Ch 9 (quick response)


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Ch 9 (quick response)

  1. 1. Quick-Response Manufacturing Systems
  2. 2. Quick-response manufacturing system Computer Integrated Manufacturing System (CIM) Physical manufacturing system CADD Manufacturing resource planning (MRP II) CAM MRP
  3. 3. Advanced Integration Technologies Distributed databases Distributed databases Computer-based information system EDI Automatic identification
  4. 4. The Physical Manufacturing System Two subsystems directly support the physical manufacturing system. CADD (computer-aided design and drafting) CAM (computer-aided manufacturing)
  5. 5. Computer-Aided Design and Drafting (CADD) Solids modeling Finite element analysis Automated drafting
  6. 6. Computer-Aided Manufacturing (CAM) Industrial robot Statistical process control Flexible manufacturing systems
  7. 7. The Manufacturing Resource Planning (MRP II) System The MRP II system comprises the materials requirements planning (MRP) system and the related systems for sales, billing, and purchasing.
  8. 8. Materials Requirements Planning (MRP) Production planning Production scheduling MRP Cost accounting Reporting
  9. 9. Advanced Integration Technologies
  10. 10. Production Planning Production planning involves the determination of which products to produce and the scheduling of production to make optimal use of production resources.
  11. 11. Production Planning Demand for a product Production requirements Production resources available
  12. 12. Production Planning 1 Marketing Production planning 2 Inventory control 1 Sales forecast 2 Finished goods status 3 Raw materials status 4 Factor availability report 5 Production schedule 3 Bill of materials 4 5 Production departments Master operations list
  13. 13. Production Planning Bill-ofmaterials file Master operations file Master production plan Production planning program(s) Production status file
  14. 14. Production Planning Production orders Material requisitions Routings Updated production status file
  15. 15. Production Scheduling Production status file Production status update Routing file Summary report Updated production status file Production loading file
  16. 16. Production Scheduling Production loading file Production scheduling program Summary report Production schedules
  17. 17. Production-Loading File This is the major input to the production-scheduling application.
  18. 18. Cost Accounting Production status file Production data file • Material requisition data • RTG data Cost accounting program(s) Summary report Updated production status file Completed production order file Resource usage file
  19. 19. Reporting Inventory Processing Inventory file Updated inventory file Inventory update Finished goods stock status report Completed production cost report Completed production order file Summary report
  20. 20. Reporting Resource Usage Reporting Report generator Resource usage reports Resource usage file
  21. 21. Activity-Based Costing Traditional cost accounting techniques may be inadequate in a computer integrated manufacturing environment. Because CIM reduces direct labor and increases overhead. Variable costs decrease and fixed costs increase.
  22. 22. Activity-Based Costing Activity-based costing (ABC) calculates several overhead rates, one for each manufacturing activity.
  23. 23. Activity-Based Costing What are some examples of activities? Machine centers Material handling Inspection stations Manual assembly A single department may contain several different activities.
  24. 24. Major Processing Modules in MRP II Bill-of-materials module Master production scheduling module Inventory control module Routings file module MRP II Production order module Production activity control module
  25. 25. Implementing JIT in a MRP II/CIM Environment Less emphasis might be placed on a complete MRP II system.