Professional Documents
Culture Documents
Operations Management
William J. Stevenson
8th edition
13-2
CHAPTER
13
McGraw-Hill/Irwin
13-3
MRP
13-4
Dependent Demand
C(2)
B(4)
D(2)
E(1)
D(3)
F(2)
13-5
Dependant Demand
13-6
Stable demand
Demand
Demand
Figure 13.1
Time
Amount on hand
Amount on hand
Time
Lumpy demand
Safety stock
Time
Time
13-7
Figure 13.2
MRP Inputs
MRP Processing
MRP Outputs
Changes
Order releases
Master
schedule
Planned-order
schedules
Primary
reports
Bill of
materials
Inventory
records
MRP computer
programs
Secondary
reports
Exception reports
Planning reports
Performancecontrol
reports
Inventory
transaction
13-8
MPR Inputs
Master Production Schedule
Time-phased plan specifying timing and
quantity of production for each end item.
Material Requirement Planning Process
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P e
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13-9
Master Schedule
Master schedule: One of three primary
inputs in MRP; states which end items are
to be produced, when these are needed,
and in what quantities.
Cumulative lead time: The sum of the lead
times that sequential phases of a process
require, from ordering of parts or raw
materials to completion of final assembly.
Planning Horizon
Figure 13.4
Assembly
Subassembly
Fabrication
Procurement
10
Bill-of-Materials
Chair
Leg
Assembly
2 Legs (2)
Cross
bar
Seat
Back
Assembly
Side Cross
Back
Rails (2) bar Supports (3)
Inventory Records
One of the three primary inputs in MRP
Includes information on the status of each
item by time period
Gross requirements
Scheduled receipts
Amount on hand
Lead times
Lot sizes
And more
Figure 13.7
Procurement of
raw material D Fabrication
of part E
Subassembly A
Procurement of
raw material F
Procurement of
part C
Final assembly
and inspection
Procurement of
part H
Fabrication
of part G
Procurement of
raw material I
Subassembly B
10
11
MRP Processing
Gross requirements
Schedule receipts
Projected on hand
Net requirements
Planned-order receipts
Planned-order releases
MPR Processing
Gross requirements
Scheduled receipts
Planned on hand
MPR Processing
Net requirements
Planned-order receipts
Planned-order releases
Regenerative system
Net-change system
MRP Outputs
Performance-control reports
Planning reports
Exception reports
Other Considerations
Safety Stock
Lot sizing
Lot-for-lot ordering
Economic order quantity
Fixed-period ordering
MRP in Services
Hotel renovation
Benefits of MRP
Requirements of MRP
Master schedules
Bills of materials
Inventory records
Integrity of data
MRP II
Financial planning
Marketing
Engineering
Purchasing
Manufacturing
MRP II
Figure 13.14
Manufacturing
Master
production schedule
Marketing
Production
plan
MRP
Rough-cut
capacity planning
Capacity
planning
Adjust
production plan
Yes
Problems?
No
Requirements
schedules
No
Problems?
Market
Demand
Finance
Yes
Capacity Planning
Capacity requirements planning: The process
of determining short-range capacity
requirements.
Capacity Planning
Figure 13.15
Develop a tentative
master production
schedule
Use MRP to
simulate material
requirements
Convert material
requirements to
resource requirements
Revise tentative
master production
schedule
No
Is shop
capacity
adequate?
Yes
Firm up a portion
of the MPS
No
Can
capacity be
changed to meet
requirements
Yes
Change
capacity
ERP