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Production Planning and Control Materials Requirement Planning. Dr. Lotfi K. Gaafar. Production Planning and Control. The Production Control System. Sales and order entry. Demand forecasting. Customer. Shop-floor scheduling and control. Materials requirement planning. Aggregate planning.

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Presentation Transcript
slide1

Production Planning and Control

Materials Requirement Planning

Dr. Lotfi K. Gaafar

Production Planning and Control- Materials Requirement Planning(1)

slide2

Production Planning and Control

The Production Control System

Sales and order entry

Demand forecasting

Customer

Shop-floor scheduling and control

Materials requirement planning

Aggregate planning

Shipping and receiving

Production

Inventory management

Inventory

Vendors

Production Planning and Control- Materials Requirement Planning(2)

slide3

Material Requirements Planning

  • Given a master schedule, what raw materials and components quantities are needed and when.
  • Requires:
    • Bill of material (Manufacturing tree)
    • Inventory status
    • Lead times

Master Production

Scheduling

Bills of

Material

Material Requirements

Planning

Inventory

Status

Quantities and

Order Times

Production Planning and Control- Materials Requirement Planning(3)

slide4

Assumptions

  • 1. Known deterministic demands.
  • 2. Fixed, known production leadtimes.
  • 3. Infinite capacity.
  • Idea is to “back out” demand for components by using leadtimes and bills of material.

Production Planning and Control- Materials Requirement Planning(4)

slide5

MRP Procedure

  • 1. Netting:net requirements against projected inventory
  • 2. Lot Sizing: planned order quantities
  • 3. Time Phasing: planned orders backed out by leadtime
  • 4. BOM Explosion: gross requirements for components

Production Planning and Control- Materials Requirement Planning(5)

slide6

Inputs

  • Master Production Schedule (MPS): due dates and quantities for all top level items
  • Bills of Material (BOM): for all parent items
  • Inventory Status: (on hand plus scheduled receipts) for all items
  • Planned Leadtimes: for all items

Production Planning and Control- Materials Requirement Planning(6)

slide7

Material Requirements Planning

Example

Consider the manufacturing tree (BOM) and the accompanying information.

Production Planning and Control- Materials Requirement Planning(7)

slide8

Material Requirements Planning

Example

CT

LT = 2

B00

LT = 1

Production Planning and Control- Materials Requirement Planning(8)

slide9

Material Requirements Planning

Example

X10

LT = 1

33 X10 cannot be scheduled.

How many CTs will be affected?

How can we fix the problem?

Production Planning and Control- Materials Requirement Planning(9)

slide10

Rough Cut Capacity Planning (RCCP)

  • Quick check on capacity of key resources
  • Use Bill of Resource (BOR) for each item in MPS
  • Generates usage of resources by exploding MPS against BOR (offset by leadtimes)
  • Infeasibilities addressed by altering MPS or adding capacity (e.g., overtime)

Production Planning and Control- Materials Requirement Planning(10)