A car part manufacturing company currently produces a suspension assembly for Toyota Motor Corporation. Figure 1 shows the breakdown structure of the suspension assembly and Figure 2 shows the final assembly and how to fit into a car. Table 1 shows the name of components, part numbers, and the number of components in each suspension assembly. Table 1. Part lists for Suspension Assembly Number in Figure 1 Part number Part name Amount per assembly 1 PA-T15-001 Shock absorber unit 1 2 PA-T15-002 Lower insulator 1 3 PA-T15-003 Spring bumper 1 4 PA-T15-004 Coil spring 1 5 PA-T15-005 Upper insulator 1 6 PA-T15-006 Spring upper seat 1 7 PA-T15-007 Bushing 1 8 PA-T15-008 Suspension Support 1 9 PA-T15-009 Washer 1 10 PA-T15-010 Stop nut 1 11 GE-001 Bolt 2 12 GE-002 Nut 5 Coil springs are produced in-house. The process to produce the coil spring in the company is as follows. (a) Heating the wire: to an appropriate temperature for the winding process. (b) Hot winding process: with a spring winding machine, align the wire into a proper pitch. (c) Cutting the wire: cut the wire in an appropriate length after the winding process. (d) Cooling process: cool down the spring immediately by plunging into the oil. (e) Heat treatment: remove internal stress within the material to provide higher resilience. Usually heated in an oven and held at an appropriate temperature for a predetermined time. (f) Grinding: the spring needs to have flat ends. The coiled spring will be placed into a jig by operators to feed into the grinding machine. (g) Shot peening: this process requires strengthening the steel to resist fatigue and cracking during its lifetime. (h) Coating: to prevent corrosion, the entire spring surface will be coated by dipping into a liquid rubber. (i) Inspection and Transporting: the final coil spring will be inspected and transported to the final assembly work station. Using the information above, answer the followings Q- Aggregate Planning: The planning department wanted to prepare a master production schedule for the next 8 weeks. The weekly demand forecast and the customer order (already committed) are given in the table below. The beginning inventory level is 350. Determine Available-to-promise inventory under the condition that schedule production when the projected on-hand inventory would be negative without production. Assume that the production lot size is 500. May June 1 2 3 4 1 2 3 4 Demand Forecasted 200 250 240 250 370 450 450 380 Customer Order (committed) 160 210 260 170 230 280
Summary:
A car part manufacturing company currently produces a suspension assembly for Toyota Motor Corporation. Figure 1 shows the breakdown structure of the suspension assembly and Figure 2 shows the final assembly and how to fit into a car. Table 1 shows the name of components, part numbers, and the number of components in each suspension assembly.
Table 1. Part lists for Suspension Assembly
| Number in Figure 1 | Part number | Part name | Amount per assembly |
| 1 | PA-T15-001 | Shock absorber unit | 1 |
| 2 | PA-T15-002 | Lower insulator | 1 |
| 3 | PA-T15-003 | Spring bumper | 1 |
| 4 | PA-T15-004 | Coil spring | 1 |
| 5 | PA-T15-005 | Upper insulator | 1 |
| 6 | PA-T15-006 | Spring upper seat | 1 |
| 7 | PA-T15-007 | Bushing | 1 |
| 8 | PA-T15-008 | Suspension Support | 1 |
| 9 | PA-T15-009 | Washer | 1 |
| 10 | PA-T15-010 | Stop nut | 1 |
| 11 | GE-001 | Bolt | 2 |
| 12 | GE-002 | Nut | 5 |
Coil springs are produced in-house. The process to produce the coil spring in the company is as follows.
(a) Heating the wire: to an appropriate temperature for the winding process.
(b) Hot winding process: with a spring winding machine, align the wire into a proper pitch.
(c) Cutting the wire: cut the wire in an appropriate length after the winding process.
(d) Cooling process: cool down the spring immediately by plunging into the oil.
(e) Heat treatment: remove internal stress within the material to provide higher resilience. Usually heated in an oven and held at an appropriate temperature for a predetermined time.
(f) Grinding: the spring needs to have flat ends. The coiled spring will be placed into a jig by operators to feed into the grinding machine.
(g) Shot peening: this process requires strengthening the steel to resist fatigue and cracking during its lifetime.
(h) Coating: to prevent corrosion, the entire spring surface will be coated by dipping into a liquid rubber.
(i) Inspection and Transporting: the final coil spring will be inspected and transported to the final assembly work station.
Using the information above, answer the followings
Q- Aggregate Planning: The planning department wanted to prepare a master production schedule for the next 8 weeks. The weekly demand forecast and the customer order (already committed) are given in the table below. The beginning inventory level is 350. Determine Available-to-promise inventory under the condition that schedule production when the projected on-hand inventory would be negative without production. Assume that the production lot size is 500.
| May | June | |||||||
| 1 | 2 | 3 | 4 | 1 | 2 | 3 | 4 | |
| Demand Forecasted | 200 | 250 | 240 | 250 | 370 | 450 | 450 | 380 |
| Customer Order (committed) | 160 | 210 | 260 | 170 | 230 | 280 |
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