Principles Of Operations Management
Principles Of Operations Management
11th Edition
ISBN: 9780135173930
Author: RENDER, Barry, HEIZER, Jay, Munson, Chuck
Publisher: Pearson,
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Textbook Question
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Chapter 14, Problem 32P

Using the data for the coffee table in Problem 14.31, build a labor schedule when the labor standard for each top is 2 labor-hours; each leg including brass cap installation requires, 1 4 hour, as does each pair of braces. Base assembly requires 1 labor-hour, and final assembly requires 2 labor-hours. What is the total number of labor-hours required each day, and how many employees are needed each day at 8 hours per day?

Expert Solution & Answer
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Summary Introduction

To determine: The number of labor hours and employees needed each day.

Explanation of Solution

Given information:

  • Table requires 1 top, 4 legs, 1/8 gallon of strain, 1/16 gallon of blue, 2 short braces, 2 long braces, and brass cap on the bottom of each leg.
  • 100 gallons of glue as inventory.
  • All items except brass caps, stain and glue are planned on a Lot for lot basis.
  • Caps are purchased in 1000’s, stain and glue by gallon.
  • Lead time = 1 (for each item).
  • 640 coffee tables needed on day 5 and 6.
  • 128 coffee tables needed on days 7 and 8.
  • Labor standard for each top is 2 labor hours.
  • Each leg with brass cap installation and each pair of braces need ¼ hour.
  • Base assembly needs 1 labor hour.
  • Final assembly of table requires 2 labor hours.
  • Number of hours per day is 8.

Product structure:

Principles Of Operations Management, Chapter 14, Problem 32P

Net requirements plan:

Table:

Period (Day)
Table 1 2 3 4 5 6 7 8
Gross requirements 640 640 128 128
Scheduled receipt
On hand (0) 0 0 0 0
Net requirement 640 640 128 128
Planned order receipt 640 640 128 128
Planned order release 640 640 128 128

Day 5:

The gross requirement is 640 (1 assembly) of Coffee table derived from the given information. The On hand is 0. Therefore, the net requirement is 640. The lead time is 1 week. The planned order release will be 640 in day 4 which will be the planned order receipt in day 5.

Day 6:

The gross requirement is 640 (1 assembly) of Coffee table derived from the given information. The On hand is 0. Therefore, the net requirement is 640. The lead time is 1 week. The planned order release will be 640 in day 5 which will be the planned order receipt in day 6.

Day 7:

The gross requirement is 128 (1 assembly) of Coffee table derived from the given information. The On hand is 0. Therefore, the net requirement is 128. The lead time is 1 week. The planned order release will be 128 in day 6 which will be the planned order receipt in day 7.

Day 8:

The gross requirement is 128 (1 assembly) of Coffee table derived from the given information. The On hand is 0. Therefore, the net requirement is 128. The lead time is 1 week. The planned order release will be 128 in day 7 which will be the planned order receipt in day 8.

Top:

Period (Day)
Top 1 2 3 4 5 6 7 8
Gross requirements 640 640 128 128
Scheduled receipt
On hand (0) 0 0 0 0
Net requirement 640 640 128 128
Planned order receipt 640 640 128 128
Planned order release 640 640 128 128

Day 4:

The gross requirement is 640 (1 assembly) of Top derived from the planned order release of Table. The On hand is 0. Therefore, the net requirement is 640. The lead time is 1 week. The planned order release will be 640 in day 3 which will be the planned order receipt in day 4.

Day 5:

The gross requirement is 640 (1 assembly) of Top derived from the planned order release of Table.  The On hand is 0. Therefore, the net requirement is 640. The lead time is 1 week. The planned order release will be 640 in day 4 which will be the planned order receipt in day 5.

Day 6:

The gross requirement is 128 (1 assembly) of Top derived from the planned order release of Table. The On hand is 0. Therefore, the net requirement is 128. The lead time is 1 week. The planned order release will be 128 in day 5 which will be the planned order receipt in day 6.

Day 7:

The gross requirement is 128 (1 assembly) of Top derived from the planned order release of Table. The On hand is 0. Therefore, the net requirement is 128. The lead time is 1 week. The planned order release will be 128 in day 6 which will be the planned order receipt in day 7.

