Hosuki Case Problem

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Hosuki, a small car maker, competes with larger manufacturers by building cars to order. The company has invested heavily in technology and close partnerships with suppliers. Customers enter their orders and choose their options on the company website. Hosuki's ERP system responds with an estimated cost and completion date. After the customer approves the order, Hosuki sets to work.
Quick response for Hosuki is dependent on collaborative manufacturing with its trading partners. A virtual bill of material for a typical car appears below. Notice each item is color-coded to its supplier and indented beneath its parent assembly. Hosuki has full visibility into its suppliers' ERP systems to check on-hand quantities and order progress. These data are essential in quoting accurate due dates. Most of the car's components are purchased. Hosuki makes the car body, assembles major subassemblies, and completes final assembly and testing. The body stamping machine operates eight hours a day; setup times per item and run times per unit are given in the next column.
Since the suppliers produce in high volume, the lead time for an order is the same regardless of the quantity of the order. In contrast, with limited sales volume and limited space, Hosuki assembles its cars in batches of 10. Each assembly process takes half a day.
 
Hosuki has just received its first corporate order—for 10 midsized vehicles. The customer would like delivery as soon as possible.
1.  
Create a time-phased assembly chart to determine when the 10 cars can be delivered.
2.  
What adjustments are needed in inventory levels, lead times, and batch sizes to fill an additional customer order for five custom cars in five days?
Virtual Bill of Material
 ItemQty
 Midsize car1
 Chassis Assembly1
 Frame1
 Power Train Subassembly1
 Engine1
 Transmission1
 Radiator1
 Battery1
 Suspension Subassembly1
 Shocks2
 Brakes1
 Body Assembly1
 Windshield1
 Seats4
 Tire Assembly4
 Wheels1
 Rims1
 Tires1
Supplier
ABCDEFHosuki
Supplier lead time is given in days
Supplier A
 OHLT
Shocks201
Barkes 24
Supplier B
 OHLT
Seats62
Supplier C
 OHLT
Wheels201
Rims 22
Tires105
Supplier D
 OHLT
Frame102
Windshield 54
Supplier E
 OHLT
Engine 55
Transmission106
 Supplier F
 OHLT
Radiator101
Battery 53
Hosuki's Body Stamping Machine
 QtySetup (hrs)Runtime (hrs/unit)
Qtr Panel420.5
Hood110.2
Fender220.3
Roof120.2
Doors (LH, RH)420.2
 
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    • Posted: 5 years ago
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      OMD8

      please see attached document