Specialized boms phantom bills transient

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Specialized BOMs Phantom bills Transient subassemblies Never stocked Immediately consumed in next stage K-bills Group small, loose parts under pseudo-item number Reduces paperwork Modular bills Time-phased bills
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Modular BOM Product assembled from major subassemblies and customer options Modular bill kept for each major subassembly Simplifies forecasting and planning X10 automobile example 3 x 8 x 3 x 8 x 4 = 2,304 configurations 3 + 8 + 3 + 8 + 4 = 26 modular bills
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Modular or Planning Bill
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Time-phased Bill
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Item Master File DESCRIPTION INVENTORY POLICY Item Pressboard Lead time 1 Item no. 734 Annual demand 5000 Item type Purch Holding cost 1 Product/sales class Comp Ordering/setup cost 50 Value class B Safety stock 0 Buyer/planner RSR Reorder point 39 Vendor/drawing 07142 EOQ 316 Phantom code N Minimum order qty 100 Unit price/cost 1.25 Maximum order qty 500 Pegging Y Multiple order qty LLC 1 Policy code 3
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Item Master File PHYSICAL INVENTORY USAGE/SALES CODES On hand 100 YTD usage/sales 1100 Location W142 MTD usage/sales 75 On order 100 YTD receipts 1200 Allocated 75 MTD receipts 0 Cycle 3 Last receipt 8/25 Last count 9/5 Last issue 10/5 Difference -2 Cost acct. 00754 Routing 00326 Engr 07142
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MRP Processes 1. Exploding the bill of material 2. Netting out inventory 3. Lot sizing 4. Time-phasing requirements
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MRP Example Master Production Schedule 1 2 3 4 5 Clipboard 85 95 120 100 100 Lapdesk 0 60 0 60 0 Item Master File Clipboard Lapdesk Pressboard On hand 25 20 150 On order 175 (Period 1) 0 0 LLC 0 0 1 Lot size L4L Mult 50 Min 100
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Product Structure Diagram Clipboard Lapdesk Pressboard (2) Trim (3’) Beanbag (1) Glue (4 oz) Level 0 Level 0 Pressboard (1) Clip Ass’y (1) Rivets (2) Level 1 Level 1
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ITEM: Clipboard LLC: 0 PERIOD LOT SIZE: L4L LT: 1 1 2 3 4 5 Gross Requirements 85 95 120 100 100 Scheduled Receipts 175 Projected on Hand 25 Net Requirements Planned Order Receipts Planned Order Releases MRP Matrix
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ITEM: Lapdesk LLC: 0 PERIOD LOT SIZE: Mult 50 LT: 1 1 2 3 4 5 Gross Requirements 0 60 0 60 Scheduled Receipts Projected on Hand 20 Net Requirements Planned Order Receipts Planned Order Releases MRP Matrix
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ITEM: Pressboard LLC: 1 PERIOD LOT SIZE: MIN 100
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Specialized BOMs Phantom bills Transient subassemblies...

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