PPT14MaterialRequirementsPlanning(MRP)(運營管理

1、Transparency Masters to accompany Operations Management, 5E (Heizer & Render)14-1?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458Transparency Masters to accompany Operations Management, 5E (Heizer & Render)14-2?1998 by Prentice Hall, Inc.A Simon & Schuster Company

2、Upper Saddle River, N.J. 07458Global Company Profile: Collins IndustriesDependent Inventory Model RequirementsMaster Production ScheduleBills of MaterialsAccurate Inventory recordsPurchase Orders OutstandingLead Times for Each ComponentMRP StructureTransparency Masters to accompany Operations Manage

3、ment, 5E (Heizer & Render)14-3?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458MRP ManagementMRP DynamicsMRP and JITLot-Sizing TechniquesExtensions in MRPClosed-Loop MRPCapacity PlanningMaterial requirements Planning II (MRP II)Enterprise Resource Planning (ERP)Tra

4、nsparency Masters to accompany Operations Management, 5E (Heizer & Render)14-4?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458MRP In ServicesDistribution Resource Planning (DRP)DRP StructureAllocationTransparency Masters to accompany Operations Management, 5E (Hei

5、zer & Render)14-5?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458Distinguish dependent from independent demand inventoryDefine material requirements planningExplain the benefits of MRPIdentify the requirements of MRP, DRP, and ERPExplain the inputs & outputs of MR

6、PCompute order releasesTransparency Masters to accompany Operations Management, 5E (Heizer & Render)14-6?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458Largest manufacturer of ambulances in the worldInternational competitor12 major ambulance designs18,000 differen

7、t inventory items6,000 manufactured parts12,000 purchased partsMRP: IBM抯 MAPICS Transparency Masters to accompany Operations Management, 5E (Heizer & Render)14-7?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458Collins requires:Material plan must meet both the requi

8、rements of the master schedule and the capabilities of the production facilityPlan must be executed as designedEffective 搕ime-phased?deliveries, consignments, and constant review of purchase methodsMaintenance of record integrityTransparency Masters to accompany Operations Management, 5E (Heizer & R

9、ender)14-8?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458InventoryProcess stageDemand TypeNumber & ValueOtherRaw Material WIP Finished GoodsIndependent DependentA Items B Items C ItemsMaintenance Dependent OperatingTransparency Masters to accompany Operations Man

10、agement, 5E (Heizer & Render)14-9?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458ItemMaterials WithIndependent DemandMaterials WithDependent DemandDemandSourceCompany CustomersParent ItemsMaterialTypeFinished GoodsWIP & Raw MaterialsMethod ofEstimatingDemandForeca

11、st & BookedCustomer OrdersCalculatedPlanningMethodEOQ & ROPMRPTransparency Masters to accompany Operations Management, 5E (Heizer & Render)14-10?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458ProductionPlanMarketingCustomerDemandEngineeringDesignCompletionManageme

12、ntReturn onInvestmentCapitalHumanResourcesManpowerPlanningProcurementSupplierPerformanceFinanceCash FlowProductionCapacityInventoryTransparency Masters to accompany Operations Management, 5E (Heizer & Render)14-11?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458 Ef

13、fective use of dependent demand inventory models requires that the operations manager know the:master production schedulespecifications or bills-of-materialinventory availabilitypurchase orders outstandinglead timesTransparency Masters to accompany Operations Management, 5E (Heizer & Render)14-12?19

14、98 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458Production PlanExecute MaterialPlansMaster ProductionScheduleMaterialRequirementsPlanCapacityRequirementsPlanExecute CapacityPlansRealistic?NoYesTransparency Masters to accompany Operations Management, 5E (Heizer & Rend

15、er)14-13?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458A customer order in a job shop (processfocused/make to order) companyModules in a repetitive (assemble-to-stock) companyAn end item in a continuous (productfocused/make to stock) companyTransparency Masters t

16、o accompany Operations Management, 5E (Heizer & Render)14-14?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458List of components & quantities needed to make product Provides product structure (tree)Parents: Items above given levelChildren: Items below given levelSho

17、ws low-level codingLowest level in structure item occursTop level is 0; next level is 1 etc.Transparency Masters to accompany Operations Management, 5E (Heizer & Render)14-15?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458Modular billsModules are final components

18、used to make assemble-to-stock end itemsPlanning billsUsed to assign artificial parentReduces number of items scheduledPhantom billsUsed for subassemblies that exist temporarilyTransparency Masters to accompany Operations Management, 5E (Heizer & Render)14-16?1998 by Prentice Hall, Inc.A Simon & Sch

