物資裝備計劃(MRP)(1)ppt課件

1、Material Requirement Planning (MRP).Contributors to MRPJoseph OrlickyGeorge PlosslOliver WightAmerican Production and Inventory Control Society.What is MRP?Computerized Inventory ControlProduction Planning SystemManagement Information SystemManufacturing Control System.When to use MRPJob Shop Produc

2、tionComplex ProductsAssemble-to-Order EnvironmentsDiscrete and Dependent Demand Items.What can MRP do?Reduce Inventory LevelsReduce Component ShortagesImprove Shipping PerformanceImprove Customer ServiceImprove ProductivitySimplified and Accurate SchedulingReduce Purchasing CostImprove Production Sc

3、hedulesReduce Manufacturing CostReduce Lead TimesLess Scrap and ReworkHigher Production Quality.What can MRP do?Improve CommunicationImprove Plant EfficiencyReduce Freight CostReduction in Excess InventoryReduce OvertimeImprove Supply SchedulesImprove Calculation of Material RequirementsImprove Comp

4、etitive Position.Three Basic Steps of MRPIdentifying RequirementsRunning MRP Creating the SuggestionsFirming the Suggestions.Step 1: Identifying the RequirementsQuantity on HandQuantity on Open Purchase OrderQuantity in/or Planned for ManufacturingQuantity Committed to Existing OrdersQuantity Foreca

5、sted.Step 1: Important InformationMRP is.Company SensitiveLocation SensitiveDate Sensitive.Step 2: Running MRP Creating the SuggestionsCritical ItemsExpedite ItemsDelay Items.Step 3: Firming the SuggestionsManufacturing OrdersPurchasing OrdersVarious Reports.Overview of the MRP SystemProduct Structu

6、re FileMaster Production ScheduleInventory Master FileMaterial Requirements PlanningManufacturing OrdersPurchase OrdersVarious Reports.MRP InputsProduct Structure FileMaster Production ScheduleInventory Master File.Product Structure FileBill of Materials.Master Production ScheduleSchedule of Finishe

7、d ProductsRepresents Production, not DemandCombination of Customer Orders and Demand ForecastsWhat Needs to be Produced.Inventory Master FileOn-Hand QuantitiesOn-Order QuantitiesLot SizesSafety StockLead TimePast-Usage Figures.MRP ProcessSchedules the Production of all items using an MRP MatrixItem:

8、 Low-Level Code: Lot Size: Lead Time:PD12345Gross RequirementsScheduled ReceiptsProjected on HandNet RequirementsPlanned Order ReceiptsPlanned Order ReleasesMRP Matrix.Terms DefinedItem name or number for the item being scheduledLow-Level Code the lowest level of the item on the product structure fi

9、leLot Size order multiples of quantityLead Time the time from when an order is placed to when it is receivedPD Past Due Time Bucket, orders behind schedule.Terms DefinedGross Requirements demand for an item by time periodScheduled Receipts material already orderedProjected on Hand expected ending in

10、ventoryNet Requirements number of items to be provided and whenPlanned Order Receipts net requirements adjusted for lot sizePlanned Order Releases planned order receipts offset for lead times.Example of the MRP ProcessItem: A Low-Level Code: 1 Lot Size: 25 Lead Time: 1PD12345Gross Requirements101525

11、2530Scheduled Receipts25Projected on Hand20Net RequirementsPlanned Order ReceiptsPlanned Order Releases.Example of the MRP ProcessItem: A Low-Level Code: 1 Lot Size: 25 min Lead Time: 1PD12345Gross Requirements1015252530Scheduled Receipts25Projected on Hand201020202015Net Requirements5510Planned Ord

12、er Receipts252525Planned Order Releases2525253025.MRP OutputsManufacturing OrdersPurchasing OrdersVarious Reports.Hubbell Lighting CaseManufactures Industrial Lighting ProductsGood-Quality ProductsPoor at Meeting Due DatesWork is Specialized for Each CustomerJob Shop EnvironmentComplex Products.Hubb

13、ell Lighting CaseBefore MRP ImplementationLess than 75% of orders completed on timeAfter MRP Implementation97% of orders completed on time2% of orders completed with 1 to 2 days after due date .Summary of MRPMRP is a.Computerized Inventory ControlProduction Planning Systemthat.Schedules Component Items as Neededwhich will.Track Inventory and.Help you in many other aspects of business.ReferencesRussell, Roberta S., and Bernard W. Taylor III. Operations Management. 3rd Edition: Prentice Hall, 2000 Grubbstrom, Robert W. Material Requirements Planning and Manufacturing Resource Planning. 0