Tabel MRP Material Requirement Planning

BAB 2 PENGOLAHAN DATA

2.1 Tabel MRP

Berikut adalah tabel MRP dan DRP dari komponen-komponen pesawat mainan yang telah dibuat dan dihitung: Tabel 2.1 Master Requirement Planning MRP Komponen Assembly 6 A6 Part No : 1 Description : Assembly 6 BOM UOM : Piece On Hand : 75 Lead Time : 1 Order Policy : Lot for Lot Safety Stock : 112 Lot Size : 97 Period Past Due Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Sept-16 Okt-16 Nov-16 Des-16 Gross Requirement 2169 1653 1546 1598 1290 1125 1105 1028 1014 965 958 1060 Scheduled Receipts PAB 1 -2094 -1516 -1413 -1459 -1100 -964 -905 -866 -813 -808 -796 -886 Net Requirement 2206 1628 1525 1571 1212 1076 1017 978 925 920 908 998 Planned Order Receipt 2231 1649 1552 1649 1261 1164 1067 1067 970 970 970 1067 Planned Order Release 2231 1649 1552 1649 1261 1164 1067 1067 970 970 970 1067 PAB 2 75 137 133 139 190 161 200 162 201 157 162 174 181 Keterangan: Jika order policy ditulis lot for lot maka tidak perlu dicari Distribution Resources Planning DRP. Integrated Industrial Engineering Laboratory Industrial Engineering Department 6 BINUS University Tabel 2.2 Master Requirement Planning MRP Komponen Subassembly 2 Part No : 16 Description : Subassembly 2 BOM UOM : Piece On Hand : 54 Lead Time : 1 Order Policy : Lot for Lot Safety Stock : 170 Lot Size : 36 Period Past Due Jan- 16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug- 16 Sep-16 Okt-16 Nov- 16 Des-16 Gross Requirement 2169 1653 1546 1598 1290 1125 1105 1028 1014 965 958 1060 Scheduled Receipts PAB 1 -2115 -1464 -1354 -1404 -1110 -939 -928 -840 -810 -767 -753 -877 Net Requirement 2285 1634 1524 1574 1280 1109 1098 1010 980 937 923 1047 Planned Order Receipt 2304 1656 1548 1584 1296 1116 1116 1044 1008 972 936 1080 Planned Order Release 230 4 1656 1548 1584 1296 1116 1116 1044 1008 972 936 1080 PAB 2 54 189 192 194 180 186 177 188 204 198 205 183 203 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 7 Tabel 2.3 Master Requirement Planning MRP Komponen Assembly 5 A5 Part No : 2 Description : Assembly 5 BOM UOM : Piece On Hand : 99 Lead Time : 1 Order Policy : Lot for Lot Safety Stock : 180 Lot Size : 66 Period Past Due Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Sep-16 Okt-16 Nov-16 Gross Requirement 2231 1649 1552 1649 1261 1164 1067 1067 970 970 970 1067 Scheduled Receipts PAB 1 -2132 -1405 -1307 -1438 -1049 -959 -838 -849 -763 -743 -789 -866 Net Requirement 2312 1585 1487 1618 1229 1139 1018 1029 943 923 969 1046 Planned Order Receipt 2376 1650 1518 1650 1254 1188 1056 1056 990 924 990 1056 Planned Order Release 2376 1650 1518 1650 1254 1188 1056 1056 990 924 990 1056 PAB 2 99 244 245 211 212 205 229 218 207 227 181 201 190 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 8 Tabel 2.4 Master Requirement Planning MRP Komponen Nose Cover NC Part No : 15 Description : Nose Cover BOM UOM : Piece On Hand : 79 Lead Time : 2 Order Policy : Least Unit Cost Safety Stock : 58 Lot Size : 30 Period Past Due Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei- 16 Jun- 16 Jul-16 Aug-16 Sep-16 Okt-16 Nov-16 Gross Requirement 2231 1649 1552 1649 1261 1164 1067 1067 970 970 970 1067 Scheduled Receipts 2620 2551 PAB 1 -2152 -1581 1137 -512 -1203 -1077 -1004 -991 1640 670 -300 -1007 Net Requirement 2210 1639 570 1261 1135 1062 