19、uster CompanyUpper Saddle River, N.J. 07458Bicycle(1)P/N 1000Handle Bars (1)P/N 1001Frame Assy (1)P/N 1002Wheels (2)P/N 1003Frame (1)P/N 1004Transparency Masters to accompany Operations Management, 5E (Heizer & Render)14-17?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J

20、. 0745812345678DGFECEDBA2 weeks1 week3 weeks2 weeks1 week1 week2 weeks1 week2 weeks to produceStart production of DMust have D and E completed here so production can begin on BTransparency Masters to accompany Operations Management, 5E (Heizer & Render)14-18?1998 by Prentice Hall, Inc.A Simon & Schu

21、ster CompanyUpper Saddle River, N.J. 0745812345Gross Requirements2202515Scheduled Receipts530Available252333338Net Requirements7Planned Order Receipts7Planned Order Releases7Manufacturing computer information system Determines quantity & timing of dependent demand items?1995 Corel Corp.Transparency

22、Masters to accompany Operations Management, 5E (Heizer & Render)14-19?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458Computer systemMainly discrete productsAccurate bill-of-materialAccurate inventory status99% inventory accuracyStable lead times?1984-1994 T/Maker

23、Co.Transparency Masters to accompany Operations Management, 5E (Heizer & Render)14-20?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458Increased customer satisfaction due to meeting delivery schedules Faster response to market changesImproved labor & equipment utili

24、zationBetter inventory planning & schedulingReduced inventory levels without reduced customer serviceTransparency Masters to accompany Operations Management, 5E (Heizer & Render)14-21?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458MRP by period reportMRP by date r

25、eportPlanned orders reportPurchase requirementsException reportsMRPProgramsMaster ProductionScheduleBOMLead Times(Item Master File)(Bill-of-Material)Inventory DataPurchasing dataTransparency Masters to accompany Operations Management, 5E (Heizer & Render)14-22?1998 by Prentice Hall, Inc.A Simon & Sc

26、huster CompanyUpper Saddle River, N.J. 07458Forecast &Firm OrdersMaterialRequirementsPlanningAggregateProductionPlanningResourceAvailabilityMasterProductionSchedulingShopFloorSchedulesCapacityRequirementsPlanningRealistic?Transparency Masters to accompany Operations Management, 5E (Heizer & Render)1

27、4-23?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458MasterProductionScheduleBill ofMaterialsMaterialRequirementsPlanning SystemInventoryStatusPlanned Order& OtherReportsItem MasterPurchasingDataTransparency Masters to accompany Operations Management, 5E (Heizer &

28、Render)14-24?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458Shows items to be producedEnd item, customer order, moduleDerived from aggregate planTransparency Masters to accompany Operations Management, 5E (Heizer & Render)14-25?1998 by Prentice Hall, Inc.A Simon &

29、 Schuster CompanyUpper Saddle River, N.J. 07458Item/WeekOct 3Oct 10Oct 17Oct 24Drills300200310300Saws300450310330Shows items to be producedEnd item, customer order, moduleDerived from aggregate planExampleTransparency Masters to accompany Operations Management, 5E (Heizer & Render)14-26?1998 by Pren

30、tice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458Supports 搑eplanningProblem with ststem 搉ervousness揟ime fence?- allows a segment of the master schedule to be designated as 搉ot to be rescheduled揚egging?- tracing upward in the bill-of-materials from the component to the parent it

31、emManager can react to changes, doesn抰 mean he/she shouldTransparency Masters to accompany Operations Management, 5E (Heizer & Render)14-27?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458MRP - a planning and scheduling technique with fixed lead timesJIT - a way to

32、 move material expeditiouslyIntegrating the two:Small bucket approach and back flushingbalanced flow approachTransparency Masters to accompany Operations Management, 5E (Heizer & Render)14-28?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458Lot-for-lotEconomic Order

33、 QuantityPart Period BalancingWagner-Whitin AlgorithmTransparency Masters to accompany Operations Management, 5E (Heizer & Render)14-29?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458Closed loop MRPCapacity planning - load reportsMRP II - Material Resource Plannin

34、gEnterprise Resource PlanningTransparency Masters to accompany Operations Management, 5E (Heizer & Render)14-30?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458Dispatch ListIsspecific capacityadequate?Isaverage capacityadequate?MaterialRequirements(detailed)Capacit

35、yRequirements(detailed)Input/OutputDesired MasterProductionScheduleRealistic?Priority ControlCapacity PlanningPriority PlanningCapacity ControlResourcePlanningFirst CutCapacityProduction PlanNoNoNoYesYesTransparency Masters to accompany Operations Management, 5E (Heizer & Render)14-31?1998 by Prentice Hall, Inc.A Simon & Schuster CompanyUpper Saddle River, N.J. 07458Tactics for smoothing the load and minimizing the impact of changed lead time include:Overlapping - reduces the lead time, entails sending pieces