The document provides an overview of resource planning systems like MRP and ERP. It describes the types of demand, evolution of material planning systems, and key components and processes of MRP like inputs, outputs, objectives, bills of materials, and lot sizing rules. It also discusses how ERP builds on MRP by integrating additional business functions for a holistic view of the organization. Benefits of ERP implementation include increased information flow and ability to replace disparate systems, though implementation requires significant costs, time, and management commitment.
Material requirements planning (MRP) is a production planning, scheduling, and inventory control system used to manage manufacturing processes. Most MRP systems are software-based, but it is possible to conduct MRP by hand as well. ... Plan manufacturing activities, delivery schedules and purchasing activities.
This topic is related to Material requirement planning, MRP.
Types of material requirement planning
Benefits of MRP. Limitation of MRP, Objective of MRP, MRP Input, MRP Output, Steps of MRP
Material requirements planning (MRP) is a production planning, scheduling, and inventory control system used to manage manufacturing processes. Most MRP systems are software-based, but it is possible to conduct MRP by hand as well. ... Plan manufacturing activities, delivery schedules and purchasing activities.
This topic is related to Material requirement planning, MRP.
Types of material requirement planning
Benefits of MRP. Limitation of MRP, Objective of MRP, MRP Input, MRP Output, Steps of MRP
This presentation is originally created by me when I reported Aggregate Planning during my Production and Operations Management class. I hope this can help you. :))
Concept of inventory, need for inventory, types of inventory, Seasonal, Decoupling, Cyclic, Pipeline, Safety, Implications of Inventory Control Methods Inventory Costs: Concept & Behavior of Ordering cost, Carrying cost & Shortage cost Basic EOQ Model & EOQ with Discount
In this presentation, we will discuss material planning systems and its evolution. Overview on MRP processes, its objectives and types of demands. We will also talk about the various terminologies like bills of material, inventory record, operating logics, MRP explosion process, capacity requirement planning.
To know more about Welingkar School’s Distance Learning Program and courses offered, visit: http://www.welingkaronline.org/distance-learning/online-mba.html
This presentation is originally created by me when I reported Aggregate Planning during my Production and Operations Management class. I hope this can help you. :))
Concept of inventory, need for inventory, types of inventory, Seasonal, Decoupling, Cyclic, Pipeline, Safety, Implications of Inventory Control Methods Inventory Costs: Concept & Behavior of Ordering cost, Carrying cost & Shortage cost Basic EOQ Model & EOQ with Discount
In this presentation, we will discuss material planning systems and its evolution. Overview on MRP processes, its objectives and types of demands. We will also talk about the various terminologies like bills of material, inventory record, operating logics, MRP explosion process, capacity requirement planning.
To know more about Welingkar School’s Distance Learning Program and courses offered, visit: http://www.welingkaronline.org/distance-learning/online-mba.html
This is an operation management assignment which covers mrp & erp topics with detail.
This is a bookish topic which we find in operations management book & describe it with the help of internet & mind. This presentation describe all the factors of mrp & erp & also represent graphs. This topics explains processes of mrp & erp. Bill of materials, inventory records, planned order receipt, planned order release, primary Reports, secondary reports.
Material requirement planning - Production and Operation ManagementSuryakumar Thangarasu
A production planning, scheduling and inventory control system, manages manufacturing process.
Ensures availability of materials for production and delivery to customers.
Maintains lowest possible material in the store.
Plans manufacturing activities and delivery schedule.
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2. Types of Demand
There are two types of demand.
Independent Demand
Is the demand for finished products
Does not depend on the demand of other products
Needs to be forecasted
Dependent Demand
Is the demand derived from finished products
Is the demand for component parts based on the
number of end items being produced and is managed
by the MRP system
3. Evolution of Material Planning Systems
Back in the sixties, manufacturing planning
systems were reorder point systems that simply
determined when and how much to order
First MRP systems translated a master schedule of
final products into time-phased net requirements
for subassemblies, assemblies, and parts
Closed-loop MRP included production planning,
master scheduling, and capacity requirements
In mid 1970’s, MRPII systems added functionality
to plan and execute all internal functions
4. An Overview of MRP
MRP uses the concept of backward scheduling to
determine how much and when to order and
replenish
The MPS module contains the authorized schedule
The BOM module contains the product structure
for each unique product
The Inventory Record module keeps track of
the inventory status for each item in the database
MRP output includes schedules for all internal
activities and parts as well as orders for all supply
chain items
6. Objectives of MRP
Determines the quantity and timing of
material requirements
Determines what to order (checks BOM), how
much to order (lot size rules), when to place
the order (need date minus lead time), and
when to schedule delivery (on date needed)
Maintain priorities
In a changing environment, MRP reorganizes
priorities to keep plans current and viable
8. MRP Inputs - Authorized MPS
From the authorized MPS, we calculate when we
need to have replenishment orders of CD cabinets;
when we need a new MPS order.
Table 14-1 Initial MPS Record for CD Cabinet
Item: CD Cabinet
Lot size rule: FOQ=100
Lead time: 1 week
1 2 3 4 5 6 7 8 9 10 11 12
Gross Requirements: 25 25 25 25 30 30 30 30 35 35 35 35
Projected Available: 80 55 30 5 -20
MPS
Table 14-2 Updated MPS Record for CD Cabinet
Item: CD Cabinet
Lot size rule: FOQ=100
Lead time: 1 week
1 2 3 4 5 6 7 8 9 10 11 12
Gross Requirements: 25 25 25 25 30 30 30 30 35 35 35 35
Projected Available: 80 55 30 5 80 50 20 90 60 25 90 55 20
MPS 100 100 100
9. MRP Inputs-Inventory Records
System checks the inventory record for each BOM item
to see if inventory is available or if a replenishment
order is needed to build the cabinets.
