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MRP 10 point plan


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This is a basic introduction to some of the issues that should be considered when contemplating an MRP system.
It is by no means an academic piece, nor is it exhaustive, but it is aimed at real users who need to understand some of the terminology and acronyms that creep in.
It raises one or two points about issues that are common to all MRP installations, such as Data Migration which will almost certainly cost the client money, if he fails to resolve them before the installation.

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MRP 10 point plan

  1. 1. MRP Ten points for consideration. 1
  2. 2. This is not an attempt to fully educate you in MRP through an arbitrary list of issues that can arise during the selection process for any MRP system……. 2
  3. 3. These are merely pointers and work as an introduction to prompt discussion. The questions raised will apply to whichever partners are selected when you start to discuss MRP, and you should not allow yourself to be fobbed off, because the questions raised here, will need an answer or will cost you money. 3
  4. 4. 1. Let’s get the alphabet soup out of the way first • MRP – Material Requirements Planning • MRP II – MRP with added whistles and bell • ERP – MRP II with yet more added whistles and bells • MSP/MPS – Master Schedule of Production (Master Production….) 4
  5. 5. 2. What is MRP? Material Requirements Planning is a production planning and inventory control system used to manage manufacturing processes. Most MRP systems are software-based, though it is possible to conduct MRP manually using spreadsheets. (Courtesy of Wikipedia – I do not believe in re-invention of the wheel!) 5
  6. 6. Any MRP system is intended to simultaneously meet three objectives : - 6
  7. 7. • Ensure materials are available for production and products are available for on time delivery to customers. 7
  8. 8. • Ensure materials are available for production and products are available for on time delivery to customers. • Maintain the lowest possible material and product levels in stock. 8
  9. 9. • Ensure materials are available for production and products are available for on time delivery to customers. • Maintain the lowest possible material and product levels in stock. • Plan manufacturing activities, delivery schedules and purchasing activities effectively and efficiently. 9
  10. 10. 3. What is MRP II? • Those whistles and bells I mentioned previously look to enhance the presentation of materials mapped by the Material Requirements Plan in line with the Manufacturing Resource Plan(ning) and the Master Production Schedule. 10
  11. 11. 4. What is ERP? • When it was seen that MRP and its derivatives could significantly enhance manufacturing output, developments took the software to a new level by incorporating administrative modules that up until this point were generally treated as add-ons. Accounts, Sales Office, CRM, Human Resources. All were becoming integral parts of the management system. 11
  12. 12. 5. Which one is for me? • That is the $64 question. Until we sit down and look at your business, and what it is you are trying to achieve, we cannot tell. Beware the salesman who tells you that his system is the one for you before he has looked in depth at your company. Truth be told, he cannot know. 12
  13. 13. 6. What will it cost me? • • See 5! Without looking at your company and its needs, we cannot tell you. There will be a system in your price range. You just have to find it. You should always work on the principle that such a system will save you money in the mid-long term, once bedded in, and should encourage your customers to remain loyal to you. And you should expect the system to pay for itself in time. 13
  14. 14. 7. Will I have to change my in-house routines? • Possibly, but again, selection of the most applicable system can see this reduced to a minimum. • You may want to change these routines and see this as an opportunity. We can work with your staff to map the current methods and how we see them post MRP installation. 14
  15. 15. 8. Data Migration? • I have got so much data. How will we get this across to the new system? • This can apply to stock levels or accounts etc, and presents us with another good question for the salesman. When they tell you the supplier of the MRP system will take care of it, just establish if this is included in the purchase price or is it an extra? It could cost you a significant amount on top of the originally quoted price if you do not take care. It does, however, present you with a golden opportunity to cleanse your data. We have helped a number of clients move data from one system to another. 15
  16. 16. 9. Will I need a specialist to look after the system once it is up and running? • Like any tool, the better it is used the greater the benefits that will accrue, so my recommendation is that one or two individual members of staff are chosen to lead the installation. From initial specification to mapping routines before and after, liaising with all those departments involved and really getting to grips with the logic. We can work with you and your staff to elect and to train the candidates selected. 16
  17. 17. 10. I’d rather have a new welding bay! • With apologies to the Production Director that said this after one presentation, as with all investment in business systems, there will be argument and counter argument about the real value. But we can demonstrate a multitude of areas that will benefit from a properly chosen and installed system, effectively employed. Such an investment is a step change in the culture of a business and will demonstrate to both employees and customers, that your company wants to engage with a more efficient and effective way of working. 17