Stain:

Period (Day)
Stain 1 2 3 4 5 6 7 8
Gross requirements 80 80 16 16
Scheduled receipt
On hand (0) 0 0 0 0
Net requirement 80 80 16 16
Planned order receipt 80 80 16 16
Planned order release 80 80 16 16

Day 4:

The gross requirement is 80 (1 assembly) of Stain derived from the planned order release of Table. The On hand is 0. Therefore, the net requirement is 80. The lead time is 1 week. The planned order release will be 80 in day 3 which will be the planned order receipt in day 4.

Day 5:

The gross requirement is 80 (1 assembly) of Stain derived from the planned order release of Table.  The On hand is 0. Therefore, the net requirement is 80. The lead time is 1 week. The planned order release will be 80 in day 4 which will be the planned order receipt in day 5.

Day 6:

The gross requirement is 16 (1 assembly) of Stain derived from the planned order release of Table. The On hand is 0. Therefore, the net requirement is 16. The lead time is 1 week. The planned order release will be 16 in day 5 which will be the planned order receipt in day 6.

Day 7:

The gross requirement is 16 (1 assembly) of Stain derived from the planned order release of Table. The On hand is 0. Therefore, the net requirement is 16. The lead time is 1 week. The planned order release will be 16 in day 6 which will be the planned order receipt in day 7.

Glue:

Period (Day)
Glue 1 2 3 4 5 6 7 8
Gross requirements 40 40 8 8
Scheduled receipt
On hand (100) 100 60 20 12 4
Net requirement 0 0 0 0
Planned order receipt
Planned order release

Day 4:

The gross requirement is 40 (1 assembly) of Glue derived from the planned order release of Table. The On hand is 100. Therefore, the net requirement is 0. Therefore there will be no planned order release. The excess inventory 60 will be available at week 5.

Day 5:

The gross requirement is 40 (1 assembly) of Glue derived from the planned order release of Table. The On hand is 60. Therefore, the net requirement is 0. Therefore there will be no planned order release. The excess inventory 20 will be available at week 6.

Day 6:

The gross requirement is 8 (1 assembly) of Glue derived from the planned order release of Table. The On hand is 20. Therefore, the net requirement is 0. Therefore there will be no planned order release. The excess inventory 12 will be available at week 7.

Day 7:

The gross requirement is 8 (1 assembly) of Glue derived from the planned order release of Table. The On hand is 12. Therefore, the net requirement is 0. Therefore there will be no planned order release. The excess inventory 8 will be available at week 8.

Base assembly:

Period (Day)
Base 1 2 3 4 5 6 7 8
Gross requirements 640 640 128 128
Scheduled receipt
On hand (0) 0 0 0 0
Net requirement 640 640 128 128
Planned order receipt 640 640 128 128
Planned order release 640 640 128 128

Day 4:

The gross requirement is 640 (1 assembly) of base assembly derived from the planned order release of Table. The On hand is 0. Therefore, the net requirement is 640. The lead time is 1 week. The planned order release will be 640 in day 3 which will be the planned order receipt in day 4.

Day 5:

The gross requirement is 640 (1 assembly) of base assembly derived from the planned order release of Table.  The On hand is 0. Therefore, the net requirement is 640. The lead time is 1 week. The planned order release will be 640 in day 4 which will be the planned order receipt in day 5.

Day 6:

The gross requirement is 128 (1 assembly) of base assembly derived from the planned order release of Table. The On hand is 0. Therefore, the net requirement is 128. The lead time is 1 week. The planned order release will be 128 in day 5 which will be the planned order receipt in day 6.

Day 7:

The gross requirement is 128 (1 assembly) of base assembly derived from the planned order release of Table. The On hand is 0. Therefore, the net requirement is 128. The lead time is 1 week. The planned order release will be 128 in day 6 which will be the planned order receipt in day 7.

Short brace:

Period (Day)
Short Brace 1 2 3 4 5 6 7 8
Gross requirements 1,280 1,280 256 256
Scheduled receipt
On hand (0) 0 0 0 0
Net requirement 1,280 1,280 256 256
Planned order receipt 1,280 1,280 256 256
Planned order release 1,280 1,280 256 256

Day 3:

The gross requirement is 1,280 (2 assembly) of short brace derived from the planned order release of base assembly. The On hand is 0. Therefore, the net requirement is 1,280. The lead time is 1 week. The planned order release will be 1,280 in day 2 which will be the planned order receipt in day 3.

