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Material Requirement Planning

Material Requirement Planning. Contents for MRP. MRP in MPC. Record Processing. Technical Issues. Using the MRP System. System Dynamics. Business Plan. MRP in MPC. Sales & Operation Plan . Demand Management. Resource Planning. Front End. Master Production Scheduling .

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Material Requirement Planning

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  1. Material Requirement Planning

  2. Contents for MRP MRP in MPC Record Processing Technical Issues Using the MRP System System Dynamics

  3. Business Plan MRP in MPC Sales & Operation Plan Demand Management Resource Planning Front End Master Production Scheduling MD (master data) PS (planning & scheduling) RCCP (rough cut capacity planning) Routing B/M Material Requirement Planning Engine DCP (detailed capacity planning) IR (inventory record) APS (advanced planning & scheduling) Purchasing Order Production Order Outsourcing Back End Manufacturing Execution System [by 이재봉,박진우] 2

  4. Record Processing: the Basic MRP Record • Gross Requirement • Scheduled Receipt • Projected Available Balance ( 예전 On Hand: may not be available if already promised for some use or already allocated) • Planned Order Release; different from Firm Planned Order which caused the Scheduled Receipt

  5. Record Processing: an example BOM

  6. Record Processing: BOM for Snow Shovel

  7. Record Processing: Gross to Net Explosion

  8. Record Processing: Front Schedule(Cutting)

  9. Record Processing: Back Schedule

  10. Technical Issues • Processing Frequency: • -Regenerative MRP vs Net Change MRP • Bucketless Systems: • -specifies exact release and due dates for each requirement, scheduled receipt, and planned order • -many firms now use bucketless systems where planning cycle itself is bucketless • Lot Sizing vs. Lot for Lot(L4L): • -basic component level vs. intermediate subassembly level

  11. Technical Issues • Low-Level Coding: LLC (for service part, for service part combined with ordinary dependent demand part) • Pegging: source of all gross requirements(selective where-used) • Firm Planned Order is a planned order that MRP does not change automatically, and to change it managerial action is needed • Planning Horizon: weeks and months combined • Scheduled Receipt vs. Planned Order Release: • Committed 여부에 따라( Purchase Order, Open Shop Order) • -SR does not explode while POR explodes

  12. Using the MRP System • MRP Planner: Order Release, Reschedule, Planning Factors,.. • Order Launching: • -prompted by MRP when Planned Order Release is in the Action Bucket(current time period) • -Converts the Planned Order into Scheduled Receipt • Allocation and Availability Checking -Partial Order, Picking Ticket(or Requisition Ticket) • Exception Messages-On week 1, 50 nails arrived on Wednesday(scheduled receipt)–On Thursday, QC found out it was a wrong size mails-Among 10 final customer orders, only 7 can be made if some actions are not taken: Immediate order and reduce lead time,Nego. for 1 week reduction in shop order, …

  13. System Dynamics • Possible Events: • -incorrect physical count, scrap(planning factor), changes in customer orders, incorrect BOM, Engineering Change, poor vendor performance,… • -예) • Stock usage 20 instead of 30 • Scheduled receipt of 50, but 10 units rejected • 20 additional pieces found • Requirement for week 5 was changed to week 4 • Marketing requested 5 samples on week 2 • …

  14. System Dynamics: relationships among parts

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