Rockwell Automation FactoryTalk Scheduler Users Guide - Manual (Page 17)

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3
The Factory Overview
The BizBikes manufacturing system
To begin our assessment of the BizBikes factory, we’ll first examine their manufacturing
system and learn about the factory resources and processes. We will then use this model to
examine possible scenarios for improving our performance.
Bill of materials
The bill of materials for BizBikes contains three levels, as shown below, for a generic end
item. There are actually four end items (or BizBikes), 15 unique manufactured items, and
five purchased parts. The shaded items in the bill of materials represent manufactured
components. This generic bill of materials also includes information on manufacturing
lead times, number required per subassembly, and lot size information.
The Manufacturing Resource Planning system
BizBikes employs a Manufacturing Resource Planning (MRP) system that performs
master planning and scheduling of weekly production. The MRP system consolidates
orders from multiple customers and plans the purchase and manufacturing of the
associated components. The MRP produces a set of manufacturing orders that are
released to the factory floor. These manufacturing orders are for both component parts
FINAL
ASSEMBLY
AND PACK
(1,1,1)
PEDAL AND
CHAIN
ASSEMBLY
(3,1,60)
HANDLEBAR
(3,1,100)
FINISHED
FRAME
(1,1,24)
NECK POST
(3,1,60)
WHEELS
(3,1,48)
FRAME
(4,1,50)
HANDLEBAR
ASSEMBLY
(1,1,75)
DERAILLEUR
ASSEMBLY
(4,1,60)
BRAKES
(2,1,75)
SEAT POST
(3,1,100)
SEAT
ASSEMBLY
(1,1,75)
SEAT
(2,1,100)
KEY: (Lead Time, Quantity, Lot Size)