SCM4
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Transcript of SCM4
Material Requirements Material Requirements PlanningPlanning
Materials Requirements Materials Requirements PlanningPlanning
Material Requirements Planning (MRP)MRP Logic and Product Structure
TreesMRP ExampleLot Sizing in MRP Programs
Material Requirements Material Requirements PlanningPlanning
Materials requirements planning (MRP) is the logic for determining the number of parts, components, and materials needed to produce a product.
MRP provides time scheduling information specifying when each of the materials, parts, and components should be ordered or produced.
Dependent demand drives MRP.MRP is a software system.
Independent Demand Independent Demand Inventory SystemsInventory Systems
Demand for an item carried in inventory is independent of the demand for any other item in inventory
Finished goods inventory is an example
Demands are estimated from forecasts and/or customer orders
Dependent Demand Dependent Demand Inventory SystemsInventory Systems
Items whose demand depends on the demands for other items
For example, the demand for raw materials and components can be calculated from the demand for finished goods
The systems used to manage these inventories are different from those used to manage independent demand items
Independent vs. Dependent Independent vs. Dependent DemandDemand
A
Independent Demand(finished goods and spare parts)
B(4) C(2)
D(2) E(1) D(3) F(2)
Dependent Demand(components)
Objectives of MRPObjectives of MRP
Improve customer serviceReduce inventory costEnhancing operating efficiency
Example of MRP Logic and Example of MRP Logic and Product Structure TreeProduct Structure Tree
B(4)
E(1)D(2)
C(2)
F(2)D(3)
A
Product Structure Tree for Assembly ALead TimesA 1 dayB 2 daysC 1 dayD 3 daysE 4 daysF 1 day
DemandDay 10 50 ADay 8 20 B (Spares)Day 6 15 D (Spares)
Given the product structure tree for “A” and the lead time and demand information below, provide a materials requirements plan that defines the number of units of each component and when they will be needed.
Material Requirements Material Requirements Planning SystemPlanning System
Based on a master production schedule, a material requirements planning system:Creates schedules identifying the
specific parts and materials required to produce end items.
Determines exact unit numbers needed.
Determines the dates when orders for those materials should be released, based on lead times.
Firm orders from knowncustomers
Forecastsof demand
from estimates
Aggregateproduct
plan
Masterproductionschedule
(MPS)
Materialplanning(MRP)
Engineeringdesign
changes
Bill ofmaterial
file
Inventorytransactions
Inventorystatus
file
10
Bill of Materials (BOM) FileBill of Materials (BOM) FileA Complete Product DescriptionA Complete Product Description Materials Parts Components Production sequence Modular BOM
Component or Subassemblies BOM Planning BOM or kits
create an artificial parent to the BOM used for inexpensive items like washers or pins to group.
CodingCoding
If identical items exist at various levels in the BOM: Item is coded at
lowest level at which it occurs
D (Level 2 or Level 3)
This number identifies the part at the lowest level of usage.
A
B C
D E E F
G D
Inventory Records FileInventory Records File
Buckets= time units in MRP system Week bucket vs. day bucket
Each inventory item carried as a separate file Status according to “time buckets”.
Pegging Identify each parent item that created demand.
Parent vs. child Parent= Items above the current level Child = Items below the current level
Primary MRP ReportsPrimary MRP Reports
Planned orders to be released at a future time.
Order release notices to execute the planned orders.
Changes in due dates of open orders due to rescheduling.
Cancellations or suspensions of open orders due to cancellation or suspension of orders on the master production schedule.
Inventory status data.
Secondary MRP ReportsSecondary MRP Reports
Planning reports, for example, forecasting inventory requirements over a period of time.
Performance reports used to determine agreement between actual and programmed usage and costs.
Exception reports used to point out serious discrepancies, such as late or overdue orders.
Additional MRP Additional MRP Scheduling TerminologyScheduling Terminology
Gross Requirements: needed during each period.
Scheduled Receipts: Existing orders that arrive at beginning of period.
On-hand or available balance:
(depending on software convention, could be at the beginning of each period or end):
Book: Inventory balance at end of each period.
Net requirements: What is need to meet requirements and safety stock.
Planned order receipt: arrives at beginning of period.
Planned order release: Addresses lead time.
MRP ExamplesMRP Examples
Closed Loop MRPClosed Loop MRP
Production PlanningMaster Production SchedulingMaterial Requirements PlanningCapacity Requirements Planning
Realistic?No
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Execute:Capacity PlansMaterial Plans
Yes
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