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MRP Systems

MRP Systems. MRP – Material Requirements Planning Commonly used method in industry to coordinate the production scheduling of end items and their associated sub components. Ford’s MRP systems is known as CMMS, c ommon m anufacturing m anagement s ystem. MRP Systems.

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MRP Systems

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  1. MRP Systems MRP – Material Requirements Planning Commonly used method in industry to coordinate the production scheduling of end items and their associated sub components. Ford’s MRP systems is known as CMMS, common manufacturing management system.

  2. MRP Systems End Item – final product that is to be shipped from the manufacturing facility (engine by engine code, replacement engine blocks, replacement crankshafts, etc…) General Idea: A desired production date for end-items is known, the inventory level of all components and sub-assemblies required by the end-item is known, the lead time to produce the subcomponents or delivery time of supplied parts is known, therefore scheduled the production of any shortfall of parts and subcomponents at a point in time to support the desired production date of the end-item.

  3. MRP Systems • Required information to support an MRP system: • Master Production Schedule (MPS) • Bill of Material (BOM) • Inventory Status Records by each part or component • Lead times • Item master data

  4. MRP Systems Master Production Schedule (MPS): Planned production quantities for end-items in each time period of the planning horizon. Planning horizon – length of time over which to plan the production schedule. This length of time must exceed the cumulative lead time to replenish an end-item through all production stages. Time period (or time bucket) – smallest unit of time in which end-item production is schedule. In practice, time buckets of one week are typical used.

  5. MRP Systems Master Production Schedule (MPS): Ex. 8.1 Production of 1000 no. 12468 staplers is planned for weeks 1, 2, and 3, followed by no more stapler production until week 6 in which 1500 staplers will be produced.

  6. MRP Systems Bill of Material (BOM): A listing of all components required for each end-item. Ex. 8.1 – personal stapler no. 12468. This stapler is assembled from 3 sub-assemblies. Insert Figure 8.5

  7. MRP Systems Inventory Status Records: Dynamic information about the current level of inventory for all components designated in the BOM of each end item. In practice, accurate inventory levels are difficult to maintain. Ex. 8.1 ComponentInventory Status Top Assembly 1212 Spring Assembly 1150 Locator Plate 146 Slide Pin 558

  8. MRP Systems Lead Times: the time from when an order to replenish a part is initiated until the part becomes available for use. Lead times in practice are variable, but for the MPS, a fixed value is applied, usually the mean plus some safety factor. Ex. 8.1 ComponentLead Time (weeks) Top Assembly 1 Spring Assembly 1 Locator Plate 2 Slide Pin 1

  9. MRP Systems • Item Master Data - unique data for each part or component. This data includes: • unique part number • annual demand • nominal order quantity • cost • scrap rate • production lead time • resource requirements • pointers to engineering drawings (if produced internally) • vendor information (if purchased) • etc…

  10. MRP Systems Requirements explosion and order release plan: Ex. 8.1 – order release plan for personal stapler no. 12468 Level One Planning – Top Assembly

  11. MRP Systems Requirements explosion and order release plan: Ex. 8.1 – order release plan for personal stapler no. 12468 Level One Planning – Spring Assembly

  12. MRP Systems Requirements explosion and order release plan: Ex. 8.1 – order release plan for personal stapler no. 12468, an order for 750 locator plates is expected to arrive early in week 1 * The 892 units released in week 1 will not arrive till week 3 unless some expedited actions occur Level Two Planning – Locator Plate

  13. MRP Systems Requirements explosion and order release plan: Ex. 8.1 – order release plan for personal stapler no. 12468, a batch of 650 slide pins is just about complete. Level Two Planning – Slide Pins

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