Day 4:

The gross requirement is 1,280 (2 assembly) of short brace derived from the planned order release of base assembly. The On hand is 0. Therefore, the net requirement is 1,280. The lead time is 1 week. The planned order release will be 1,280 in day 3 which will be the planned order receipt in day 4.

Day 5:

The gross requirement is 256 (2 assembly) of short brace derived from the planned order release of base assembly.  The On hand is 0. Therefore, the net requirement is 256. The lead time is 1 week. The planned order release will be 256 in day 4 which will be the planned order receipt in day 5.

Day 6:

The gross requirement is 256 (2 assembly) of short brace derived from the planned order release of base assembly. The On hand is 0. Therefore, the net requirement is 256. The lead time is 1 week. The planned order release will be 256 in day 5 which will be the planned order receipt in day 6.

Long brace:

Period (Day)
Long Brace 1 2 3 4 5 6 7 8
Gross requirements 1,280 1,280 256 256
Scheduled receipt
On hand (0) 0 0 0 0
Net requirement 1,280 1,280 256 256
Planned order receipt 1,280 1,280 256 256
Planned order release 1,280 1,280 256 256

Day 3:

The gross requirement is 1,280 (2 assembly) of long brace derived from the planned order release of base assembly. The On hand is 0. Therefore, the net requirement is 1,280. The lead time is 1 week. The planned order release will be 1,280 in day 2 which will be the planned order receipt in day 3.

Day 4:

The gross requirement is 1,280 (2 assembly) of long brace derived from the planned order release of base assembly. The On hand is 0. Therefore, the net requirement is 1,280. The lead time is 1 week. The planned order release will be 1,280 in day 3 which will be the planned order receipt in day 4.

Day 5:

The gross requirement is 256 (2 assembly) of long brace derived from the planned order release of base assembly.  The On hand is 0. Therefore, the net requirement is 256. The lead time is 1 week. The planned order release will be 256 in day 4 which will be the planned order receipt in day 5.

Day 6:

The gross requirement is 256 (2 assembly) of long brace derived from the planned order release of base assembly. The On hand is 0. Therefore, the net requirement is 256. The lead time is 1 week. The planned order release will be 256 in day 5 which will be the planned order receipt in day 6.

Leg:

Period (Day)
Leg 1 2 3 4 5 6 7 8
Gross requirements 2,560 2,560 512 512
Scheduled receipt
On hand (0)
Net requirement 2,560 2,560 512 512
Planned order receipt 2,560 2,560 512 512
Planned order release 2,560 2,560 512 512

Day 3:

The gross requirement is 2,560 (4 assembly) of leg derived from the planned order release of base assembly. The On hand is 0. Therefore, the net requirement is 2,560. The lead time is 1 week. The planned order release will be 2,560 in day 2 which will be the planned order receipt in day 3.

Day 4:

The gross requirement is 2,560 (4 assembly) of leg derived from the planned order release of base assembly. The On hand is 0. Therefore, the net requirement is 2,560. The lead time is 1 week. The planned order release will be 2,560 in day 3 which will be the planned order receipt in day 4.

Day 5:

The gross requirement is 512 (4 assembly) of leg derived from the planned order release of base assembly.  The On hand is 0. Therefore, the net requirement is 512. The lead time is 1 week. The planned order release will be 512 in day 4 which will be the planned order receipt in day 5.

Day 6:

The gross requirement is 512 (4 assembly) of leg derived from the planned order release of base assembly. The On hand is 0. Therefore, the net requirement is 256. The lead time is 1 week. The planned order release will be 512 in day 5 which will be the planned order receipt in day 6.

Brass caps:

Period (Day)
Brass caps 1 2 3 4 5 6 7 8
Gross requirements 2,560 2,560 512 512
Scheduled receipt
On hand (0) 0 440 880 368 856 856 856
Net requirement 2,560 2,120 0 144
Planned order receipt 3,000 3,000 1,000
Planned order release 3,000 3,000 1,000

Day 2:

The gross requirement is 2,560 (1 assembly) of brass caps derived from the planned order release of legs. The On hand is 0. Therefore, the net requirement is 2,560. The lead time is 1 week. The planned order release will be 3,000 (1 Lot = 1,000) in day 1 which will be the planned order receipt in day 2. The excess inventory of 440 is available at day 3.