Table 14-3 First Inventory Record for CD Cabinet
Item: CD Cabinet
Lot size rule: L4L
Lead time: 1 week
1 2 3 4 5 6 7 8 9 10 11 12
Gross Requirements: 0 0 0 100 0 0 100 0 0 100 0 0
Scheduled Receipts:
Projected Available: 0 0 0 0 -100
Planned Orders
Table 14-4 Updated Inventory Record for CD Cabinet
Item: CD Cabinet
Lot size rule: L4L
Lead time: 1 week
1 2 3 4 5 6 7 8 9 10 11 12
Gross Requirements: 0 0 0 100 0 0 100 0 0 100 0 0
Scheduled Receipts:
Projected Available: 0 0 0 0 0 0 0 0 0 0 0 0 0
Planned Orders 100 100 100
10. MRP Inputs-Bills of Material
A BOM lists all of the
items needed to produce
one CD cabinet
The BOM is exactly like a
recipe for baking a cake
The BOM’s must be
complete and accurate
and can only be changed
by an ECN
MRP BOM’s are indented
bills of materials
Indented BOM
12. The MRP Explosion Process
Using this table and the product structure tree, we will
work through an example of how the MRP explosion
process calculates the requirements for building a CD
cabinet. Next we start with the cabinet top to show
how MRP calculates the gross requirements for this
component.
Table 14-6 Updated Inventory Record for CD Cabinet
Item: CD Cabinet Parent: none
Lot size rule: L4L Children: Top, bottom, door, left side, right side, shelves, shelf supports
Lead time: 1 week
1 2 3 4 5 6 7 8 9 10 11 12
Gross Requirements: 0 0 0 100 0 0 100 0 0 100 0 0
Scheduled Receipts:
Projected Available: 0 0 0 0 0 0 0 0 0 0 0 0 0
Planned Orders: 100 100 100
13. Inventory Records - Components
It was noted on the previous slide that the parent item (CD
Cabinet) has planned orders in periods 3, 6, and 9.
Its children (top, bottom, door, left & right side, shelves, and
supports) have gross requirements in periods 3, 6, and 9.
20. MRP Action Notices
Action Notices:
Indicate items that need a production planner’s
attention
Are created when a planned order needs to be
released, due dates need to be adjusted, or
when there is insufficient lead time for normal
replenishment
Often require planners to rush or expedite
orders
21. MRP Action Notices
Action Bucket:
Is the current period where we take actions such
as releasing, rescheduling, or canceling orders
A positive quantity in current period’s planned
order row means that an order must be released
22. Lot Sizing Rules
Rules are used to change the frequency
of replenishment orders & set the
quantity of each order (balance holding
& ordering costs to reduce total costs)
Common rules:
Fixed Order Quantity (FOQ)
Lot-for-Lot (L4L)
Periodic Order Quantity (POQ)
23. Example Comparing Lot Size Rules: Three lot sizing
rules used within MRP Systems are: fixed order quantity (FOQ), lot
for lot (L4L), and period order quantity (POQ). Cost comparison is
based on Inventory holding costs ($0.10/period) and ordering cost
($25/order). In this example POQ is best at $133.50.
24. Rough Cut Capacity Example: The CRP module uses data from
MRP. Calculate workloads for critical work centers based on open
shop orders and planned shop orders. These shop orders are
translated into hours of work by work center and by time period.
Table 14-11 show items scheduled for work Center 101.
Available = 4 machines x 2 shifts x 10 hours x 5 days x 0.85 utiliza- x 0.95 effi-
Capacity per shift per wk. tion ciency
Available = 323.0 standard hours
Capacity
25. Workload Graph for Work Center 101: CRP enables a
company to evaluate both the feasibility of the MRP system and
how well the company is using its critical work centers.
26. Enterprise Resource Planning
What Is ERP?
Software designed for organizing and managing
business processes
Modules share information across all business
functions
Can share customer sales data with the supply
chain to help with global replenishment
All modules are fully integrated and use a
common database – some PC based
28. ERP Modules-4 Categories
Finance and accounting
Investment, cost, asset, capital, and debt management
Budgets, profitability analysis, and performance reports
Sales and marketing
Handles pricing, availability, orders, shipments, & billing
Production and materials management
Process planning, BOM, product costing, ECN’s, MRP,
allocates resources, schedules, PO’s, & inventory
Human resources
Workforce planning, payroll & benefits, & org. charts
29. Benefits of ERP Implementation
ERP presents a holistic view of the business functions from
a single information and IT architecture
Increases organizational information flow
Increases ability to incorporate better management
control, speedier decision making, and cost reductions
Allows replacement of disparate systems
e.g. ExxonMobile used ERP to replace 300 different
systems
A study of ERP implementations reports that benefits
typically start 8 months after implementation with median
annual savings of $1.6 million
30. Cost and Implementation Issues
Major suppliers are SAP, Peoplesoft, Oracle, and Baan. Also
smaller PC based suppliers.
Costs for larger ERP systems range from hundreds of
thousands to several million dollars.
Outside consultants are usually involved in selection,
configuration, and implementation.
Consultant costs can run up to 3 times the cost of the
system itself according to a Gartner Group study.
Added costs also include additional people, new computer
hardware, and the cost to develop a new, integrated
database
Successful implementation requires leadership and top
management commitment to a vision for the business