MPS ^M MRP ^M Kanban yujimodzoomin.idt.mdh.se/course/ppu426/MPS MRP Kanban.pdf · • Kanban...
Transcript of MPS ^M MRP ^M Kanban yujimodzoomin.idt.mdh.se/course/ppu426/MPS MRP Kanban.pdf · • Kanban...
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Yuji Yamamoto
PPU426
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Today’s topic
• What is MPS and MRP
• Developing MPS
• How to make MRP
• Enterprise Resource Planning
• Kanban system
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Production planning and scheduling
Demand
1,400pcs/m for coming months
How many to make?How much to work?
Production planning
What model/part to make until when?
Resource planning
MPSScheduling
Lets make 1,200pcs/mwith overtime!
MRP
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What is Master Production Schedule (MPS)?
1200 1200Volume per month
Model A
Model B
Model C
500
300
500
300
A schedule showing how many end items need to be produced within specified period of time
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What is Material Resource Planning (MRP)?
x10
x3
Translate MPS into the requirement of what parts are needed when, in order to make the end item
1w 1w
(2w to get purchasedparts)
500 pcsat week n!
When to order? How many?=1500pcsWeek n-4
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MPR is for dependent demand
x10
x3
Independent demand
Marketdemand
Dependent demand(Dependent on the constitute of the product)
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Bill of Material (BOM)
x10
x3
Information of parent-component relationship
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Bill of Material (BOM)
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MRP exploration
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Developing MPS
Lot size 150 units, Lead time 1w
Forecast
Booked orders
Projected on-hand inventory
MPS quantity
MPS Start
How many items left at the end of the week?
How many items to be completed in this week?
I week lead time
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Developing MPS
Lot size 150 units, Lead time 1w
Forecast
Booked orders
Projected on-hand inventory
MPS quantity
MPS Start
Development of MPS
• Calculate product on-hand inventory
• Decide MPS quantity and MPS start
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Calculation of Projected on-hand inventory
= + –Projected on-hand
inventory at endof this week
On-handinventory at
end of last week
MPS quantitydue at startof this week
Projectedrequirements
this week
where:
Projected requirements = max(Forecast, Customer orders booked)
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Calculation of Projected on-hand inventory
Lot size 150 units, Lead time 1w
Forecast
Booked orders
Projected on-hand inventory
MPS quantity
MPS Start
= 55 + 0 - 38
= 17 + 150 - 30
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If we do not produce anything….
Lot size 150 units, Lead time 1w
Forecast
Booked orders
Projected on-hand inventory
MPS quantity
MPS Start
-13 -43 -73 -108 -143 -178 -….
Add lot size to avoid out of stockAdd lot size to avoid out of stock
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Developing MPS
Lot size 150 units, Lead time 1w
Forecast
Booked orders
Projected on-hand inventory
MPS quantity
MPS Start
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Making MRP
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Making MRP
Inventory record
BOM
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Inventory record
Gross requirement
Total demand from parent’s MPS
Scheduled receipts
Order actually placed and to be completed this week
Projected on-hand inventory
Planned receipts
The amount should be completed to avoid out of stock
Lot size 230 units, Lead time 2w
Planned order release
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Calculation of Projected on-hand inventory
Gross requirement
Scheduled receipts
Projected on-hand inventory
Planned receipts
Lot size 230 units, Lead time 2w
= 37 + 230 - 150
= 117 + 230 - 120
Planned order release
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Lot size rules
• Fixed order quantity (FOQ)
• Periodic order quantity
• Lot for LotAs shown in the previous slides.Lot size can be decided by…
• Discount• Truckload capacity• Minimum purchased quantity• EOQ• etc.
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Periodic order quantity
Gross requirement
Scheduled receipts
Projected on-hand inventory
Planned receipts
TBO (P) = 3, Lead time 2w
Planned order release
We know when but how many to order?We know when but how many to order?
