Blow moulding tool - gt3.bme.hugt3.bme.hu/wp-content/uploads/2016/06/MW01_S_sample-I_MRP-english.pdf · 3 1. Estimated Demand To estimate how many blow molding tools will the Szentkirályi

Blow molding tool – Material Requirements Planning

Szentkirályi 1.5 liter sparkling mineral water bottle

Borián Marcell AOC4BP

2011.12.10.

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Table of Contents

Table of Contents ............................................................................................................ 2

1. Estimated Demand ................................................................................................... 3

2. Bill of Materials ........................................................................................................ 4

3. Conditions ................................................................................................................ 5

3.1. Time ........................................................................................................................ 5

3.2. Lots ......................................................................................................................... 5

3.3. Master Data............................................................................................................. 5

3.4. Master production schedule for the complete tooling assembly .............................. 5

4. Component MRPs ................................................................................................... 6

4.1. MRP Assembly #100 – Left tool assembly set ........................................................ 6

4.2. MRP Assembly #200 – Right tool assembly set ...................................................... 6

4.3. MRP Part #300 - Bottom tool .................................................................................. 7

4.4. MRP Part #101 – Right side tool ............................................................................. 7

4.5. MRP Part #102 – Cooling cover .............................................................................. 8

4.6. MRP Part #103 - Bolts ............................................................................................ 8

4.7. MRP Part #201 – Left side tool ............................................................................... 9

5. MRP output ........................................................................................................... 10

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1. Estimated Demand

To estimate how many blow molding tools will the Szentkirályi Company need, we

will have to estimate the yearly return of the company. Hungary’s yearly mineral water

consumption has the following distribution regarding the carbon dioxide content of the

product:

It is known that Szentkirályi sells overall 200 million liters of mineral water a year,

which means it sells approximately 114 million liters of sparkling water. Since this

amount contains the 0.5 liter bottles and the huge 20 liter balloons together –which has

a small percentage in the whole selling, we can approximate the amount of sparkling

water sold in 1.5 liter bottles is about 105 million liters. This means 70 million bottles a

year.

Regarding the fact that around 1 million bottles can be produced with one set of

tool, the total need for a year is 70 toolsets per a year.

Let we assume that the demand for new tool sets has the following distribution for a

year:

57% 37%

6%

Mineral water consuption in Hungary - 2010

Sparkling

Non-carbonated

Still

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2. Bill of Materials

TOOLING ASSEMBLY

#100 LEFT TOOL ASSY.

#101 LEFT TOOL

#102 COOLING

COVER

#103 (6) M5X8 BOLT

#200 RIGHT TOOL

ASSY.

#201 RIGHT TOOL

#102 COOLING

COVER

#103 (6) M5X8 BOLT

#300 BOTTOM TOOL

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3. Conditions

3.1. Time

The time bucket of this planning will be a month and the whole plan is evaluated

for a period of a year.

3.2. Lots

The side and bottom tool manufacturing can be started with the minimum amount

of 10 units.

3.3. Master Data

Part / Assy.

