Lot size min 100 lt 1 1 2 3 4 5 gross requirements

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LOT SIZE: MIN 100 LT: 1 1 2 3 4 5 Gross Requirements Scheduled Receipts Projected on Hand 150 Net Requirements Planned Order Receipts Planned Order Releases PERIOD PLANNED ORDER RELEASES 1 2 3 4 5 Clipboard 100 100 100 Lapdesk 50 50
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PERIOD ITEM 1 2 3 4 5 Clipboard Lapdesk Pressboard Planned Order Report
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Planned Order Report Item #2740 Date 9 - 25 - 15 On hand 100 Lead time 2 weeks On order 200 Lot size 200 Allocated 50 Safety stock 50 SCHEDULED PROJECTED DATE ORDER NO. GROSS REQS. RECEIPTS ON HAND ACTION 50 9-26 AL 4416 25 25 9-30 AL 4147 25 0 10-01 GR 6470 50 - 50 10-08 SR 7542 200 150 Expedite SR 10-01 10-10 CO 4471 75 75 10-15 GR 6471 50 25 10-23 GR 6471 25 0 10-27 GR 6473 50 - 50 Release PO 10-13 Key: AL = allocated WO = work order CO = customer order SR = scheduled receipt PO = purchase order GR = gross requirement
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MRP Action Report Current date 9-25-15 ITEM DATE ORDER NO. QTY. ACTION #2740 10-08 7542 200 Expedite SR 10-01 #3616 10-09 Move forward PO 10-07 #2412 10-10 Move forward PO 10-05 #3427 10-15 Move backward PO 10-25 #2516 10-20 7648 100 De-expedite SR 10-30 #2740 10-27 200 Release PO 10-13 #3666 10-31 50 Release WO 10-24
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Capacity Requirements Planning (CRP) Creates a load profile Identifies under-loads and over-loads Determines whether MRP plan is doable
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MRP planned order releases Routing file Capacity requirements planning Open orders file Load profile for each machine center
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Remedies for Underloaded Conditions 1. Acquire more work 2. Pull work ahead that is scheduled for later time periods 3. Reduce normal capacity
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Remedies for Overloaded Conditions 1. Eliminating unnecessary requirements 2. Rerouting jobs to alternative machines, workers, or work centers 3. Splitting lots between two or more machines 4. Increasing normal capacity 5. Subcontracting 6. Increasing efficiency of the operation 7. Pushing work back to later time periods
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Initial Load Profile Hours of capacity 1 2 3 4 5 6 Time (weeks) Normal capacity 120 – 110 – 100 – 90 – 80 – 70 – 60 – 50 – 40 – 30 – 20 – 10 – 0 –
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Adjusted Load Profile Hours of capacity 1 2 3 4 5 6 Time (weeks) Normal capacity 120 – 110 – 100 – 90 – 80 – 70 – 60 – 50 – 40 – 30 – 20 – 10 – 0 – Pull ahead Push back Push back Overtime Work an extra shift
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LOT SIZE MIN 100 LT 1 1 2 3 4 5 Gross Requirements...

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