1049 358 1065 Planned Order Receipt 2220 1650 570 1290 1140 1080 1050 360 1080 Planned Order Release 2220 1650 570 1290 1140 1080 1050 360 1080 PAB 2 79 68 69 1137 58 87 63 76 59 1640 670 60 73 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 9 Tabel 2.5 Distribution Resources Planning DRP Metode Least Unit Cost dari Komponen Nose Cover NC Period Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Sep-16 Okt-16 Nov-16 Demand 2220 1650 570 1290 1140 1080 1050 360 1080 Setup Cost k 100 Holding Cost h 16 Start Period 1: C1 0.05 Start Period 2: C1 0,07 Start Period 4: C1 0,18 C2 6,85 STOP C2 0,07 C2 11,16 STOP C3 8,27 STOP Start Period 5: C1 0,08 Start Period 6: C1 0,09 Start Period 7: C1 0,1 C2 7,55 STOP C2 7,83 STOP C2 7,94 STOP Start Period 8: C1 0,1 Start Period 11: C1 0,28 Start Period 12: C1 0,1 C2 0,1 C2 12,07 STOP C3 0,1 C4 12,33 STOP Order Policy 2220 1650 570 1290 1140 1080 1050 360 1080 Total Cost 900 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 10 Tabel 2.6 Master Requirement Planning MRP Komponen Sub-subassembly 1 SSA1 Part No : 17 Description : Sub-subassembly 1 BOM UOM : Piece On Hand : 72 Lead Time : 1 Order Policy : Lot for Lot Safety Stock : 105 Lot Size : 82 Period Past Due Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Sep-16 Okt-16 Nov-16 Gross Requirement 2304 1656 1548 1584 1296 1116 1116 1044 1008 972 936 1080 Scheduled Receipts PAB 1 -2232 -1510 -1418 -1444 -1182 -986 -954 -932 -874 -862 -814 -910 Net Requirement 2337 1615 1523 1549 1287 1091 1059 1037 979 967 919 1015 Planned Order Receipt 2378 1640 1558 1558 1312 1148 1066 1066 984 984 984 1066 Planned Order Release 237 8 1640 1558 1558 1312 1148 1066 1066 984 984 984 1066 PAB 2 72 146 130 140 114 130 162 112 134 110 122 170 156 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 11 Tabel 2.7 Master Requirement Planning MRP Komponen Prop P Part No : 20 Description : Prop BOM UOM : Piec e On Hand : 59 Lead Time : 1 Order Policy : Find the Optimal Solution Safety Stock : 258 Lot Size : 250 Period Past Due Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Sep-16 Okt-16 Nov-16 Gross Requirement 2304 1656 1548 1584 1296 1116 1116 1044 1008 972 936 1080 Scheduled Receipts 1465 PAB 1 -2245 -1151 -1199 182 -864 -730 -846 -640 -648 -620 -556 -636 Net Requirement 2503 1409 1457 76 1122 988 1104 898 906 878 814 894 Planned Order Receipt 2750 1500 1500 250 1250 1000 1250 1000 1000 1000 1000 1000 Planned Order Release 2750 1500 1500 250 1250 1000 1250 1000 1000 1000 1000 1000 PAB 2 59 505 349 301 432 386 270 404 360 352 380 444 364 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 12 Tabel 2.8 Distribution Resources Planning DRP Metode Silver-Meal Heuristic dari Komponen Prop P Period Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Sep-16 Okt-16 Nov-16 Demand 2750 1500 1500 250 1250 1000 1250 1000 1000 1000 1000 1000 Setup Cost k 109 Holding Cost h 18 Start Period 1: C1 109 Start Period 2: c1 109 Start Period 3: c1 109 C2 13554,5 STOP c2 13554,5 STOP c2 2304.5 STOP Start Period 4: C1 109 Start Period 5: c1 109 Start Period 6: c1 109 C2 11304,5 STOP c2 9054,5 STOP c2 11304.5 STOP Start Period 7: C1 109 Start Period 8: c1 109 Start Period 9: c1 109 C2 9054,5 STOP c2 9054,5 STOP c2 9054.5 STOP Start Period 10: C1 109 Start Period 11: c1 109 Start Period 12: c1 109 STOP C2 9054,5 