On-hand

Scheduled receipt Lot-sizing rule

Lead time

(month) Due Qty

#100 8 - - LFL 1

#200 8 - - LFL 1

#300 10 - - FOQ, 10+ pcs 1

#101 22 - - FOQ, 10+ pcs 1

#102 24 3 36 LFL 1

#103 148 3 400 FOP, 3 months 1

#201 22 - - FOQ, 10+ pcs 1

3.4. Master production schedule for the complete tooling assembly

Month 1 2 3 4 5 6 7 8 9 10 11 12

Gross requirements (MPS) 3 3 5 6 7 8 8 8 7 6 5 4

Available 4 1 - - - - - - - - - -

Net requirement - 2 5 6 7 8 8 8 7 6 5 4

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4. Component MRPs

4.1. MRP Assembly #100 – Left tool assembly set

LLC = 1

Demand from tooling assembly

Month 1 2 3 4 5 6 7 8 9 10 11 12

Gross requirements 2 5 6 7 8 8 8 7 6 5 4 -

Scheduled receipts - - - - - - - - - - - -

Adjusted Scheduled Receipts - - - - - - - - - - - -

Available 8 6 1 0 0 0 0 0 0 0 0 0

Net requirement 0 0 5 7 8 8 8 7 6 5 4 0

Planned order receipt 5 7 8 8 8 7 6 5 4

Planned order release 5 7 8 8 8 7 6 5 4

4.2. MRP Assembly #200 – Right tool assembly set

LLC = 1


Month 1 2 3 4 5 6 7 8 9 10 11 12




Available 8 6 1 0 0 0 0 0 0 0 0 0

Net requirement 0 0 5 7 8 8 8 7 6 5 4 0

Planned order receipt 5 7 8 8 8 7 6 5 4

Planned order release 5 7 8 8 8 7 6 5 4

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4.3. MRP Part #300 - Bottom tool

LLC = 1


Minimum Order Quantity: 10+ units

Month 1 2 3 4 5 6 7 8 9 10 11 12




Available 10 8 3 7 0 2 4 6 9 3 8 4

Net requirement 0 0 3 0 8 6 4 1 0 2 0 0

Planned order receipt 10 10 10 10 10 10

Planned order release 10 10 10 10 10 10

4.4. MRP Part #101 – Right side tool

LLC = 2

Demand from #100 assembly

Minimum Order Quantity: 10+ units

Month 1 2 3 4 5 6 7 8 9 10 11 12

Requirement from #100 5 7 8 8 8 7 6 5 4 - - -

Gross requirements 5 7 8 8 8 7 6 5 4 - - -



Available 3 7 0 2 4 6 9 3 8 4 4 4

Net requirement 2 0 8 6 4 1 0 2 0 0 0 0

Planned order receipt 10 10 10 10 10 10

Planned order release 10* 10 10 10 10 10

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4.5. MRP Part #102 – Cooling cover

LLC = 2

Demand from assembly #100 and #200

Month 1 2 3 4 5 6 7 8 9 10 11 12




Available 22 12 34 18 2 0 0 0 0 0 0 0

Net requirement 0 2 0 0 14 14 12 12 8 - - -

Scheduled receipts - - 36 - - - - - - - - -

Adjusted Scheduled Receipts - 36 - - - - - - - - - -

Planned order receipt 14 14 12 12 8

Planned order release 14 14 12 12 8

4.6. MRP Part #103 - Bolts

LLC = 2

Demand from assembly #100 and #200 (6 units per assembly!)

Month 1 2 3 4 5 6 7 8 9 10 11 12




Available 148 88 4 308 212 116 44 166 106 0 0 0

Net requirement 0 0 0 0 0 0 28 0 0 0 0 0

Scheduled receipts - - 400 - - - - - - - - -


Planned order receipt 194

Planned order release 194

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4.7. MRP Part #201 – Left side tool

LLC = 2

Demand from assembly #200

Minimum Order quantity: 10+ units

Month 1 2 3 4 5 6 7 8 9 10 11 12





Available 3 7 0 2 4 6 9 3 8 4 4 4

Net requirement 2 0 8 6 4 1 0 2 0 0 0 0

Planned order receipt 10 - 10 10 10 10 - 10 - - - -

Planned order release 10* 10 10 10 10 - 10 - - - - -

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5. MRP output

Transaction Part # Old due Release

date New due Quantity Notice

Change Notice #102 3 2 36 expedite

Planned order release #100 2 3 5 OK
























Planned order release #101 1 1 10 Late






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Planned order release #201 1 1 10 Late






Documents

Blow moulding tool - gt3.bme.hugt3.bme.hu/wp-content/uploads/2016/06/MW01_S_sample-I_MRP-english.pdf · 3 1. Estimated Demand To estimate how many blow molding tools will the Szentkirályi