Beruflich Dokumente
Kultur Dokumente
Planning
12-Apr-16
MRP
DETAILED SCHEDULE FOR
RAW MATERIALS &
Dependent demand
lumpy
12-Apr-16
COMPONENTS
USED IN THE END PRODUCTS
2
Independent Demand:
Demand unrelated to demand of other products
(end products, spare parts)
Usually forecast
Conventional inventory control (EOQ,
Wagner/Whitin) applicable.
12-Apr-16
Dependent Demand:
Demand directly related to demand of some
other product (components, raw materials,
subassemblies)
Requirements derived from delivery schedule
of end items.
MRP is the appropriate tool for planning &
control of manufacture inventories
raw materials
WIP
Component parts
Subassemblies
12-Apr-16
LUMPY DEMAND
Avg.
rate of
demand
CONTINUOUS DEMAND
Assumed in economic lot size
formula
Inv.
LEVEL
TIME
Inv.
LEVEL
t1 t2
t3
t4 t5
t6
LUMPY DEMAND
TYPICAL OF MRP
APPLICATIONS
(raw materials, components
sub-assemblies consumed in
Large increments
corresponding to a certain
batch of final product)
TIME
12-Apr-16
LEAD TIMES
Ordering Lead Time:
(for purchased parts)
Initiation of
purchase
requisition
Place order
Item delivered
INPUTS TO MRP
The master production schedule and other
order data.
12-Apr-16
C1
C2
C3
Cn
PRODUCTS
P1
P2
P3
PN
Sales
forecasts
Service
Parts
requirements
Engg.
changes
Master
Production
schedule
Inventory
transactions
Bill of
Materials
file
MRP
PROCESSOR
Inventory
Record
file
OUT PUT
REPORTS
Gross &
Net requirements
report
12-Apr-16
Capacity vs
Load report
Shop floor
Planning
report
Production Order
Status & exceptions
report
9
Product P1
Product P2
50
70
80
10
100
25
Etc.
DEMAND
Forecasted demand
10
Level 0
(product)
P1
Level 1
(sub-assemblies)
Level 2
(raw materials)
S1
C1
C2
(1)
S2
(1)
C3
(4)
C4
(1)
(2)
C5
(2)
C6
(2)
(1)
11
Ordering
Lead time
Manufacturing
Lead time
Purchasing
records
Process
Route
sheets
12
P1
S1
C1
(1)
C2
S2
(1)
C3
(4)
(1)
C4
(2)
C5
S3
(2)
(2)
C6
(1)
C4
(1)
S4
(1)
C6
C7
(4)
(2)
C2
(1)
C8
(2)
(1)
M4
7
70
8
50
80
Master
Production
Schedule
10
100
25
Manufacturing
Ordering
P1 = 1
P2 = 1
S2 = 1
S3 = 1
C4 = 2
M4 = 3
13
14
PERIOD
10
ITEM PRODUCT P1
GROSS REQUIREMENTS
50
100
50
100
SCHEDULED RECEIPTS
ON HAND
NET REQUIREMENTS
PLANNED ORDER RELEASES
50
100
ITEM PRODUCT P2
GROSS REQUIREMENTS
70
80
25
70
80
25
80
25
SCHEDULED RECEIPTS
ON HAND
NET REQUIREMENTS
PLANNED ORDER RELEASES
12-Apr-16
70
15
PERIOD
10
100
200
100
200
SCHEDULED RECEIPTS
ON HAND
NET REQUIREMENTS
PLANNED ORDER RELEASES
100
200
70
80
25
70
80
25
80
25
SCHEDULED RECEIPTS
ON HAND
NET REQUIREMENTS
12-Apr-16
70
16
PERIOD
10
ITEM COMPONENT C4
GROSS REQUIREMENTS
70
280
25
400
70
280
25
400
SCHEDULED RECEIPTS
ON HAND
NET REQUIREMENTS
PLANNED ORDER RELEASES
70
280
25
400
GROSS REQUIREMENTS
70
280
25
400
SCHEDULED RECEIPTS
40
25
400
ON HAND
50
NET REQUIREMENTS
PLANNED ORDER RELEASES
12-Apr-16
260
90
20
-20
260
25 400
17
18
future periods.
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19
BENEFITS OF MRP
12-Apr-16
20
EVOLUTION OF MRP
Improved
computational
efficiency of
computers
Unrealistic M/c
schedules, ignoring
plant capacities
PRIORITY PLANNING
MRP II
Manufacturing
Resource
Planning
(Links functions
-Capacity planning
-Inventory management
-Shop floor control
-MRP)
21
Class B
System has MRP, capacity planning shop floor control,
but no vendor scheduling
Used as a production control system
Needs help from shortage list
Inventory higher than need be
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22
Class D (beginner)
mismanaged
Relies on shortage list & expediting rather than MRP
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23
IT IS A SIMULATOR
What if questions
Simulate probable outcomes of alternative production
plans and management decisions.
12-Apr-16
24
SUMMARY
25
SUMMARY (Contd)
26