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MaterialRequirementsPlanning

MaterialRequirementsPlanning - Material Requirements...

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Material Requirements Planning Peter L. Jackson School of O.R. and I.E. Cornell University Design of Manufacturing Systems
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Design of Manufacturing Systems: MRP 2 Objectives of Lecture Become familiar with key concepts and terminology of MRP: the dominant planning system in discrete parts manufacturing Provide graphical interpretation of MRP logic Summarize strengths and weaknesses of MRP
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Design of Manufacturing Systems: MRP 3 Durable Goods Supply and Disposal Chain Mining / Extraction Refining / Blending Fabrication / Assembly Sales / Distribution Consumption Refurbishing / Reselling / Recovery Disposal
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Design of Manufacturing Systems: MRP 4 Shrinking Time Windows consumer distributor assembly plant component fabrication factory processing plant mine, forest, field Contract Lead Times years months weeks days hours competitive pressure
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Design of Manufacturing Systems: MRP 5 Lead Times Determine Policies Purchase- to-Stock Make-to- Stock Purchase- to-Build Make-to- Order Supplier Lead Time Production Lead Time Customer Lead Time Supplier Lead Time Production Lead Time Customer Lead Time RM FG
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Design of Manufacturing Systems: MRP 6 Product Flows Process / Transfer / Store Product Differentiation / Distribution Product Blending / Assembly
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A0: The MRP Process A 1 F O R E C A S T D E M A N D A 3 D E V E L O P M P S A 2 P L A N C A P A C I T Y A 5 P R O J E C T M A T E R I A L R E Q U I R E M E N T S A 6 R E L E A S E P R O D U C T I O N / P U R C H A S E P A R T S A 4 M A N A G E C U S T O M E R O R D E R S C u s t o m e r D e m a n d H i s t o r y S a l e s P r o m o t i o n P l a n s F i n i s h e d G o o d s I n v e n t o r y L e v e l s D e m a n d F o r e c a s t R e q u e s t s F o r Q u o t e C u s t o m e r O r d e r s Q u o t e s f o r P r i c e / A v a i l a b i l i t y C a p a c i t y S c h e d u l e M P S R a w M a t e r i a l s a n d W o r k I n P r o c e s s I n v e n t o r y L e v e l s S c h e d u l e d R e c e i p t s B o o k e d O r d e r s A v a i l a b l e t o P r o m i s e S c h e d u l e ( A T P ) B i l l o f M a t e r i a l s M a s t e r P r o d u c t i o n S c h e d u l e ( M P S ) M a t e r i a l P l a n
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Design of Manufacturing Systems: MRP 8 A3: Develop the Master Production Schedule A 3 1 P L A N O R D E R S A 3 2 S C H E D U L E O R D E R S A 3 3 C O M P U T E A V A I L A B L E T O P R O M I S E D e m a n d F o r e c a s t F i n i s h e d G o o d s I n v e n t o r y L e v e l s P l a n n e d O r d e r s C a p a c i t y S c h e d u l e L o t S i z i n g R u l e s P r i o r i t y R u l e s M a s t e r P r o d u c t i o n S c h e d u l e ( M P S ) B o o k e d O r d e r s A v a i l a b l e t o P r o m i s e S c h e d u l e ( A T P ) A 1 A 4 A 4 A 6 A 2 A 5 U n i t C a p a c i t y R e q u i r e m e n t s
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Design of Manufacturing Systems: MRP 9 A31 Plan Orders Simplified Ethan Allen Furniture Example (Volman, Berry, Whybark. 1993. Integrated Production and Inventory Management . Irwin.) Product Current Inventory Weekly Forecast Lot Size A 20 5 50 B 50 40 250 C -30 35 150 D 25 10 100
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