MaterialRequirementsPlanning - Material Requirements...

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Unformatted text preview: Material Requirements Planning Peter L. Jackson School of O.R. and I.E. Cornell University Design of Manufacturing Systems 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 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 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 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 Design of Manufacturing Systems: MRP 6 Product Flows Process / Transfer / Store Product Differentiation / Distribution Product Blending / Assembly A0: The MRP Process A1 FORECAST DEMAND A3 DEVELOP MPS A2 PLAN CAPACITY A5 PROJECT MATERIAL REQUIREMENTS A6 RELEASE PRODUCTION / PURCHASE PARTS A4 MANAGE CUSTOMER ORDERS Customer Demand History Sales Promotion Plans Finished Goods Inventory Levels Demand Forecast Requests For Quote Customer Orders Quotes for Price / Availability Capacity Schedule MPS Raw Materials and Work In Process Inventory Levels Scheduled Receipts Booked Orders Available to Promise Schedule (ATP) Bill of Materials Master Production Schedule (MPS) Material Plan Design of Manufacturing Systems: MRP 8 A3: Develop the Master Production Schedule A31 PLAN ORDERS A32 SCHEDULE ORDERS A33 COMPUTE AVAILABLE TO PROMISE Demand Forecast Finished Goods Inventory Levels Planned Orders Capacity Schedule Lot Sizing Rules Priority Rules Master Production Schedule (MPS) Booked Orders Available to Promise Schedule (ATP) A1 A4 A4 A6 A2 A5 Unit Capacity Requirements 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 Design of Manufacturing Systems: MRP 10 Plan Orders for A Week 1 2 3 4 5 6 7 8 Gross requirements 5 5 5 5 5 5 5 5 Scheduled receipts Available 20 15 10 5 0 45 40 35 30 Planned Orders 0 0 0 0 50 0 0 0 Cumulative Demand and Planned Orders: A 10 20 30 40 50 60 70 1 2 3 4 5 6 7 8 Week Units Demand Orders Design of Manufacturing Systems: MRP 11 Plan Orders for B Week 1 2 3 4 5 6 7 8 Gross requirements 40 40 40 40 40 40 40 40 Scheduled receipts Available 50 10 220 180 140 100 60 20 230 Planned Orders 250 250...
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MaterialRequirementsPlanning - Material Requirements...

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