As The Production Planner For Scott Sampson Products 023990

148as The Production Planner For Scott Sampsonproducts Inc You Hav

As the production planner for Scott Sampson Products, Inc., you have been given a bill of material for a bracket that is made up of a base, two springs, and four clamps. The base is assembled from one clamp and two housings. Each clamp has one handle and one casting. Each housing has two bearings and one shaft. There is no inventory on hand.

a) Design a product structure noting the quantities for each item and show the low-level coding.

b) Determine the gross quantities needed of each item if you are to assemble 50 brackets.

c) Compute the net quantities needed if there are 25 of the base and 100 of the clamp in stock.

Paper For Above instruction

The task involves designing a product structure, calculating gross requirements, and determining net requirements based on stock levels for a bracket assembly at Scott Sampson Products, Inc. This comprehensive planning process ensures efficient manufacturing and inventory management.

Introduction

Manufacturing planning is a critical aspect of production management, particularly for complex assemblies like brackets that involve multiple components and subassemblies. The objectives include developing a structured bill of materials, calculating required quantities for a specified production volume, and adjusting for existing inventory to determine net requirements. This paper delineates these steps systematically, applying them to the bracket assembly at Scott Sampson Products, Inc.

Product Structure and Low-Level Coding

Designing a product structure involves breaking down the assembly into a hierarchy, identifying all components, and assigning low-level codes that facilitate Material Requirements Planning (MRP). The bracket consists of the main assembly and secondary subassemblies. The hierarchy is as follows:

  • Bracket (Top level)
  • Base (Level 1)
  • Housings (Level 2)
  • Bearings (Level 3)
  • Shafts (Level 3)
  • Clamps (Level 1)
  • Handles (Level 2)
  • Castings (Level 2)
  • Springs (Level 1)

Low-level coding assigns each component the lowest level number at which it appears, ensuring accurate scheduling and inventory control. For example:

  • Bracket – Level 0
  • Base – Level 1
  • Housings – Level 2
  • Bearings and Shafts – Level 3
  • Clamps – Level 1
  • Handles and Castings – Level 2
  • Springs – Level 1

Calculation of Gross Requirements

The assembly of 50 brackets requires the quantities outlined in the BOM:

  • Base: 1 per bracket -> 50 units
  • Springs: 2 per bracket -> 100 units
  • Clamps: 4 per bracket -> 200 units

Each clamp consists of:

  • Handle: 1 per clamp -> 200 handles
  • Casting: 1 per clamp -> 200 castings

The base is assembled from:

  • Clamp: 1 per base -> 50 clamps
  • Housings: 2 per base -> 100 housings

The housings contain:

  • Bearings: 2 per housing -> 200 bearings
  • Shafts: 1 per housing -> 100 shafts

Gross Quantities Computation

Totals associated with assembly of 50 brackets:

  • Clamps: 200 (already calculated)
  • Housings: 100
  • Bearings: 200
  • Shafts: 100
  • Handles: 200
  • Castings: 200
  • Springs: 100

Net Requirements Calculation

Given the current inventory levels:

  • Base stock: 25 units
  • Clamp stock: 100 units

Net requirements are calculated by subtracting stock from gross requirements:

  • Base: 50 (needed) – 25 (stock) = 25 units
  • Clamp: 200 – 100 = 100 units

Other components with sufficient stock (clamps and base) do not require additional procurement. This process ensures we only produce or purchase what is necessary for the upcoming production schedule.

Production Scheduling and Lead Time Planning

The schedule indicates that the unit is to be produced in week 10, with specific lead times for each component:

  • Bracket: 1 week
  • Base: 1 week
  • Spring: 1 week
  • Clamp: 1 week
  • Housing: 2 weeks
  • Handle: 1 week
  • Casting: 3 weeks
  • Bearing: 1 week
  • Shaft: 1 week

To meet the production deadline, the start of component manufacturing must accommodate these lead times, especially for the components with longer durations like castings.

Time-Phased Product Structure and Lead Time Planning

Starting from week 10, backward scheduling necessitates the following key actions:

  • The casting must begin three weeks prior, i.e., in week 7, to ensure its availability by week 10.
  • Housings, which require 2 weeks, must start in week 8.
  • The base, assembled from clamp and housing, needs to start in week 9 to be ready for final assembly in week 10.
  • Similarly, clamps and other components must be scheduled accordingly to align with these milestones.

Discussion of Production Planning Implications

Effective production planning involves meticulous synchronization between component lead times and final assembly schedules. The complexity of components like castings requires early initiation, underscoring the importance of forward scheduling and utilization of Gantt charts and Material Requirements Planning (MRP) systems for optimal production flow.

Conclusion

Constructing a detailed product structure, accurately calculating gross and net requirements, and planning based on lead times are fundamental to successful manufacturing operations. The structured approach ensures resource availability, minimizes inventory costs, and guarantees timely product delivery. For Scott Sampson Products, Inc., adhering to these principles facilitates efficient production scheduling and inventory control, leading to cost savings and improved customer satisfaction.

References

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