Day 3:

The gross requirement is 2,560 (1 assembly) of brass caps derived from the planned order release of legs. The On hand is 440. Therefore, the net requirement is 2,120. The lead time is 1 week. The planned order release will be 3,000 (1 Lot = 1,000) in day 2 which will be the planned order receipt in day 3. The excess inventory of 880 is available at day 4.

Day 4:

The gross requirement is 512 (1 assembly) of brass caps derived from the planned order release of legs. The On hand is 880. Therefore, the net requirement is 0. Therefore, there will be no planned release. The excess inventory of 368 is available at day 5.

Day 5:

The gross requirement is 512 (1 assembly) of brass caps derived from the planned order release of legs.  The On hand is 368. Therefore, the net requirement is 144. The lead time is 1 week. The planned order release will be 1,000 (1 Lot = 1,000) in day 4 which will be the planned order receipt in day 5. The excess inventory of 856 is available at the next day.

Calculation of labor hours / day:

Master Schedule Hours Required Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7 Day 8
Table assembly 2 1280 1280 256 256
Top preparation 2 1280 1280 256 256
Assemble base 1 640 640 128 128
Long brace (2) 0.25 320 320 64 64
Short brace (2) 0.25 320 320 64 64
Leg (4) 0.25 640 640 128 128
Total Hours 0 1280 3200 3456 1920 640 256
Employees need  @ 8 hours / day 0 160 400 432 240 80 32

The master production schedule is derived from net requirements plan.

Formula to calculate number of hours / each day:

Number of hours=Number of hours per assembly×Planned order release

Formula to calculate the number of employees per 8 hour day:

Number of employees=Total hours required per dayNumber of hours available per day

Day 2:

Calculation of total hours for each day for each component:

Long brace:

Number of hours=0.25×1,280=320

Short brace:

Number of hours=0.25×1,280=320

Leg:

Number of hours=0.25×2,560=640

Calculation of total hours / day:

The total hours is calculated by summing all the hours needed for each component in a day.

Total hours=320+320+640=1,280

Calculation of number of employees per 8 hour day:

The number of employees is calculated by dividing the total hours per day with the number of hours per day.

Number of employees=Total hours required per dayNumber of hours available per day=1,2808=160 employees

Day 3:

Calculation of total hours for each day for each component:

Top preparation:

Number of hours=2×640=1,280

Assemble base:

Number of hours=1×640=640

Long brace:

Number of hours=0.25×1,280=320

Short brace:

Number of hours=0.25×1,280=320

Leg:

Number of hours=0.25×2,560=640

Calculation of total hours / day:

The total hours is calculated by summing all the hours needed for each component in a day.

Total hours=1,280+640+320+320+640=3,200

Calculation of number of employees per 8 hour day:

The number of employees is calculated by dividing the total hours per day with the number of hours per day.

Number of employees=Total hours required per dayNumber of hours available per day=3,2008=400 employees

Day 4:

Calculation of total hours for each day for each component:

Table assembly:

Number of hours=2×640=1,280

Top preparation:

Number of hours=2×640=1,280

Assemble base:

Number of hours=1×640=640

Long brace:

Number of hours=0.25×256=64

Short brace:

Number of hours=0.25×256=64

Leg:

Number of hours=0.25×512=128

Calculation of total hours / day:

The total hours is calculated by summing all the hours needed for each component in a day.

Total hours=1,280+1,280+640+64+64+128=3,456

Calculation of number of employees per 8 hour day:

The number of employees is calculated by dividing the total hours per day with the number of hours per day.

Number of employees=Total hours required per dayNumber of hours available per day=3,4568=432 employees

Day 5:

Calculation of total hours for each day for each component:

Table assembly:

Number of hours=2×640=1,280

Top preparation:

Number of hours=2×128=256

Assemble base:

Number of hours=1×128=128

Long brace:

Number of hours=0.25×256=64

Short brace:

Number of hours=0.25×256=64

Leg:

Number of hours=0.25×512=128

Calculation of total hours / day:

The total hours is calculated by summing all the hours needed for each component in a day.

