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- Toy Discovery, Inc. is a relatively small company in Boston. It designs, develops, and produces a variety of innovative learning toys, games, and books for early child education. The company was founded in 1980 by a preschool educator and, since the creation, continues to grow from the passion for helping children through play. Today, Toy Discovery is a leader in providing toys and games for early childhood education. It is also a foremost direct marketing company of its kind, because most of these toys and games are sold to the customers directly via the Internet.

- One of the company's product lines is dedicated to two types of toy cars: the red-and-yellow race car (20-CAR-RED) and blue retro car (20-CAR-BLUE) (see pictures of the cars below).

- The list of finished units and parts/components used in both toys is shown in table 1, and bills of materials (BOMs) for these toys are presented in Figures 1 and 2 .

- Toy Discovery assembles car toys in its Boston Manufacturing facility (M2) from several component parts: wheels, axles, and main car body. These components are outsourced from two major suppliers: Seattle Manufacturing (M1) and Dallas Manufacturing (M3) (see Table 2).

- The master demand schedule (MDS) on week 5 of is 940 units for the red-and-yellow car (20-CAR-RED), and 850 units for the blue car (20-CAR-BLUE).

- Questions.

• Briefly explain what inputs you will use for the MRP in this case.

• Use Excel to develop the MRP for the toys using the MDS on the week of June 6 and information presented.

• Provide a brief explanation of the developed MRP schedules for 20-AXLE and 20-WHEEL.

Finished Product and Component

Table 1

 

 

Component

Item Description

Characteristic

Producer/Su pplier

20-CAR-RED

Red-and-yellow race car

Finished product

Boston Manufacturing (M2)

20-CAR-BLUE

Blue retro car

Finished product

Boston Manufacturing (M2)

20-BODY-RED

Body of the red-and-yellow car

Purchased part

Seattle Manufacturing (M1)

20-BODY-BLUE

Body of the blue retro car

Purchased part

Seattle Manufacturing (M1)

20-W HL-ASSEM

Wheel assembly

Sub assembly

Boston Manufacturing (M2)

20-AXLE

Car axle

Purchased part

Dallas Manufacturing (M3)

20-W HEEL

Car wheel

Purchased part

Dallas Manufacturing (M3)

1969_Bill.png

Table 2:

Item

Item Description

Characteristic

Producer/Supplier

Lead
Time.days

Safety
stock units

On-hand
Inventory.
units

Orc@ring
Policy

20-CAR-RED

R ed-andlellovr race car

Finished product

Boston It nufacturing (M2)

5

30

50

Lot-for-lot

20-CAR-BLUE

Blue retro car

Finished product

Boston fit nufacturinq (M2)

5

25

35

Lot-for-lot

20-BODY-RED

Body of the red-and-yelbv:

Purchased part

Seattle Itnufacturing (MU

5

50

100

Lot-for-lot

20-BODY-BLUE

Body of the blue retro car

Purchased part

Settle rAinufacturing (M1)

5

75

120

Lot-for-lot

20-WHL-ASSEM

Wheel assently

Sub assently

Boston filinufacturing (M2)

5

130

210

Lot-for-lot

20-AXLE

Car axle

Purchased part

Dallas Manufacturing (M3)

10

100

180

Lot-for-lot

20-WHEEL

Cartwheel

Purchased part

Dallas Manufacturing (M3)

10

100

320

Lot-for-lot

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