STOP c2 9054,5 STOP Order Policy 2750 1500 1500 250 1250 1000 1250 1000 1000 1000 1000 1000 Total Cost 1.308 Tabel 2.9 Master Requirement Planning MRP Komponen Assembly 4 A4 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 13 Part No : 3 Description : Assembly 4 BOM UOM : Piece On Hand : 75 Lead Time : 1 Order Policy : Lot for Lot Safety Stock : 109 Lot Size : 79 Period Past Due Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei- 16 Jun-16 Jul-16 Aug-16 Sep-16 Okt-16 Gross Requirement 2376 1650 1518 1650 1254 1188 1056 1056 990 924 990 1056 Scheduled Receipts PAB 1 -2301 -1502 -1361 -1510 -1105 -1029 -900 -929 -813 -789 -831 -939 Net Requirement 2410 1611 1470 1619 1214 1138 1009 1038 922 898 940 1048 Planned Order Receipt 2449 1659 1501 1659 1264 1185 1027 1106 948 948 948 1106 Planned Order Release 2449 1659 1501 1659 1264 1185 1027 1106 948 948 948 1106 PAB 2 75 148 157 140 149 159 156 127 177 135 159 117 167 Tabel 2.10 Master Requirement Planning MRP Komponen Front Wheel FW Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 14 Part No : 14 Description : Front Wheel BOM UOM : Piece s On Hand : 233 Lead Time : 2 Order Policy : Least Unit Cost Safety Stock : 165 Lot Size : 40 Period Past Due Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Sep-16 Okt-16 Gross Requirement 4752 3300 3036 3300 2508 2376 2112 2112 1980 1848 1980 2112 Scheduled Receipts 1145 PAB 1 -4519 -3099 -2855 -1970 -2318 -2174 -1926 -1918 -1778 -1666 -1806 -1918 Net Requirement 4684 3264 3020 2135 2483 2339 2091 2083 1943 1831 1971 2083 Planned Order Receipt 4720 3280 3040 2160 2520 2360 2120 2120 1960 1840 2000 2120 Planned Order Release 4720 3280 3040 2160 2520 2360 2120 2120 1960 1840 2000 2120 PAB 2 233 201 181 185 190 202 186 194 202 182 174 194 202 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 15 Tabel 2.11 Distribution Resources Planning DRP Metode Least Unit Cost dari Komponen Front Wheel FW Period Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Sep-16 Okt-16 Demand 4720 3280 3040 2160 2520 2360 2120 2120 1960 1840 2000 2120 Setup Cost k 150 Holding Cost h 12 Start Period 1: C1 0,04 Start Period 2: C1 0,05 Start Period 3: C1 0,05 C2 4,94 STOP C2 5,8 STOP C2 5,02 STOP Start Period 4: C1 0,07 Start Period 5: C1 0,06 Start Period 6: C1 0,07 C2 6,5 STOP C2 5,84 STOP C2 5,72 STOP Start Period 7: C1 0,08 Start Period 8: C1 0,08 Start Period 9: C1 0,08 C2 6,04 STOP C2 5,81 STOP C2 5,85 STOP Start Period 10: C1 0,09 Start Period 11: C1 0,08 Start Period 12: C1 0,08 C2 6,29 STOP C2 6,22 STOP Order Policy 4720 3280 3040 2160 2520 2360 2120 2120 1960 1840 2000 2120 Total Cost 1.800 Tabel 2.12 Master Requirement Planning MRP Komponen Axle A Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 16 Part No : 19 Description : Axle BOM UOM : Piec e On Hand : 184 Lead Time : 2 Order Policy : Silver-Meal Heuristic Safety Stock : 78 Lot Size : 500 Period Past Due Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Sep-16 Okt-16 Gross Requirement 2378 1640 1558 1558 1312 1148 1066 1066 984 984 984 1066 Scheduled Receipts 532 PAB 1 -2194 -1334 -1392 -1450 -762 -910 -444 -510 -494 -478 -462 -528 Net Requirement 2272 1412 1470 1528 840 988 522 588 572 556 540 606 Planned Order Receipt 2500 1500 1500 2000 1000 1000 1000 1000 1000 1000 1000 1000 Planned Order Release 2500 1500 1500 2000 