Material requirements plan Master production schedule AGGREGATE PRODUCTION PLAN

Material requirements plan master production schedule

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Material requirements plan Master production schedule
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AGGREGATE PRODUCTION PLAN Months January February Aggregate Plan 1,500 1,200 (Shows the total quantity of amplifiers) Weeks 1 2 3 4 5 6 7 8 Master Production Schedule (Shows the specific type and quantity of amplifier to be produced 240-watt amplifier 100 100 100 100 150-watt amplifier 500 500 450 450 75-watt amplifier 300 100 Figure 14.2 28 ARLIZA ABDULLAH (OPM549)
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MASTER PRODUCTION SCHEDULE (MPS) Can be expressed in any of the following terms: 1. A customer order in a job shop (make-to-order) company 2. Modules in a repetitive (assemble- to-order or forecast) company 3. An end item in a continuous (stock- to-forecast) company 29
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MPS EXAMPLE TABLE 14.1 Master Production Schedule for Chef John’s Buffalo Chicken Mac & Cheese GROSS REQUIREMENTS FOR CHEF JOHN’S BUFFALO MAC & CHEESE Day 6 7 8 9 10 11 12 13 14 And so on Quanti ty 450 200 350 525 235 375 30
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BILLS OF MATERIAL List of components, ingredients, and materials needed to make product Provides product structure Items above given level are called parents Items below given level are called components or children 31
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32 BOM EXAMPLE – ORDER OF 50 AWESOME SPEAKER KITS B (2) C (3) 1 E (2) E (2) F (2) 2 D (2) D (2) G (1) 3 Product structure for “Awesome” (A) A Level 0 Part B: 2 x number of As = (2)(50) = 100 Part C: 3 x number of As = (3)(50) = 150 Part D: 2 x number of Bs + 2 x number of Fs = (2)(100) + (2)(300) = 800 Part E: 2 x number of Bs + 2 x number of Cs = (2)(100) + (2)(150) = 500 Part F: 2 x number of Cs = (2)(150) = 300 Part G: 1 x number of Fs = (1)(300) = 300
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MRP STRUCTURE Figure 14.4 Output Reports MRP by period report MRP by date report Planned order report Purchase advice Exception reports Order early or late or not needed Order quantity too small or too large Data Files Purchasing data BOM Lead times (Item master file) Inventory data Master production schedule Material requirement planning programs (computer and software) 33
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MRP MANAGEMENT MRP dynamics Facilitates replanning when changes occur System nervousness can result from too many changes Time fences put limits on replanning Pegging links each item to its parent allowing effective analysis of changes MRP limitations MRP does not do detailed scheduling–it plans Works best in product-focused, repetitive environments Requires fixed lead time and infinite size time buckets 34
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MRP IN SERVICES Some services or service items are directly linked to demand for other services These can be treated as dependent demand services or items Restaurants Hospitals Hotels 35
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Buffalo Chicken Mix Buffalo Sauce Smoked Pulled Chicken Blue Cheese Crumble s Cooked Elbow Macaroni Grated Pepper Jack Cheese Chopped Scallions Mac & Cheese Base Milk Unbaked Buffalo Chicken Mac & Cheese MRP IN SERVICES (a) PRODUCT STRUCTURE TREE Figure 14.9 Garnish with Buffalo Chicken mix, Blue Cheese, Scallions Baked Buffalo Chicken Mac & Cheese Buffalo Chicken Mac & Cheese 36
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