PPT14MaterialRequirementsPlanningMRP运营管理

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1、Transparency Masters to accompany Operations Management,5E(Heizer&Render)14-1?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Operations ManagementMaterial Requirements Planning(MRP)Chapter 14Transparency Masters to accompany Operations Management,5E(Heizer&Render)14-2?

2、1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458OutlineGlobal Company Profile:Collins IndustriesDependent Inventory Model RequirementsMaster Production ScheduleBills of MaterialsAccurate Inventory recordsPurchase Orders OutstandingLead Times for Each ComponentMRP Struct

3、ureTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-3?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Outline-continuedMRP ManagementMRP DynamicsMRP and JITLot-Sizing TechniquesExtensions in MRPClosed-Loop MRPCapacity PlanningMaterial requirem

4、ents Planning II(MRP II)Enterprise Resource Planning(ERP)Transparency Masters to accompany Operations Management,5E(Heizer&Render)14-4?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Outline-continuedMRP In ServicesDistribution Resource Planning(DRP)DRP StructureAllocat

5、ionTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-5?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Learning ObjectivesDistinguish dependent from independent demand inventoryDefine material requirements planningExplain the benefits of MRPIde

6、ntify the requirements of MRP,DRP,and ERPExplain the inputs&outputs of MRPCompute order releasesTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-6?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Collins IndustriesLargest manufacturer of ambula

7、nces in the worldInternational competitor12 major ambulance designs18,000 different inventory items6,000 manufactured parts12,000 purchased partsMRP:IBM抯 MAPICS Transparency Masters to accompany Operations Management,5E(Heizer&Render)14-7?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddl

8、e River,N.J.07458Collins IndustriesCollins requires:Material plan must meet both the requirements of the master schedule and the capabilities of the production facilityPlan must be executed as designedEffective 搕ime-phased?deliveries,consignments,and constant review of purchase methodsMaintenance of

9、 record integrityTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-8?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458InventoryProcess stageDemand TypeNumber&ValueOtherRaw Material WIP Finished GoodsIndependent DependentA Items B Items C ItemsMa

10、intenance Dependent OperatingInventory ClassificationsTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-9?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458ItemMaterials WithIndependent DemandMaterials WithDependent DemandDemandSourceCompany Cust

11、omersParent ItemsMaterialTypeFinished GoodsWIP&Raw MaterialsMethod ofEstimatingDemandForecast&BookedCustomer OrdersCalculatedPlanningMethodEOQ&ROPMRPDependent versus Independent DemandTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-10?1998 by Prentice Hall,Inc.A Simon&Sch

12、uster CompanyUpper Saddle River,N.J.07458Inputs to the Production PlanProductionPlanMarketingCustomerDemandEngineeringDesignCompletionManagementReturn onInvestmentCapitalHumanResourcesManpowerPlanningProcurementSupplierPerformanceFinanceCash FlowProductionCapacityInventoryTransparency Masters to acc

13、ompany Operations Management,5E(Heizer&Render)14-11?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Requirements for Effective Use of Dependent Demand Inventory Models Effective use of dependent demand inventory models requires that the operations manager know the:maste

14、r production schedulespecifications or bills-of-materialinventory availabilitypurchase orders outstandinglead timesTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-12?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458The Planning ProcessProducti

15、on PlanExecute MaterialPlansMaster ProductionScheduleMaterialRequirementsPlanCapacityRequirementsPlanExecute CapacityPlansRealistic?NoYesTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-13?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Typica

16、l Level for the Master ScheduleA customer order in a job shop(processfocused/make to order)companyModules in a repetitive(assemble-to-stock)companyAn end item in a continuous(productfocused/make to stock)companyTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-14?1998 by Pr

17、entice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458List of components&quantities needed to make product Provides product structure(tree)Parents:Items above given levelChildren:Items below given levelShows low-level codingLowest level in structure item occursTop level is 0;next level

18、 is 1 etc.Bill-of-MaterialTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-15?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Modular billsModules are final components used to make assemble-to-stock end itemsPlanning billsUsed to assign artifi

19、cial parentReduces number of items scheduledPhantom billsUsed for subassemblies that exist temporarilySpecial Bills-of-MaterialTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-16?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Bicycle(1)P/N 10

20、00Handle Bars(1)P/N 1001Frame Assy(1)P/N 1002Wheels(2)P/N 1003Frame(1)P/N 1004Bill-of-Material Product Structure TreeTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-17?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Time-Phased Product Struct

21、ure12345678DGFECEDBA2 weeks1 week3 weeks2 weeks1 week1 week2 weeks1 week2 weeks to produceStart production of DMust have D and E completed here so production can begin on BTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-18?1998 by Prentice Hall,Inc.A Simon&Schuster Compan