1000 1000 1000 1000 1000 1000 1000 1000 PAB 2 184 306 166 108 550 238 90 556 490 506 522 538 472 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 17 Tabel 2.13 Distribution Resources Planning DRP Metode Silver-Meal Heuristic dari Komponen Axle A Period Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Sep-16 Okt-16 Demand 2500 1500 1500 2000 1000 1000 1000 1000 1000 1000 1000 1000 Setup Costk 264 Holding Costh 30 Start Period 1: C1 264 Start Period 2: C 1 264 Start Period 3: C1 264 C2 22632 STOP C2 22632 STOP C2 30132 STOP Start Period 4: C1 264 Start Period 5: C1 264 Start Period 6: C1 264 C2 15132 STOP C2 15132 STOP C2 15132 STOP Start Period 7: C1 264 Start Period 8: C1 264 Start Period 9: C1 264 C2 15132 STOP C2 15132 STOP C2 15132 STOP Start Period 10: C1 264 Start Period 11: C1 264 Start Period 12: C1 264 C2 15132 STOP C2 15132 STOP Order Policy 2500 1500 1500 2000 1000 1000 1000 1000 1000 1000 1000 1000 Total Cost 3.168 Tabel 2.14 Master Requirement Planning MRP Komponen Engine E Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 18 Part No : 18 Description : Engine BOM UOM : Piec e On Hand : 206 Lead Time : 1 Order Policy : Part Period Balancing Safety Stock : 200 Lot Size : 50 Period Past Due Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Sep-16 Okt-16 Gross Requirement 2378 1640 1558 1558 1312 1148 1066 1066 984 984 984 1066 Scheduled Receipts 2135 1322 PAB 1 -2172 -1412 -1320 -1328 -1090 -938 1281 1537 553 -431 -765 -831 Net Requirement 2372 1612 1520 1528 1290 1138 631 965 1031 Planned Order Receipt 2400 1650 1550 1550 1300 1150 650 1000 1050 Planned Order Release 2400 1650 1550 1550 1300 1150 650 1000 1050 PAB 2 206 228 238 230 222 210 212 1281 1537 553 219 235 219 Tabel 2.15 Distribution Resources Planning DRP Metode Part Period Balancing dari Komponen Engine E Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 19 Period Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Sep-16 Okt-16 Demand 2400 1650 1550 1550 1300 1150 650 1000 1050 Setup Costk 144 Holding Costh 49 Start Period 1: C1 Start Period 2: C1 Start Period 3: C1 C2 80850 STOP C2 75950 STOP C2 75950 STOP Start Period 4: C1 Start Period 5: C1 Start Period 6: C1 C2 63700 STOP C2 56350 STOP C2 C3 C4 C5 31850 STOP Start Period 10: C1 Start Period 11: C1 Start Period 12: C1 C2 49000 STOP C2 51450 STOP Order Policy 2400 1650 1550 1550 1300 1150 650 1000 1050 Total Cost 1.296 Tabel 2.16 Master Requirement Planning MRP Komponen Assembly 3 A3 Part No : 4 Description : Assembly 3 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 20 BOM UOM : Piece On Hand : 99 Lead Time : 1 Order Policy : Lot for Lot Safety Stock : 172 Lot Size : 93 Period Past Due Okt-15 Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug- 16 Sep-16 Gross Requirement 2449 1659 1501 1659 1264 1185 1027 1106 948 948 948 1106 Scheduled Receipts PAB 1 -2350 -1405 -1325 -1403 -1086 -969 -787 -870 -702 -720 -738 -914 Net Requirement 2522 1577 1497 1575 1258 1141 959 1042 874 892 910 1086 Planned Order Receipt 2604 1581 1581 1581 1302 1209 1023 1116 930 930 930 1116 Planned Order Release 2604 1581 1581 1581 1302 1209 1023 1116 930 930 930 1116 PAB 2 99 254 176 256 178 216 240 236 246 228 210 192 202 Tabel 2.17 Master Requirement Planning MRP Komponen Subassembly 1 SA1 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 