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  • Material Requirement Planning

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    Kunal Mandalaywala
    166 просмотров26 страниц
    The document is a lecture on materials management from Dr. T.T. Narendran of IIT Madras. It covers topics like Materials Requirements Planning (MRP), comparisons between MRP and traditional systems, logical analysis for MRP, requirements and pre-requisites for effective MRP, reasons for MRP failure, Just-in-Time manufacturing, evolution of manufacturing control systems, inventory control models, and the economic order quantity formula. Diagrams and tables are used to explain key concepts and differences between approaches.

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    Material management's topic... Material requirement planning

    Оригинальное название

    Material requirement planning

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    The document is a lecture on materials management from Dr. T.T. Narendran of IIT Madras. It covers topics like Materials Requirements Planning (MRP), comparisons between MRP and traditional systems, logical analysis for MRP, requirements and pre-requisites for effective MRP, reasons for MRP failure, Just-in-Time manufacturing, evolution of manufacturing control systems, inventory control models, and the economic order quantity formula. Diagrams and tables are used to explain key concepts and differences between approaches.

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    Attribution Non-Commercial (BY-NC)
    Скачайте в формате PDF, TXT или читайте онлайн в Scribd
    Отметить как неприемлемый контент
    166 просмотров26 страниц

    Material Requirement Planning

    Загружено:

    Kunal Mandalaywala
    The document is a lecture on materials management from Dr. T.T. Narendran of IIT Madras. It covers topics like Materials Requirements Planning (MRP), comparisons between MRP and traditional systems, logical analysis for MRP, requirements and pre-requisites for effective MRP, reasons for MRP failure, Just-in-Time manufacturing, evolution of manufacturing control systems, inventory control models, and the economic order quantity formula. Diagrams and tables are used to explain key concepts and differences between approaches.

    Авторское право:

    Attribution Non-Commercial (BY-NC)
    Скачайте в формате PDF, TXT или читайте онлайн в Scribd
    Отметить как неприемлемый контент
    из 26

    Management Science II

    Dr.T.T.Narendran

    MODULE 3
    Materials Management Materials Requirements Planning (Mrp)

    Materials Requirements Planning (Mrp)

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    A Typical Mrp

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Comparison Of Mrp And Traditional Systems

    Dimension

    MRP

    Traditional

    Demand

    Dependent

    Independent

    Order Philosophy

    Requirements

    Replenishment

    Forecast

    Based on master schedule

    Based on past demand

    Control Concept

    Control on all items

    ABC

    Objectives

    Meet manufacturing needs

    Meet customer needs

    Lot Sizing

    Discrete

    EOQ

    Demand Pattern

    Lumpy but predictable Random

    Types of Inventory

    Work-in-process and raw materials

    Finished goods and spare parts

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Logical Analysis Preceding Mrp


    When do we want to make how many of each product? What components are required? How many of each of these is already on hand? How many have already been ordered? When will they arrive? When are more needed and how many more? When should these be ordered?

    Requirements For A Sound Mrp


    A valid master plan Accurate bills of materials Accurate information on current inventories Accurate information on orders already placed. Reliable lead times An adequate flow of materials

    Pre-Requisites Of Mrp
    A time-phased master production schedule in which every item is described by bill of materials (BOM) A unique no. identifying each component and the parent in every BOM Properly structured, accurate BOM and tight control of engineering changes Accurate current inventory balances Accurate quantities and reliable delivery dates

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Reliable lead times

    Further requirements for practical application Computer software and hardware to handle huge volume of data Timely reporting of issues, receipts, inventory adjustments and order releases Discipline in handling and order releases Capable people (for handling and deciding)

    Reasons For Failure Of Mrp


    It is part of an incomplete system Driven by an invalid / mismanaged Master Production Schedule Inaccurate data Improperly structured BOM Under qualified users

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Manufacturing Resource Planning (Mrp-Ii)

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Just In Time (Jit) Manufacturing

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Steps To Jit Manufacture

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Steps To Jit Manufacture Jit Vs. Mrp: A Comparison


    JIT MRP

    Vendors

    Part of your team

    Adversaries

    Scrap

    Eliminate

    Tolerate

    Maintenance

    Constant care to minimize breakdowns

    Not critical, allow queues

    Lead times

    Minimize

    Plan with them

    Workers

    Involve them

    Impersonal-drive them

    Inventory

    Liability, try to eliminate

    Asset, useful to absorb fluctuations

    JIT VS. MRP: A COMPARISON (CONTD.)


    JIT MRP

    Lot size

    Bare minimum (Single piece?)

    To balance set-up cost & holding cost

    Set-ups

    Cut down the time

    Plan for them

    Queues (WIP)

    Eliminate PRO-ACTIVE

    Necessary RE-ACTIVE

    Suitability

    High to medium volume Medium to low volume

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Evolution Of Manufacturing Control Systems


    Order Point system
    Forecast with past data. Inventory control with EOQ and ABC analysis.

    Mrp
    Based on Master schedule, B.O.M. and predicted demand. Complete inventory control. Convenient lot-size.

    Evolution Of Manufacturing Control Systems (Contd.) Mrp Ii


    Incorporates capacity planning. Incorporates feed back.

    Jit
    Emphasis on waste reduction. Aim for Zero defect. Aim for Zero Inventory. Quick change-overs. Small lots.

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Multi-Skilled Worker

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Kanban

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Inventory Control Inventory Control


    Costs In Inventory Control
    Item cost or unit cost Ordering / set-up cost Clerical, administrative, expediting,

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    transportation, etc.,

    Costs In Inventory Control


    Inventory carrying costs

    Locked-up capital

    storage space

    handling,

    taxes (?)

    insurance

    obsolescence,

    deterioration,

    maintaining records

    Shortage costs

    Overtime requirements due to shortage

    special clerical and administrative costs, expediting

    loss of goodwill (?)

    special transportation

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    lost production time

    Classification Of Inventory Models


    Static Dynamic Deterministic Probabilistic Uncertain

    Probabilistic

    Stock Level

    Time

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    A Typical Inventory Model


    Order quantity
    = Economic Order Quantity (EOQ) + Safety (buffer) stock

    inventory on hand - units on order

    + average demand over lead time

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Indian Institute of Technology Madras

    Management Science II

    Dr.T.T.Narendran

    Filename: CHAPTER 4 Directory: C:\Documents and Settings\User 1\Desktop\5 Template: C:\Documents and Settings\User 1\Application Data\Microsoft\Templates\Normal.dot Title: Subject: Author: User 1 Keywords: Comments: Creation Date: 6/29/2006 10:32:00 AM Change Number: 24 Last Saved On: 7/21/2006 12:44:00 PM Last Saved By: User 1 Total Editing Time: 544 Minutes Last Printed On: 9/21/2006 11:55:00 AM As of Last Complete Printing Number of Pages: 25 Number of Words: 742 (approx.) Number of Characters: 4,231 (approx.)

    Indian Institute of Technology Madras

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