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Calculation of Periodic order quantity
= –POQ lot size to arrive in
week t
Total gross requirementsfor P week, including
week t
Projected on-hand inventory balance at
end of week t–1
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Calculation of POQ
Gross requirement
Scheduled receipts
Projected on-hand inventory
Planned receipts
TBO (P) = 3, Lead time 2w
Planned order release
Need to make sure we do not get out of stock until the next fill-up
= 120 + 0 + 150 -117
153
150 150 0
0
= 120 + 0 + 0 - 0
0 0
120
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Lot for Lot
Gross requirement
Scheduled receipts
Projected on-hand inventory
Planned receipts
Order any week, Lead time 2w
Planned order release
Order any week so that inventory will not be below zero
Order any week so that inventory will not be below zero
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Lot for Lot
Gross requirement
Scheduled receipts
Projected on-hand inventory
Planned receipts
Order any week, Lead time 2w
Planned order release
3
3
0 0 -150
150
150
0 -120
120
120
0 0
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Comparison of Lot-sizing rules
Average inventory from week 4 to 8:
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EXAMPLE 5MRP explosion
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Inventory recordD E F
Lot size rule FOQ =150 Lot for Lot POQ, P=2Lead time 3 w 1 w 2 wSafety stock 40 0 30Scheduled receipts 250
(week 1)120(week 2)
None
Beginning inventory 150 0 100
MPSItem Qty Due
(week)Leadtime
A 80 4 1A 55 7 1B 125 7 2C 60 7 3
Question: Develop MRP for D, E, F for the next 8 weeks
BOM
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Solution
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Solution
Gross requirement for D
80x2
125
60x2
55x2
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ITEM D150
1 2 3 4 5 6 7 8
Gross requirement 160 120 125 110
Scheduled receipts 250
Projected on-hand inventoryPlanned receiptsPlanned order release
FOQ = 150, LT= 3, Safety stock = 40Inventory beginning 150
Scheduled receipts 250 at w1
400 400 240 120 -5
150
150
Order when lower than 40
145 35
150
150
185 185 185
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Solution
Gross requirement for E
80
125x2
60x2
55
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ITEM E0
1 2 3 4 5 6 7 8
Gross requirement 80 120 250 55
Scheduled receipts 120
Projected on-hand inventoryPlanned receiptsPlanned order release
Lot for Lot, LT= 1, Safety stock = 0Inventory beginning 0
Scheduled receipts 120 at w2
0 120 40 -80
80
250
0
250 55
0 0 00
5580
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Solution
Gross requirement for F
ITEM E0
1 2 3 4 5 6 7 8
Planned order release
80 250 55
80x2 250x2 55x2
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ITEM F100
1 2 3 4 5 6 7 8
Gross requirement 160 500 110
Scheduled receiptsProjected on-hand inventoryPlanned receiptsPlanned order release
POQ P=2, LT= 2, Safety stock = 30Inventory beginning 100
Scheduled receipts none
100 100 -60
160+500+30-100
590
590
530 30 -80
110+0+30-30
Make sure no out of stock until the next fill-up + Safety stock 30
110
110
30 30 30 30
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Today’s topic
• What is MPS and MRP
• Developing MPS
• How to make MRP
• Enterprise Resource Planning
• Kanban system
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What is Enterprise Resource Planning (ERP)?A large integrated information system. It supports operations processes through data processing and storage.
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Problems with MRP
• MPR works only when everything goes as planned
• Otherwise it often makes situation worse!
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Problems with MRP: examples
MRP
LT is fixed inMPR
LT in reality Set LT worst scenario
Not possible to update all the LT data
Table is not reliable
Run with own adjustment
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Problems with MRP: examples
MRP
Inventory/Q/when
Can tell out of stock (delay) but not tell when ready No recovery
plan until we know when ready
Planner running around the factory
Not consider capacity
Req. amount
Run with own adjustment,Changing LT
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Problems with MRP
• MPR works only when everything goes as planned
• Otherwise it often makes situation worse!
It’s like planning an efficient trip with
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Kanban system
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Kanban system
Prerequisite of using Kanban system
• Flow production• Small batch production• Pull production• Leveling production• Relatively steady demand on end item• Frequent internal transport (mizusumashi)• Small standardized containers• Fixed address for containers
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Conventional production (mass production)Resource efficiency focus
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Flow production
Flow efficiency focus
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• Stability in machines and equipment
• Stability in quality
• Stability in man power
• Stability of material supply from suppliers
Flow production requires stability
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Sensitiveness till disturbances is an improvement opportunity
DefectsLack of parts
Machine break down
High inventory level (work-in-process) can hide problems
With low inventory level, you can easily identify problems
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MRPPush production
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Sold Product A
Make A
Flow production + Pull production
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Leveling productionTo meet demand and keep inventories low, a “level” schedule is developed so that the same mix of products is made every day in small quantities.
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Kanban system
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Kanban system
Advantage:
• Prevent overproduction• Prevent mismatch between information and
actual things• Visualize information flow• etc.
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Relevant book chapters
• Chapter: “Planning sufficient resources”
• Chapter: “Designing and managing processes”:– The Kanban system.