Beruflich Dokumente
Kultur Dokumente
(MRP)
MN 4110
Mrs. P. S. T. Perera
Lecture # 12
Objectives
Define the term MRP
Discuss input, output, and the MRP process
Describe MRP11
Describe ERP
MRP Defined
MRP is a tool for determining the
number of parts, components, and
materials needed to produce a
product.
Provides time scheduling information specifying
Purposes of MRP
Control Inventory.
(Exception messages)
The orders could be purchase orders,
manufacturing orders or transfer orders.
Product Structure
Clipboard
Pivot (1)
Spring (1)
Rivets (2)
Finished clipboard
Pressboard (1)
Pressboa
rd (1)
Top Clip
(1)
Level
0
Clip Assy
(1)
Bottom
Clip (1)
Rivet
s (2)
Pivo
t
(1)
Level
1
Sprin
g (1)
Level
2
0--1--2
--2
--2
-1-1-
BA
320
ITEM
Clipboard
Clip Assembly
Top Clip
Pivot
Spring
Rivet
Press Board
u
u
u
u
u
u
u
1
1
1
1
1
2
1
Items
On
Hand
Lead Time
Order Qty
Safety
Stock
Raw material A
200
4 weeks
75
100
Part X
120
2 weeks
75
100
Component Y
100
2 weeks
50
100
Raw material B
500
3 weeks
400
300
Pegging
Etc.
11
Aggregate Plan
(Product Groups)
MPS
(Specific End Items)
12
products
Quantities represent production not demand
Quantities may consist of a combination of
customer orders and demand forecasts
Quantities represent what needs to be
produced, not what can be produced
Quantities represent end items that may or
may not be finished products
MPS ITEM
Clipboard
Lapdesk
Lapboard
Pencil Case
BA
320
1
85
0
75
125
PERIOD
2
3
4
95
50
120
125
120
0
47
125
100
50
20
125
5
100
0
17
125
Month
Mattress production
900
950
Master Production
Schedule for
Mattresses Model
1
Model 327
Model 538
Model 749
200
400
100
100
100
200
100
150
100
200
200
date.
Revision of a previous action.
Time Periods
1
Requirements
Orders
10
10 10
10 10
10 10
MRP System
Based on MPS details, MRP system
Creates
Determines
Determines
17
18
Firm orders
from known
customers
Aggregate
product
plan
Forecasts
of demand
from random
customers
Engineering
design
changes
Master
production
schedule
(MPS)
Inventory
transactions
Bill of
material
file
Material
planning
(MRP)
Inventory
record
file
Reports
18
time.
Order release notices to execute the
planned orders.
Changes in due dates of open orders due
to re-scheduling.
Cancellations or suspensions of open
orders due to changes in MPS
Inventory status to show the stock levels
19
20
Sequence of Events in
MRP
Enter independent demands
Enter Independent
Demand
Build MPS
Generate RCCP
Feasible
?
No
MRP Generation
CRP Generation
Feasible
?
Execute Final Plan
No
Components of MRP
Items: Children of the parent
Demand: can be dependent (children to parent) or
shrinkage, scrap
process item
22
Advantages MRP
Reduced inventory.
Better customer service.
Better response to market demands.
Ability to change the master schedule.
Support managers to plan schedule before
23
Disadvantages of MRP
MRP assumes infinite capacity (doesnt look at
resources constraints)
MRP generation can take more time / always in a
batch mode and therefore lacks the dynamics to
react to change
Lead time is assumed to be fixed and definable,
Use of forecasts has its weakness forecast are
wrong usually
MRP does not recognize job operation activity,
only the completion of units.
Lack of knowledge about MRP among the users.
Integration problems of MRP and JIT.
24
MRP Terminology
Gross Requirements
Projected on-hand
Net requirements
Planned order receipt
Planned order release
Open order
Net
Gross
Inventory Scheduled Safety Inventory allocated
requirements
requirements on hand
receipts
stock
to other uses
25
A
B(4)
D(2)
26
C(2)
E(1)
D(3)
F(2)
Lead Times
A 1 day
B 2 days
C 1 day
D 3 days
E 4 days
F 1 day
Demand
Day 10 50 A
Day 8
20 B (Spares)
Day 6
15 D (Spares)
9
50
LT = 1 day
27
10
50
20
20
LT = 2
A
B(4)
28
D(2)
D(3)
200
Spares
4x50=200
C(2)
E(1)
50
200
F(2)
10
50
A
Part D: Day 6
B(4)
29
D(2)
C(2)
E(1)
D(3)
40 + 15 spares
F(2)
Required
Order Placement
Required
Order Placement
Required
Order Placement
Required
Order Placement
Required
Order Placement
Required
Order Placement
20
20
50
200
200
100
55
20
400
55
400
20
200
100
300
300
200
200
200
A
Part D: Day 6
B(4)
30
D(2)
C(2)
E(1)
D(3)
40 + 15 spares
F(2)
10
50
MRP Example - 2
Item
X
A
B
C
D
X
A(2)
C(3)
B(1)
C(2)
D(5)
31
1
A
B
C
D
7
10
15
9
12
10
32
33
No
Feedback
Realistic?
Yes
Execute:
Capacity Plans
Material Plans
Feedback
MRP II Defined
Manufacturing Resource
Planning
A tool to support planning of all
35
MRP II - Goal
36
Components of MRP II
Includes all the elements of MRP
Use of existing load information
(Schedule)
Shop Calendar, Units of Capacity
(machine / people hours), routings
What-if capability
Scheduling Modifiers
Allow finite or infinite capacity planning
Forward and backward scheduling
Efficiency and utilization rates
37
Sequence of Events of
MRP II
Supply a business plan
Supply a sales and operation plan
38
Business Plan
Sales & Operation
Plan
Production Plan
Feasible
?
Build MPS
MRP Generation
CRP Generation
Feasible
?
F
E
E
D
B
A
C
K
ERP Modules