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    Production Planning and Control

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    RAlexanderS
    The document discusses materials requirement planning (MRP), which determines the quantities and timing of needed raw materials and components given a master production schedule and bills of material. MRP works by exploding gross requirements down through the bill of material structure using lead times to determine net requirements and planned order releases. It provides an example MRP calculation and discusses how rough cut capacity planning can check for capacity feasibility issues using resource requirements.

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    Production Planning and Control

    Uploaded by

    RAlexanderS
    20 views10 pages
    The document discusses materials requirement planning (MRP), which determines the quantities and timing of needed raw materials and components given a master production schedule and bills of material. MRP works by exploding gross requirements down through the bill of material structure using lead times to determine net requirements and planned order releases. It provides an example MRP calculation and discusses how rough cut capacity planning can check for capacity feasibility issues using resource requirements.

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    The document discusses materials requirement planning (MRP), which determines the quantities and timing of needed raw materials and components given a master production schedule and bills of material. MRP works by exploding gross requirements down through the bill of material structure using lead times to determine net requirements and planned order releases. It provides an example MRP calculation and discusses how rough cut capacity planning can check for capacity feasibility issues using resource requirements.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    20 views10 pages

    Production Planning and Control

    Uploaded by

    RAlexanderS
    The document discusses materials requirement planning (MRP), which determines the quantities and timing of needed raw materials and components given a master production schedule and bills of material. MRP works by exploding gross requirements down through the bill of material structure using lead times to determine net requirements and planned order releases. It provides an example MRP calculation and discusses how rough cut capacity planning can check for capacity feasibility issues using resource requirements.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 10

    Production Planning and Control

    Materials Requirement Planning

    Dr. Lotfi K. Gaafar

    Production Planning and Control- Materials Requirement Planning (1) Gaafar 2001
    Production Planning and Control
    The Production Control System

    Demand Sales and


    order entry Customer
    forecasting

    Aggregate Materials Shop-floor Shipping


    planning requirement scheduling Production and
    planning and control receiving

    Inventory
    Inventory Vendors
    management

    Production Planning and Control- Materials Requirement Planning (2) Gaafar 2001
    Material Requirements Planning

    Given a master schedule, what raw materials and


    components quantities are needed and when.
    Master Production
    Scheduling
    Bills of
    Material
    Material Requirements
    Planning
    Inventory
    Status
    Requires:
    Quantities and
    Order Times
    •Bill of material (Manufacturing tree)
    •Inventory status
    •Lead times

    Production Planning and Control- Materials Requirement Planning (3) Gaafar 2001
    Assumptions

    1. Known deterministic demands.

    2. Fixed, known production leadtimes.

    3. Infinite capacity.

    Idea is to “back out” demand for components by using


    leadtimes and bills of material.

    Production Planning and Control- Materials Requirement Planning (4) Gaafar 2001
    MRP Procedure

    1. Netting: net requirements against projected inventory

    2. Lot Sizing: planned order quantities

    3. Time Phasing: planned orders backed out by leadtime

    4. BOM Explosion: gross requirements for components

    Production Planning and Control- Materials Requirement Planning (5) Gaafar 2001
    Inputs

    – Master Production Schedule (MPS): due dates and


    quantities for all top level items

    – Bills of Material (BOM): for all parent items

    – Inventory Status: (on hand plus scheduled receipts) for all


    items

    – Planned Leadtimes: for all items

    Production Planning and Control- Materials Requirement Planning (6) Gaafar 2001
    Material Requirements Planning
    Example
    Consider the manufacturing tree
    (BOM) and the accompanying
    information.

    Period GR
    1 10
    2 15
    3 12
    Scheduled Order Receipts (SOR)
    4 16
    5 15 Period 1 2 3 4 5 6 7 8
    6 12 CT 12 14 0 0 0 0 0 0
    7 18 B00 8 2 2 0 0 0 0 0
    8 14 X10 2 2 1 1 0 0 0 0

    Production Planning and Control- Materials Requirement Planning (7) Gaafar 2001
    Material Requirements Planning
    Example
    Time 1 2 3 4 5 6 7 8
    GR 10 15 12 16 15 12 18 14
    CT SOR 12 14 0 0 0 0 0 0
    BI 0 2 1 0 0 0 0 0
    LT = 2 NR -2 -1 11 16 15 12 18 14
    POR 0 0 11 16 15 12 18 14
    EI 2 1 0 0 0 0 0 0
    PORE 11 16 15 12 18 14 ? ?

    Time 1 2 3 4 5 6 7 8
    GR 22 32 30 24 36 28 ? ?
    SOR 8 2 2 0 0 0 0 0
    B00 BI 14 0 0 0 0 0 0 0
    NR 0 30 28 24 36 28 ? ?
    LT = 1 POR 0 30 28 24 36 28 ? ?
    EI 0 0 0 0 0 0 0 0
    PORE 30 28 24 36 28 ? ? ?

    Production Planning and Control- Materials Requirement Planning (8) Gaafar 2001
    Material Requirements Planning
    Example
    Time 1 2 3 4 5 6 7 8
    GR 41 44 39 48 46 14 ? ?
    SOR 2 2 1 1 0 0 0 0
    X10 BI 8 0 0 0 0 0 0 0
    LT = 1 NR 31 42 38 47 46 14 0 0
    POR 31 42 38 47 46 14 0 0
    EI 0 0 0 0 0 0 0 0
    PORE 42 38 47 46 14 0 0 ?

    33 X10 cannot be scheduled.


    How many CTs will be affected?
    How can we fix the problem?

    Production Planning and Control- Materials Requirement Planning (9) Gaafar 2001
    Rough Cut Capacity Planning (RCCP)

    – Quick check on capacity of key resources

    – Use Bill of Resource (BOR) for each item in MPS

    – Generates usage of resources by exploding MPS against BOR


    (offset by leadtimes)

    – Infeasibilities addressed by altering MPS or adding capacity (e.g.,


    overtime)

    Production Planning and Control- Materials Requirement Planning (10) Gaafar 2001

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