21 Part No : 11 Description : Subassembly 1 BOM UOM : Piece On Hand : 80 Lead Time : 1 Order Policy : Lot for Lot Safety Stock : 159 Lot Size : 58 Period Past Due Okt-15 Nov- 15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug- 16 Sep-16 Gross Requirement 2449 1659 1501 1659 1264 1185 1027 1106 948 948 948 1106 Scheduled Receipts PAB 1 -2369 -1476 -1295 -1446 -1086 -995 -862 -924 -770 -732 -752 -930 Net Requirement 2528 1635 1454 1605 1245 1154 1021 1083 929 891 911 1089 Planned Order Receipt 2552 1682 1508 1624 1276 1160 1044 1102 986 928 928 1102 Planned Order Release 255 2 1682 1508 1624 1276 1160 1044 1102 986 928 928 1102 PAB 2 80 183 206 213 178 190 165 182 178 216 196 176 172 Tabel 2.18 Master Requirement Planning MRP Komponen Assembly 2 A2 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 22 Part No : 5 Description : Assembly 2 BOM UOM : Piece On Hand : 165 Lead Time : 1 Order Policy : Lot for Lot Safety Stock : 174 Lot Size : 12 Period Past Due Sep-15 Okt-15 Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Gross Requirement 2604 1581 1581 1581 1302 1209 1023 1116 930 930 930 1116 Scheduled Receipts PAB 1 -2439 -1404 -1401 -1398 -1128 -1029 -840 -936 -750 -756 -750 -942 Net Requirement 2613 1578 1575 1572 1302 1203 1014 1110 924 930 924 1116 Planned Order Receipt 2616 1584 1584 1572 1308 1212 1020 1116 924 936 924 1116 Planned Order Release 2616 1584 1584 1572 1308 1212 1020 1116 924 936 924 1116 PAB 2 165 177 180 183 174 180 183 180 180 174 180 174 174 Tabel 2.19 Master Requirement Planning MRP Komponen Tail Rudder TR Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 23 Part No : 10 Description : Tail Rudder BOM UOM : Piece On Hand : 78 Lead Time : 2 Order Policy : Find the Optimal Solution Safety Stock : 78 Lot Size : 30 Period Past Due Sep-15 Okt-15 Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Gross Requirement 2604 1581 1581 1581 1302 1209 1023 1116 930 930 930 1116 Scheduled Receipts 656 PAB 1 -2526 -1497 -1488 -1479 -1221 -1110 -933 -373 -823 -823 -823 -1009 Net Requirement 2604 1575 1566 1557 1299 1188 1011 451 901 901 901 1087 Planned Order Receipt 2610 1590 1590 1560 1320 1200 1020 480 930 930 930 1110 Planned Order Release 2610 1590 1590 1560 1320 1200 1020 480 930 930 930 1110 PAB 2 78 84 93 102 81 99 90 87 107 107 107 107 101 Tabel 2.20 Distribution Resources Planning DRP Metode Silver-Meal Heuristic dari Komponen Tail Rudder TR Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 24 Period Sep-15 Okt-15 Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Demand 2610 1590 1590 1560 1320 1200 1020 480 930 930 930 1110 Setup Costk 154 Holding Costh 20 Start Period 1: C1 154 Start Period 2: C 1 154 Start Period 3: c1 154 C2 15977 STOP C2 15977 STOP c2 15677 STOP Start Period 4: C1 154 Start Period 5: C1 154 Start Period 6: c1 154 C2 13277 STOP C2 12077 STOP c2 10277 STOP Start Period 7: C1 154 Start Period 8: C1 154 Start Period 9: c1 154 C2 4877 STOP C2 9377 STOP c2 9377 STOP Start Period 10: C1 154 Start Period 11: C1 154 Start Period 12: c1 154 C2 9377 STOP C2 11177 STOP Order Policy 2610 1590 1590 1560 1320 1200 1020 480 930 930 930 1110 Total Cost 1.848 Tabel 2.21 Master Requirement Planning MRP Komponen Rear Wheel RW Part No : 12 Description : Rear Wheel Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 25 BOM