Toys Plus Inc

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  • Topic: 3rd millennium, Centuries in the future, Years in the future
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  • Published : June 19, 2008
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1.Calculate economic order quantities for each of the three types of toys. MASTER SCHEDULE FORECAST INPUT
SEP26OCT3OCT10OCT17OCT24OCT31
------------------------------
TOY AUTO110011501200130014001500
TOY TRUCK500450400350300300
TOY ROBOT700650650625625600
------------------------------------
TOTAL UNITS230022502250227523252400

AVERAGE WEEKLY DEMAND (CALCULATED)
TOY AUTO1275
TOY TRUCK383
TOY ROBOT642

MASTER SCHEDULE
EOQ CALCULATIONS
AUTOTRUCKROBOT
WEEKLY DEMAND RATE1275383 642
PRODUCTION RATE PER WEEK350017502333
UNIT COST3.26.54.1

SETUP COST293
CARRYING COST(% Per Year)25%

ECONOMIC ORDER QUANTITY8740 3034 5130

BEGINNING INVENTORY LEVEL INPUT400020001500

Run-out Time = Inventory Level / Demand (in weeks)3.145.222.34

2.Prepare a master production schedule for the next six weeks MASTER SCHEDULE (INPUT PLANNED QUANTITY FOR EACH WEEK)
PLANNED PRODUCTION (WEEK BEGINNING)
SEP26OCT3OCT10OCT17OCT24OCT31
------------------------------
TOY AUTO002600350026400
TOY TRUCK0003801750
TOY ROBOT22672333530000
------------------------------------
TOTAL UNITS226723333130350030201750
TOTAL LABOR HOURS350 350 350 350 350 350
CALCULATED RUN-OUT TIMES (WEEKS)EOQ
TOY AUTO10.08740
TOY TRUCK10.83034
TOY ROBOT10.35130

PROJECTED INVENTORIES OF FINISHED GOODS
SEP26OCT3OCT10OCT17OCT24OCT31
------------------------------
TOY AUTO290017503150535065905090
TOY TRUCK150010506503003801830
TOY ROBOT3066.66747504630400533802780
------------------------------------
TOTAL UNITS7466.667755084309655103509700

FINISHED GOODS INVENTORY ANALYSIS:
AVERAGE WEEKLY USAGE IN $$10,929
AVERAGE WEEKLY INVENTORY IN $$42,676

FINISHED GOODS TURNOVER RATIO13.3
COMPONENT PART INPUTS
BEGINNINGG PARTSLEADSAFETY
COMPENENT PARTINVENTORYY \UNITTIMESTOCK
-------
523 CAR BODY2500131275
525 AUTO WHEELS9800425100
529 AUTO SIDE WINDOWS4300212350
531 AUTO WINDSHIELD2620121275
615 TRUCK CAB120013383
617 TRUCK DUAL WHEELS 9900 8 2 3064 619 TRUCK SINGLE WHEELS 2500 2 2 766 621 TRUCK TRAILER460014383
730 ROBOT BODY160012642
732 ROBOT ARMS3500221284
734 ROBOT LEGS4020211284
736 ROBOT HEAD215012642

3.Prepare a parts explosion to support the master schedule
COMPONENT PARTS EXPLOSION
WEEK BEGINNING

SEP26OCT3OCT10OCT 17OCT 24OCT 31
523GROSS REQUIREMENTS0 0 2600 3500 2640 0
SCHEDULED RECEIPTS0 0 0 0 0 0
PROJ. ON HAND INV.250025001275127512751275
NET REQUIREMENTS0 0 1375 3500 2640 0
PLAN. ORDER RELEASES3500 2640 0 0 0 0
-------
525GROSS REQUIREMENTS0 0 10400 14000 10560 0
SCHEDULED RECEIPTS0 0 0 0 0 0
PROJ. ON HAND INV.980098005100510051005100
NET REQUIREMENTS0 0 5700 14000 10560 0
PLAN. ORDER RELEASES5700 14000 10560 0 0 0
-------
529GROSS REQUIREMENTS0 0 5200 7000 5280 0
SCHEDULED RECEIPTS0 0 0 0 0 0
ON HAND INVENTORY430043002350235023502350
NET REQUIREMENTS0 0 3250 7000 5280 0
PLAN. ORDER RELEASES0 3250 7000 5280 0 0
-------
531GROSS REQUIREMENTS0 0 2600 3500 2640 0
SCHEDULED RECEIPTS0 0 0 0 0 0
PROJ. ON HAND INV.262026201275127512751275
NET REQUIREMENTS0 0 1255 3500 2640 0
PLAN. ORDER RELEASES1255 3500 2640 0 0 0
-------
615GROSS REQUIREMENTS0 0 0 0 380 1750
SCHEDULED RECEIPTS0 800 0 0 0 0
PROJ. ON HAND INV.12002000200020001620383
NET REQUIREMENTS0 0 0 0 0 513
PLAN. ORDER RELEASES0 0 513 0 0 0...
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