Basic explosion DiagramRequirementsSidelamp100week 1380week 15110week 16Headlamp120week 1490week 1575week 16BOM for SidelampWeek 13100C206P200SL111P10040SL112A100C310P100SL113P100SL121F100SL122A100SL131F100SL123A100SL132P100SL133F100SL134P100Week 1580C206P160SL111P80SL112A80C310P80SL113P80SL121F80SL122A80SL131F80SL123A80SL132P80SL133F80SL134P80Week 16110C206P220SL111P11035SL112A110C310P110SL113P110SL121F110SL122A110SL131F110SL123A110SL132P110SL133F110SL134P110BOM for HeadlampWeek 14120C206P480HL211A120C206P240HL212P120C310P120HL222P120HL223F120Week 1590C206P360HL211A90C206P180HL212P90C310P90HL222P90HL223F90Week 1675C206P300HL211A75C206P150HL212P75C310P75HL222P75HL223F75

BOM-Side lamp+Action noticesExploded MRP for each assembly, subassembly component and subcomponent level for the sidelamp.C206PFOQ RuleLot Size2500Lead Time1Action Notices:Safety Stock3012345678Gross Requirements00200016022000Scheduled Receipts00000000Projected On-Hand Inventory150150150245024502290207020702070Planned Receipts00250000000Planned Order Releases02500000000SL111PFOQ RuleLot Size350Lead Time2Action Notices:Safety Stock01. Action notice to release planned order of 350 units12345678Gross Requirements0014008014500Scheduled Receipts00000000Projected On-Hand Inventory151515225225145000Planned Receipts0035000000Planned Order Releases3500000000SL112AL4L RuleLead Time3Safety Stock0Action Notices:Quantity on Hand12345678Gross Requirements0010008011000Scheduled Receipts0010000000Projected On-Hand Inventory20202020200000Planned Receipts00006011000Planned Order Releases06011000000SL113PFOQ RuleLot Size100Lead Time1Action Notices:Safety Stock2012345678Gross Requirements0010008011000Scheduled Receipts00000000Projected On-Hand Inventory202020202040303030Planned Receipts00100010010000Planned Order Releases01000100100000SL112ASubassembly level planned order release becomes gross requirements for the component levelC310PFOQ RuleLot Size180Lead Time1Action Notices:Safety Stock2012345678Gross Requirements06011000000Scheduled Receipts0180000000Projected On-Hand Inventory3030150404040404040Planned Receipts00000000Planned Order Releases00000000SL121FL4L RuleLead Time3Safety Stock0Action Notices:Quantity on Hand123456781. Here wecan expedite the open order by 11 week to take care ofrequirements in week 12 but still we will not be able to meet Gross Requirements06011000000requirements in week 13 and the shortfall of 100 units has to beordered in week 10Scheduled Receipts0070000002. Because of the above method the inventory carried subsequently willbe lowerProjected On-Hand Inventory000707070707070Planned Receipts06011000000Planned Order Releases00000000SL122AL4L RuleLead Time1Safety Stock0Action Notices:Quantity on Hand12345678Gross Requirements06011000000Scheduled Receipts050000000Projected On-Hand Inventory10100000000Planned Receipts0011000000Planned Order Releases0110000000SL123AL4L RuleLead Time1Safety Stock0Quantity on Hand12345678Action Notices:1. Action notice for planned order release of 60 unitsGross Requirements06011000000Scheduled Receipts00000000Projected On-Hand Inventory000000000Planned Receipts06011000000Planned Order Releases60110000000SL122A Planned order release becomes the gross requirements for the sub sub component levelSL131FPOQ RulePeriod (P)2Lead Time2Action Notices:Safety Stock0Quantity on Hand12345678Gross Requirements0110000000Scheduled Receipts00000000Projected On-Hand Inventory000000000Planned Receipts0110000000Planned Order Releases00000000SL132PFOQ RuleLot Size100Lead Time1Action Notices:Safety Stock2512345678Gross Requirements0110000000Scheduled Receipts0100000000Projected On-Hand Inventory353525252525252525Planned Receipts00000000Planned Order Releases00000000SL123A Planned order release becomes gross requirements for sub sub component level

SL133FPOQ RulePeriod (P)2Lead Time2Action Notices:Safety Stock01. Here we can expedite the open order to reach on week 11Quantity on Hand12345678as aresult we do not have to take the planned receipt in week 11and we can manage with the scheduled receipt of 180 and the subsequentGross Requirements60110000000inventory will also be less i.e 10Scheduled Receipts0180000000Projected On-Hand Inventory0110180180180180180180180Planned Receipts1700000000Planned Order Releases00000000SL134PFOQ RuleLot Size100Lead Time1Action Notices:Safety Stock251. Here if the open order would have been expedited then we would have12345678placed a planned order on the week 11 which we would have received on week 122. Because of the above action we could have released an action order on week 11Gross Requirements60110000000to release 100 units.Scheduled Receipts0100000000Projected On-Hand Inventory206050505050505050Planned Receipts1000000000Planned Order Releases00000000

BOM-Headlamp+Action noticesExploded MRP for each assembly, subassembly component and subcomponent level for the HeadlampC206PFOQ RuleLot Size2500Lead Time1Action Notices:Safety Stock3012345678Gross Requirements00048036030000Scheduled Receipts00000000Projected On-Hand Inventory15015015015021701810151015101510Planned Receipts00025000000Planned Order Releases00250000000HL211AL4L RuleLead Time2Safety Stock0Action Notices:Quantity on Hand123456781. We could have delayed the open receipt from week 12 to week 14This would have reduced the average inventory carried in those weeksGross Requirements000120907500Scheduled Receipts050000000Projected On-Hand Inventory1010606000000Planned Receipts00060907500Planned Order Releases06090750000HL212PFOQ RuleLot Size350Lead Time2Action Notices:Safety Stock1512345678Gross Requirements000120907500Scheduled Receipts00000000Projected On-Hand Inventory15151515245155808080Planned Receipts0003500000Planned Order Releases0350000000HL211A Planned order release becomes gross requirements at component levelC206PFOQ RuleLot Size2500Lead Time1Action Notices:Safety Stock3012345678Gross Requirements01201801500000Scheduled Receipts00000000Projected On-Hand Inventory15015030235022002200220022002200Planned Receipts00250000000Planned Order Releases02500000000C310PFOQ RuleLot Size180Lead Time1Action Notices:Safety Stock2012345678Gross Requirements06090750000Scheduled Receipts0180000000Projected On-Hand Inventory150150270180105105105105105Planned Receipts00000000Planned Order Releases00000000HL222PPOQ RulePeriod (P)4Lead Time4Action Notices:Safety Stock101. Here expediting the open order would not have helped becauseQuantity on Hand12345678if we would have received the order on week 12 we would have been safe in week 12 and week 13 but again problem would have beenGross Requirements06090750000in week 14 but even if we would have planned order release on week 11we would not have received ithe order until week 15 as lead time is Scheduled Receipts00011000004 weeks, so the above exercise will not yield resultsProjected On-Hand Inventory505017585120120120120120Planned Receipts0185000000Planned Order Releases00000000HL223FL4L RuleLead Time1Safety Stock0Action Notices:Quantity on Hand12345678Gross Requirements06090750000Scheduled Receipts00000000Projected On-Hand Inventory707010000000Planned Receipts0080750000Planned Order Releases0807500000