物资装备计划(MRP)(1)39049

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1、Material Requirement Planning(MRP)Contributors to MRPJoseph OrlickyGeorge PlosslOliver WightAmerican Production and Inventory Control SocietyWhat is MRP?Computerized Inventory ControlProduction Planning SystemManagement Information SystemManufacturing Control SystemWhen to use MRPJob Shop Production

2、Complex ProductsAssemble-to-Order EnvironmentsDiscrete and Dependent Demand ItemsWhat can MRP do?Reduce Inventory LevelsReduce Component ShortagesImprove Shipping PerformanceImprove Customer ServiceImprove ProductivitySimplified and Accurate SchedulingReduce Purchasing CostImprove Production Schedul

3、esReduce Manufacturing CostReduce Lead TimesLess Scrap and ReworkHigher Production QualityWhat can MRP do?Improve CommunicationImprove Plant EfficiencyReduce Freight CostReduction in Excess InventoryReduce OvertimeImprove Supply SchedulesImprove Calculation of Material RequirementsImprove Competitiv

4、e PositionThree Basic Steps of MRPIdentifying RequirementsRunning MRP Creating the SuggestionsFirming the SuggestionsStep 1:Identifying the RequirementsQuantity on HandQuantity on Open Purchase OrderQuantity in/or Planned for ManufacturingQuantity Committed to Existing OrdersQuantity ForecastedStep

5、1:Important InformationMRP is.Company SensitiveLocation SensitiveDate SensitiveStep 2:Running MRP Creating the SuggestionsCritical ItemsExpedite ItemsDelay ItemsStep 3:Firming the SuggestionsManufacturing OrdersPurchasing OrdersVarious ReportsOverview of the MRP SystemProduct Structure FileMaster Pr

6、oduction ScheduleInventory Master FileMaterial Requirements PlanningManufacturing OrdersPurchase OrdersVarious ReportsMRP InputsProduct Structure FileMaster Production ScheduleInventory Master FileProduct Structure FileBill of MaterialsMaster Production ScheduleSchedule of Finished ProductsRepresent

7、s Production,not DemandCombination of Customer Orders and Demand ForecastsWhat Needs to be ProducedInventory Master FileOn-Hand QuantitiesOn-Order QuantitiesLot SizesSafety StockLead TimePast-Usage FiguresMRP ProcessSchedules the Production of all items using an MRP MatrixItem:Low-Level Code:Lot Siz

8、e:Lead Time:PD123 4 5Gross RequirementsScheduled ReceiptsProjected on HandNet RequirementsPlanned Order ReceiptsPlanned Order ReleasesMRP MatrixTerms DefinedItem name or number for the item being scheduledLow-Level Code the lowest level of the item on the product structure fileLot Size order multipl

9、es of quantityLead Time the time from when an order is placed to when it is receivedPD Past Due Time Bucket,orders behind scheduleTerms DefinedGross Requirements demand for an item by time periodScheduled Receipts material already orderedProjected on Hand expected ending inventoryNet Requirements nu

10、mber of items to be provided and whenPlanned Order Receipts net requirements adjusted for lot sizePlanned Order Releases planned order receipts offset for lead timesExample of the MRP ProcessItem:A Low-Level Code:1 Lot Size:25 Lead Time:1PD12345Gross Requirements1015 25 25 30Scheduled Receipts25Proj

11、ected on Hand20Net RequirementsPlanned Order ReceiptsPlanned Order ReleasesExample of the MRP ProcessItem:A Low-Level Code:1 Lot Size:25 min Lead Time:1PD12345Gross Requirements1015 25 25 30Scheduled Receipts25Projected on Hand201020 20 20 15Net Requirements5510Planned Order Receipts25 25 25Planned

12、Order Releases2525 25 30 25MRP OutputsManufacturing OrdersPurchasing OrdersVarious ReportsHubbell Lighting CaseManufactures Industrial Lighting ProductsGood-Quality ProductsPoor at Meeting Due DatesWork is Specialized for Each CustomerJob Shop EnvironmentComplex ProductsHubbell Lighting CaseBefore M

13、RP ImplementationLess than 75%of orders completed on timeAfter MRP Implementation97%of orders completed on time2%of orders completed with 1 to 2 days after due date Summary of MRPMRP is a.Computerized Inventory ControlProduction Planning Systemthat.Schedules Component Items as Neededwhich will.Track Inventory and.Help you in many other aspects of businessReferences