UOM : Piece On Hand : 57 Lead Time : 1 Order Policy : Wagner-Whitin Method Safety Stock : 200 Lot Size : 10 Period Past Due Sep-15 Okt-15 Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Gross Requirement 2552 1682 1508 1624 1276 1160 1044 1102 986 928 928 1102 Scheduled Receipts 2056 PAB 1 -2495 -1477 -1305 -1419 -1075 -955 -839 -901 -777 -725 1333 231 Net Requirement 2695 1677 1505 1619 1275 1155 1039 1101 977 925 Planned Order Receipt 2700 1680 1510 1620 1280 1160 1040 1110 980 930 Planned Order Release 2700 1680 1510 1620 1280 1160 1040 1110 980 930 PAB 2 57 205 203 205 201 205 205 201 209 203 205 1333 231 Tabel 2.22 Distribution Resources Planning DRP Metode Wagner-Whitin dari Komponen Rear Wheel RW Period Sep-15 Okt-15 Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Setup Cost k Holding Cost h Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 26 Demand 2700 1680 1510 1620 1280 1160 1040 1110 980 930 133 15 1 133 25333 70633 143533 220333 307333 400933 517483 635083 760633 760633 760633 2 133 45433 118333 195133 282133 375733 492283 609883 735433 735433 735433 3 133 73033 149833 236833 330433 446983 564583 690133 690133 690133 4 133 76933 163933 257533 374083 491683 617233 617233 617233 5 133 87133 180733 297283 414883 540433 540433 540433 6 133 93733 210283 327883 453433 453433 453433 7 133 116683 234283 359833 359833 359833 8 133 117733 243283 243283 243283 9 133 125683 125683 125683 10 133 133 133 11 133 133 12 133 Tabel 2.22 Distribution Resources Planning DRP Metode Wagner-Whitin dari Komponen Rear Wheel RW lanjutan 1 2 3 4 5 6 7 8 9 10 11 12 1 133 25333 70633 143533 220333 307333 400933 517483 635083 760633 760633 760633 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 27 2 266 45566 118466 195266 282266 375866 492416 610016 735566 735566 735566 3 399 73299 150099 237099 330699 447249 564849 690399 690399 690399 4 532 77332 164332 257932 374482 492082 617632 617632 617632 5 665 87665 181265 297815 415415 540965 540965 540965 6 798 94398 210948 328548 454098 454098 454098 7 931 117481 235081 360631 360631 360631 8 1064 118664 244214 244214 244214 9 1197 126747 126747 126747 10 1330 1330 1330 11 1463 1463 12 1596 Min 133 266 399 532 665 798 931 1064 1197 1330 1463 1596 Total Cost 1.596 Tabel 2.23 Master Requirement Planning MRP Komponen Rear Wheel Mount RM Part No : 13 Description : Rear Wheel Mount BOM UOM : Piece On Hand : 25 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 28 Lead Time : 1 Order Policy : Least Unit Cost Safety Stock : 150 Lot Size : 10 Period Past Due Sep-15 Okt-15 Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Gross Requirement 2552 1682 1508 1624 1276 1160 1044 1102 986 928 928 1102 Scheduled Receipts 1568 PAB 1 -2527 -1529 -1357 -1471 -1117 -1007 -891 -943 -829 791 -137 -949 Net Requirement 2677 1679 1507 1621 1267 1157 1041 1093 979 287 1099 Planned Order Receipt 2680 1680 1510 1630 1270 1160 1050 1100 980 290 1100 Planned Order Release 2680 1680 1510 1630 1270 1160 1050 1100 980 290 1100 PAB 2 25 153 151 153 159 153 153 159 157 151 791 153 151 Tabel 2.24 Distribution Resources Planning DRP Metode Least Unit Cost dari Komponen Rear Wheel Mount RM Period Sep-15 Okt-15 Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Aug-16 Demand 2680 1680 1510 1630 1270 1160 1050 1100 980 290 1100 