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MRP and ERP (Lec 7 - Chapter 12), image, image - Coggle Diagram
MRP and ERP
(Lec 7 - Chapter 12)
Material Requirements Planning (MRP)
MRP in Services
Benefits and Requitements of MRP
Benefits
Low levels of in-process inventories
Ability to track material requirements
Ability to evaluate capacity requirements
Means of allocating production time
Requirements
A computer and the necessary software programs to handle computations and maintain records.
Accurate and up-to-date
Master schedules
Bills of materials
Inveentory records
Integrity of file data
MRP Outputs
Primary Reports
Order releases
- Authorization for the execution of planned orders.
Changes
- revisions of due dates or order quantities, or cancellations of orders
Planned orders
- schedule indicating the amount and timing of future orders.
Secondary Reports
Planning reports:
Dase useful for assessing future material
requirements.
Exception reports:
Data on any major discrepancies encountered.
Performance-control reports:
Evaluation of system operation, including deviations from plans and cost information.
MRP Process
Gross requirements:
Toal expected demand for an item or
raw material in a time period.
Schedule receipts:
Open orders scheduled to arrive from vendors or elsewhere in the pipeline
Projected on hand:
Expected amount of inventory that will be on hand at the beginning of each time period.
Net requirements:
The actual amount needed in each time period
Planned-order receipts:
Quantity expected to be received by the beginning of the period in which it is shown
Planned-order releases:
Planned amount to order in each time period; planned-order receipts offset by lead time.
Updating the System
Regenerative system:
Approach that updates MRP records
periodically
.
Net-change system:
Approach that updates MRP records
continuously
MRP Inputs
Master Schedule
Master schedule
, also referred to as the
master production schedule
, states which end items are to be produced, when they are needed, and in what quantities.
Based on customer orders, forecasts, warehouses orders.
Cumulative lead time:
the sum of the lead times that sequential phases of the production or assembly process require, from ordering of parts or raw materials to completion of final assembly
+ LT= move+ waiting +setup+ run time
The Bill of Materials (BOM)
Định mức nguyên vật liệu hay Hóa đơn nguyên vật liệu
BOM:
A listing of all of the assemblies, subassemblies, parts,
and raw materials that are needed to produce one unit of a finished product.
Listing in the bill of materials is
hierarchical
Product Structure Tree:
a visual depiction of the requirement in a BOM, where all components needed are listed by levels
Low-level Coding:
Restructuring the BOM so that multiple occurrences of a component all coincide with the lowest level at which the component occurs.
The Inventory Records
stored information on:
quantities on hand, quantities ordered
other details such as supplier, lead time, lot
size policy
the status of each item by time period, called
time buckets.
hanges due to canceled order, withdrawal, canceled orders, and similar events
Methodology that translates master schedule requirements for end items into time-phased requirements for subassemblies, components, and raw materials
MRP II
MRP II:
Expanded approach to production resource planning, involving other areas of a firm in the planning process and enabling capacity requirement planning
Closed-Loop MRP
Capacity Requirement Planning
Load reports:
Department or work center reports that compare known and expected future capacity requirements with projected capacity availability.
Time fence:
Series of time intervals during which order changes are allowed or restricted
Capacity Requirement Planning:
The process of determining short-range capacity requirements
Enterprise resource planning (ERP)
:
ERP in Services
ERP Strategy Considerations
High initial cost
High cost to maintain
Future upgrades
Training
ERP
Integration of financial, manufacturing, and human resources in a single database.
Next step in an evolution that began
with MPR and evolved into MRPII
Integration of all parts of an
organization on a single computer system
