1 and 2
C21 30 4 35 in week 3
D33 25 2 40 in weeks 2
E23 45 1 60 in week 1
F15 15 1 50 in week 1
Determine the MRP for the following eight weeks in order to meet the product demand.
A54
EXERCISE 2.-
The company ARIEL SAC. is dedicated to the production of spare parts for heavy machinery. Its
production is entirely made to order. The production schedule for the next eight (8)
weeks of the AB1 spare, which is a special type of gear used in the
CAT backhoe loaders are as follows:
Weeks 1 2 3 4 5 6 7 8
AB1 (unid.) ----- ------ 100 150 500 300 400 550
The assembly details of product AB1 and its components are shown below:
AB1
AR1 (2) AR2 (3) AR3 (2)
10% LOSS 5% LOSS
(2) ST1 ST2 PQ1 PQ2 TV1 TV2 (5)
The number in parentheses indicates the number of components required for manufacturing.
from the top; it should also be taken into account the material loss indicated in % for
the pieces that are found at that level.
The information about the current inventories of each component, as well as about the
Scheduled receptions and the delivery and production times are:
INVENTORY COMPONENT RECEPTIONS TIMES OF
INITIAL SCHEDULED PRODUCTION
( Units ) ( Units ) THE DELIVERY
AB1 300 -------------- 1 week
AR1 400 400 in weeks 1, 2 2 weeks
AR2 900 600 in week 2 2 weeks
AR3 800 400 in weeks 1 and 3 3 weeks
ST1 300 600 in week 1 1 week
ST2 150 100 in weeks 1 and 2 2 weeks
PQ1 300 200 in weeks 1 and 2 2 weeks
PQ2 200 150 in weeks 1, 2, and 3 3 weeks
TV1 300 300 in weeks 2 2 weeks
TV2 3000 1500 in week 1 1 week
Considering that component ST1 has an economic production lot of 300
units,
You are asked to develop the material requirements plan (MRP) to supply the line of
production for the assembly of spare part AB1 over the next eight weeks.
EXERCISE 3.
Due to a change in its sales forecast, the company RIEGEL S.A. must make a new
material requirements plan for the next 8 weeks for your product 'A'.
The master materials list for product 'A' is as follows:
A
B (3) C (2) D (3)
E (1) C (2) G (2) F (2) C (5)
I (4) I (4)
H (2)
The number in parentheses indicates the quantity of parts required for the assembly of the
top. The revised production program of 'A' for the next 8 weeks is the
next:
Week 1 2 3 4 5 6 7 8
Quantity 100 200 200 300 200 300 500 250
The initial inventory position, delivery time, and scheduled receptions are:
Product or Inventario inicial Tiempo de entrega Recepciones Programadas
Component (units) weeks (units / week)
A 600 1 week 600 week 1
B 500 1 week ------------------
C 800 3 weeks 500 week 2
D 300 1 week 500 week 1
E 400 2 weeks -----------------
F 300 2 weeks 400 in semester 1, 500 in semester 2
G 500 2 weeks 800 week 1
H 250 1 week 500 week 1
I 200 1 week ----------------
EXERCISE 4.-
The company DISMAC S.A. must make its material requirement plan for the upcoming
six weeks of the article 'A' that is assembled in its production line.
The master list of product "A" is presented below:
A
B (2) C (2) D (1)
E (1) F (2) G (2) H (2) C (3)
The number in parentheses indicates the amount of pieces required for the assembly of the
top. The production program for 'A' for the next 6 weeks is as follows:
Week 0 1 2 3 4 5 6
Quantity ---- ---- 300 400 400 500 350
You are asked to develop the material requirement plan (MRP) for product 'C'.
taking into account the inventory position in week 0 (zero), the delivery time, and
the scheduled receptions by piece are:
Inventory Article in Delivery Time Scheduled Receipts
Week 0 Weeks ( amount / week )
A 300 ----------- ---------
B 200 1 400/1
C 1,250 2 800/2
D 100 2 250/1, 100/2
E 500 2 500/2
F 400 2 400 divided by 2
G 500 1 200/1, 200/2
H 400 2 300/1, 500/2
EXERCISE 5.-
The company OPERACIONES SA is engaged in the production of compressors for refrigeration.
The sales department has accepted orders for 800 compressors of model AB1 to be
delivered to customers within the next six weeks according to the following
delivery scheduling:
Delivery week 1 2 3 4 5 6
Quantity ----- 100 100 300 200 100
The list of materials for product AB1 is shown below.
AB1
AR1 (2) AR2 (3) AR3 (2)
10% LOSS 5% LOSS
(2) ST1 ST2 PQ1 PQ2 TV1 TV2 (5)
The number in parentheses indicates the amount of components required for manufacturing.
from the top; and where not indicated, the requirement is one unit (1). Additionally, it must be
take into account the material loss indicated in % for the parts that are in that
level and branch.
The information about current inventories of each component, as well as about the receipts
scheduled and the delivery and production times:
PRODUCT INVENTORY RECEPTIONS TIMES OF
COMPONENT The initial SCHEDULED PRODUCTION
E (units) ( units ) THE DELIVERY
AB1 120 400 in week 1 1 week
AR1 ---- 500 in week 2 2 weeks
AR2 200 ----------------- 1 week
AR3 100 300 in week 2 2 weeks
ST1 150 100 in weeks 1 and 2 weeks
2
ST2 50 200 in week 1 2 weeks
PQ1 200 150 in weeks 1 and 2 weeks
2
PQ2 350 350 in week 1 1 week
TV1 300 400 in week 2 3 weeks
TV2 1000 1000 in week 1 1 week
Considering that the AB1 compressor has an economic production lot of 400
units, you are asked to prepare the material requirements plan (MRP) to supply the
assembly line in order to meet the quantities and delivery dates promised by the area
of sales.