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 29 Setup Cost k 100 Holding Cost h 19 Start Period 1: C1 0,04 Start Period 2: C1 0,06 Start Period 3: C1 0,07 C2 7,35 STOP C2 9,03 STOP C2 9,9 STOP Start Period 4: C1 0,07 Start Period 5: C1 0,08 Start Period 6: C1 0,09 C2 8,36 STOP C2 9,12 STOP C2 9,08 STOP Start Period 7: C1 0,1 Start Period 8: C1 0,1 Start Period 9: C1 0,11 C2 9,77 STOP C2 9 STOP C2 0,11 C3 4,42 STOP Start Period 11: C1 0,35 Start Period 12: C1 0,1 C2 15,11 STOP Order Policy 2680 1680 1510 1630 1270 1160 1050 1100 980 290 1100 Total Cost 1.100 Tabel 2.25 Master Requirement Planning MRP Komponen Assembly 1 A1 Part No : 6 Description : Assembly 1 BOM UOM : Piece On Hand : 200 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 30 Lead Time : 1 Order Policy : Lot for Lot Safety Stock : 122 Lot Size : 46 Period Past Due Aug-15 Sep-15 Okt-15 Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Gross Requirement 2616 1584 1584 1572 1308 1212 1020 1116 924 936 924 1116 Scheduled Receipts PAB 1 -2416 -1424 -1444 -1406 -1150 -1074 -898 -956 -776 -792 -796 -992 Net Requirement 2538 1546 1566 1528 1272 1196 1020 1078 898 914 918 1114 Planned Order Receipt 2576 1564 1610 1564 1288 1196 1058 1104 920 920 920 1150 Planned Order Release 257 6 1564 1610 1564 1288 1196 1058 1104 920 920 920 1150 PAB 2 200 160 140 166 158 138 122 160 148 144 128 124 158 Tabel 2.26 Master Requirement Planning MRP Komponen Rear Flap RF Part No : 9 Description : Rear Flap BOM UOM : Pieces On Hand : 169 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 31 Lead Time : 2 Order Policy : Silver-Meal Heuristic Safety Stock : 200 Lot Size : 20 Period Past Due Aug-15 Sep-15 Okt-15 Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Gross Requirement 5232 3168 3168 3144 2616 2424 2040 2232 1848 1872 1848 2232 Scheduled Receipts 2050 815 PAB 1 -5063 -2951 -2959 -2943 -2399 -173 -1833 -2025 -1633 -850 -1638 -2030 Net Requirement 5263 3151 3159 3143 2599 373 2033 2225 1833 1050 1838 2230 Planned Order Receipt 5280 3160 3160 3160 2600 380 2040 2240 1840 1060 1840 2240 Planned Order Release 5280 3160 3160 3160 2600 380 2040 2240 1840 1060 1840 2240 PAB 2 169 217 209 201 217 201 207 207 215 207 210 202 210 Tabel 2.27 Distribution Resources Planning DRP Metode Silver-Meal Heuristic dari Komponen Rear Flap RF Period Aug-15 Sep-15 Okt-15 Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Jul-16 Demand 5280 3160 3160 3160 2600 380 2040 2240 1840 1060 1840 2240 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 32 Setup Cost k 99 Holding Cost h 22 Start Period 1: C1 99 Start Period 2: C1 99 Start Period 3: C1 99 C2 34809.,5 STOP C2 34809,5 STOP C2 34809,5 STOP Start Period 4: C1 99 Start Period 5: C1 99 Start Period 6: C1 99 C2 28649,5 STOP C2 4229,5 STOP C2 22489,5 STOP Start Period 7: C1 99 Start Period 8: C1 99 Start Period 9: C1 99 C2 24689,5 STOP C2 20289,5 STOP C2 11709,5 STOP Start Period 10: C1 99 Start Period 11: C1 99 Start Period 12: C1 99 C2 20289,5 STOP C2 24689,5 STOP Order Policy 5280 3160 3160 3160 2600 2440 2040 2220 1860 1860 1860 2220 Total Cost 1.188 Tabel 2.28 Master Requirement Planning MRP Komponen Main Body MB Part No : 7 Descriptio n : Main Body BOM UOM : Piece On Hand : 56 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 33 Lead Time : 1 Order Policy : Part Period Balancing Safety