Total hours=1,280+256+128+64+64+128=1,920

Calculation of number of employees per 8 hour day:

The number of employees is calculated by dividing the total hours per day with the number of hours per day.

Number of employees=Total hours required per dayNumber of hours available per day=1,9208=240 employees

Day 6:

Calculation of total hours for each day for each component:

Table assembly:

Number of hours=2×128=256

Top preparation:

Number of hours=2×128=256

Assemble base:

Number of hours=1×128=128

Calculation of total hours / day:

The total hours is calculated by summing all the hours needed for each component in a day.

Total hours=256+256+128=640

Calculation of number of employees per 8 hour day:

The number of employees is calculated by dividing the total hours per day with the number of hours per day.

Number of employees=Total hours required per dayNumber of hours available per day=6408=80 employees

Day 7:

Calculation of total hours for each day for each component:

Table assembly:

Number of hours=2×128=256

Calculation of total hours / day:

The total hours is calculated by summing all the hours needed for each component in a day.

Total hours=256

Calculation of number of employees per 8 hour day:

The number of employees is calculated by dividing the total hours per day with the number of hours per day.

Number of employees=Total hours required per dayNumber of hours available per day=2568=32 employees

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Chapter 14 Solutions

Principles Of Operations Management

Ch. 14 - Ethical Dilemma For many months your prospective...Ch. 14 - What is the difference between a gross...Ch. 14 - Prob. 2DQCh. 14 - What are the similarities between MRP and DRP?Ch. 14 - How does MRP II differ from MRP?Ch. 14 - Which is the best lot-sizing policy for...Ch. 14 - What impact does ignoring carrying cost in the...Ch. 14 - MRP is more than an inventory system; what...Ch. 14 - What are the options for the production planner...Ch. 14 - Master schedules are expressed in three different...
Ch. 14 - What functions of the firm affect an MRP system?...Ch. 14 - Prob. 11DQCh. 14 - Prob. 12DQCh. 14 - Prob. 13DQCh. 14 - Prob. 14DQCh. 14 - As an approach to inventory management, how does...Ch. 14 - Prob. 16DQCh. 14 - Use the Web or other sources to: a) Find stories...Ch. 14 - Prob. 18DQCh. 14 - Prob. 19DQCh. 14 - You have developed the following simple product...Ch. 14 - You are expected to have the gift bags in Problem...Ch. 14 - Prob. 3PCh. 14 - Your boss at Xiangling Hu Products, Inc., has just...Ch. 14 - The demand for subassembly S is 100 units in week...Ch. 14 - Prob. 6PCh. 14 - Prob. 7PCh. 14 - Prob. 8PCh. 14 - Prob. 9PCh. 14 - Prob. 10PCh. 14 - Prob. 11PCh. 14 - Prob. 12PCh. 14 - Prob. 13PCh. 14 - Prob. 14PCh. 14 - You are product planner for product A (in Problem...Ch. 14 - Prob. 16PCh. 14 - Prob. 17PCh. 14 - Heather Adams, production manager for a Colorado...Ch. 14 - Prob. 19PCh. 14 - Prob. 20PCh. 14 - Prob. 21PCh. 14 - Prob. 22PCh. 14 - Data Table for Problems 14.22 through 14.25 ...Ch. 14 - Develop a POQ solution and calculate total...Ch. 14 - Using your answers for the lot sizes computed in...Ch. 14 - M. de Koster, of Rene Enterprises, has the master...Ch. 14 - Grace Greenberg, production planner for Science...Ch. 14 - Prob. 28PCh. 14 - Prob. 29PCh. 14 - Prob. 30PCh. 14 - Courtney Kamauf schedules production of a popular...Ch. 14 - Using the data for the coffee table in Problem...Ch. 14 - Prob. 1CSCh. 14 - Prob. 2CSCh. 14 - Prob. 1.1VCCh. 14 - Prob. 1.2VCCh. 14 - Prob. 1.3VCCh. 14 - Prob. 2.1VCCh. 14 - Prob. 2.2VCCh. 14 - Prob. 2.3VC
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