22、yUpper Saddle River,N.J.07458Manufacturing computer information system Determines quantity&timing of dependent demand items?1995 Corel Corp.Material Requirements Planning(MRP)Transparency Masters to accompany Operations Management,5E(Heizer&Render)14-19?1998 by Prentice Hall,Inc.A Simon&Schuster Com

23、panyUpper Saddle River,N.J.07458Computer systemMainly discrete productsAccurate bill-of-materialAccurate inventory status99%inventory accuracyStable lead times?1984-1994 T/Maker Co.MRP RequirementsTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-20?1998 by Prentice Hall,In

24、c.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Increased customer satisfaction due to meeting delivery schedules Faster response to market changesImproved labor&equipment utilizationBetter inventory planning&schedulingReduced inventory levels without reduced customer serviceMRP BenefitsTransp

25、arency Masters to accompany Operations Management,5E(Heizer&Render)14-21?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Structure of the MRP SystemMRP by period reportMRP by date reportPlanned orders reportPurchase requirementsException reportsMRPProgramsMaster Product

26、ionScheduleBOMLead Times(Item Master File)(Bill-of-Material)Inventory DataPurchasing dataTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-22?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Forecast&Firm OrdersMaterialRequirementsPlanningAggreg

27、ateProductionPlanningResourceAvailabilityMasterProductionSchedulingShopFloorSchedulesCapacityRequirementsPlanningRealistic?No,modify CRP,MRP,or MPSNo,modify CRP,MRP,or MPSYesYesMRP and The Production Planning ProcessTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-24?1998

28、by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Shows items to be producedEnd item,customer order,moduleDerived from aggregate planMaster Production ScheduleTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-25?1998 by Prentice Hall,Inc.A Simon&Schus

29、ter CompanyUpper Saddle River,N.J.07458Item/WeekOct 3Oct 10Oct 17Oct 24Drills300200310300Saws300450310330Shows items to be producedEnd item,customer order,moduleDerived from aggregate planExampleMaster Production ScheduleTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-26?

30、1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458MRP DynamicsSupports 搑eplanningProblem with ststem 搉ervousness揟ime fence?-allows a segment of the master schedule to be designated as 搉ot to be rescheduled揚egging?-tracing upward in the bill-of-materials from the component

31、 to the parent itemManager can react to changes,doesn抰 mean he/she shouldTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-27?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458MRP and JITMRP-a planning and scheduling technique with fixed lead tim

32、esJIT-a way to move material expeditiouslyIntegrating the two:Small bucket approach and back flushingbalanced flow approachTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-28?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Lot-Sizing Technique

33、sLot-for-lotEconomic Order QuantityPart Period BalancingWagner-Whitin AlgorithmTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-29?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Extensions of MRPClosed loop MRPCapacity planning-load reportsMR

34、P II-Material Resource PlanningEnterprise Resource PlanningTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-30?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Extensions of MRPClosed Loop MRPDispatch ListIsspecific capacityadequate?Isaverage c

35、apacityadequate?MaterialRequirements(detailed)CapacityRequirements(detailed)Input/OutputDesired MasterProductionScheduleRealistic?Priority ControlCapacity PlanningPriority PlanningCapacity ControlResourcePlanningFirst CutCapacityProduction PlanNoNoNoYesYesTransparency Masters to accompany Operations

36、 Management,5E(Heizer&Render)14-31?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Extensions of MRPCapacity PlanningTactics for smoothing the load and minimizing the impact of changed lead time include:Overlapping-reduces the lead time,entails sending pieces to the sec

37、ond operation before the entire lot has completed the first operationOperations splitting-sends the lot to two different machines for the same operationLot splitting-breaking up the order and running part of it ahead of the scheduleTransparency Masters to accompany Operations Management,5E(Heizer&Re

38、nder)14-32?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Extensions to MRPEnterprise Resource PlanningMRP II with ties to customers and suppliersTransparency Masters to accompany Operations Management,5E(Heizer&Render)14-33?1998 by Prentice Hall,Inc.A Simon&Schuster C

39、ompanyUpper Saddle River,N.J.07458MRP in ServicesCan be used when demand for service or service items is directly related to or derived from demand for other servicesrestaurant-rolls required for each mealhospitals-implements for surgeryetc.Transparency Masters to accompany Operations Management,5E(

40、Heizer&Render)14-34?1998 by Prentice Hall,Inc.A Simon&Schuster CompanyUpper Saddle River,N.J.07458Distribution Resource PlanningDRP requires:Gross requirements,which are the same as expected demand or sales forecastsMinimum levels of inventory to meet customer service levelsAccurate lead timesDefinition of the distribution structure