Stock : 111 Lot Size : 1 Period Past Due Jul-15 Aug-15 Sep-15 Okt-15 Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Gross Requirement 2576 1564 1610 1564 1288 1196 1058 1104 920 920 920 1150 Scheduled Receipts PAB 1 -2520 -1453 -1499 -1453 -1177 -1085 -947 -993 -809 -809 -809 -1039 Net Requirement 2631 1564 1610 1564 1288 1196 1058 1104 920 920 920 1150 Planned Order Receipt 2631 1564 1610 1564 1288 1196 1058 1104 920 920 920 1150 Planned Order Release 2631 1564 1610 1564 1288 1196 1058 1104 920 920 920 1150 PAB 2 56 111 111 111 111 111 111 111 111 111 111 111 111 Tabel 2.29 Distribution Resources Planning DRP Metode Part Period Balancing dari Komponen Main Body MB Period Jul-15 Aug-15 Sep-15 Okt-15 Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Demand 2631 1564 1610 1564 1288 1196 1058 1104 920 920 920 1150 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 34 Setup Cost k 200 Holding Cost h 36 Start Period 1: C1 Start Period 2: C1 Start Period 3: C1 C2 56304 STOP C2 57960 STOP C2 56304 STOP Start Period 4: C1 Start Period 5: C1 Start Period 6: C1 C2 46368 STOP C2 43056 STOP C2 38088 STOP Start Period 7: C1 Start Period 8: C1 Start Period 9: C1 C2 39744 STOP C2 33120 STOP C2 33120 STOP Start Period 10: C1 Start Period 11: C1 Start Period 12: C1 C2 33120 STOP C2 41400 STOP C2 Demand 2631 1564 1610 1564 1288 1196 1058 1104 920 920 920 1150 Total Cost 2.400 Tabel 2.30 Master Requirement Planning MRP Komponen Front Flap FF Part No : 8 Description : Front Flap BOM UOM : Pieces On Hand : 300 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 35 Lead Time : 1 Order Policy : Find the Optimal Solution Safety Stock : 350 Lot Size : 100 Period Past Due Jul-15 Aug-15 Sep-15 Okt-15 Nov-15 Des-15 Jan-16 Feb-16 Mar-16 Apr-16 Mei-16 Jun-16 Gross Requirement 10304 6256 6440 6256 5152 4784 4232 4416 3680 3680 3680 4600 Scheduled Receipts 862 PAB 1 -10004 -5860 -6000 -5856 -4708 -4392 -3824 -4040 -3320 -2438 -3318 -4218 Net Requirement 10354 6210 6350 6206 5058 4742 4174 4390 3670 2788 3668 4568 Planned Order Receipt 10400 6300 6400 6300 5100 4800 4200 4400 3700 2800 3700 4600 Planned Order Release 10400 6300 6400 6300 5100 4800 4200 4400 3700 2800 3700 4600 PAB 2 300 396 440 400 444 392 408 376 360 380 362 382 382 Tabel 2.31 Distribution Resources Planning DRP Metode Silver-Meal Heuristic dari Komponen Front Flap FF Period Jul-15 Aug-15 Sep-15 Oct-15 Nov-15 Dec-15 Jan-16 Feb-16 Mar-16 Apr-16 May- 16 Jun-16 Demand 10400 6300 6400 6300 5100 4800 4200 4400 3700 2800 3700 4600 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 36 Setup Costk 163 Holding Costh 24 Start Period 1: C1 163 Start Period 2: C1 163 Start Period 3: C1 163 C2 75681,5 STOP C2 76881,5 STOP C2 75681,5 STOP Start Period 4: C1 163 Start Period 5: C1 163 Start Period 6: C1 163 C2 61281,5 STOP C2 57681,5 STOP C2 50481,5 STOP Start Period 7: C1 163 Start Period 8: C1 163 Start Period 9: C1 163 C2 52881,5 STOP C2 44481,5 STOP C2 33681,5 STOP Start Period 10: C1 163 Start Period 11: C1 163 Start Period 12: C1 163 STOP C2 44481,5 STOP C2 55281,5 STOP Order Policy 10400 6300 6400 6300 5100 4800 4200 4400 3700 2800 3700 4600 Total Cost 1,956 Integrated Industrial Engineering Laboratory Industrial Engineering Department BINUS University 37 Production Operation Analysis ISYE6101

2.2 Contoh Perhitungan MRP