krajewski chapter 15
TRANSCRIPT
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Resource Planning
Chapter 15 Chapter 15
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How Resource Planning
fits the Operations Management
Philosophy
Operations As a CompetitiveWeapon
Operations StrategyProject Management Process Strategy
Process AnalysisProcess Performance and Quality
Constraint ManagementProcess LayoutLean Systems
Supply Chain StrategyLocation
Inventory Managementorecasting
Sales and Operations PlanningResource Planning
Scheduling
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Resource Planning
at Starwood
Starwood manages employees, equipment, and supplies at750 hotels around the world to ensure that the needs andexpectations of each and eery customer are met!
"o help forecast these needs, Starwood now uses anenterprise resource planning #E$P% system!
&ncluded in the E$P system 'y (racle is an electronicreseration system that profiles the preferences of guests,allowing the staff to proide a )customi*ed+ experience foreach guest!
"he E$P system schedules the hotels staff mem'ers,
pro-ects the amount of food, 'eerages, and otherresources needed for the hotels food.serice department!
Starwoods E$P system also features a centrali*eddata'ase with accounting data, payroll, accounts paya'leinformation, general ledger and 'alance sheet, as well asincome statements for its arious properties!
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Resource Planning and
ERP
Resource planning/ process that ta1es sales and
operations plans processes information in the way
of time standards, routings, and other information
on how the firm produces its serices or productsand then plans the input requirements!
Enterprise process/ companywide process that
cuts across functional areas, 'usiness units,
geographical regions, and product lines! Enterprise resource planning (ERP) systems/
3arge, integrated information systems that support
many enterprise processes and data storage needs!
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ERP Application Modules
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ERP esign
E$P reoles around a single comprehensie
data'ase that can 'e made aaila'le across the
entire organi*ation #or enterprise%!
"he data'ase collects data and feeds them into thearious modular applications #or suites%! s new information is entered as a transaction in one
application, related information is automatically updated in
the other applications!
"he E$P system streamlines the data flows throughout theorgani*ation and proides employees with direct access to
a wealth of real.time operating information!
E$P eliminates many of the cross.functional coordination
pro'lems older nonintegrated systems suffered from!
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ependent emand
Dependent demand/ "he demand for an item that
occurs 'ecause the quantity required aries with the
production plans for other items held in the firms
inentory!
Parent/ ny product that is manufactured from one
or more components!
Component/ n item that goes through one ormore operations to 'e transformed into or 'ecome
part of one or more parents!
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!umpy ependent emand Resulting
from Continuous "ndependent emand
Parent Inventory
(Independent)
Component Demand
(Dependent)
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Possi#le Planning
and Control Systems
• Products with many leels
of components, and more
customi*ation
4 3umpy demand, often with
larger 'atch si*es4 a1e.to.order, assem'le.
to.order, and ma1e.to.stoc1
strategies
4 3ower and intermediate
olumes, with flexi'le flows
• 6apacity is leeraged to
control 'ottlenec1s and
entire system flow
4 Simpler product structures
and more standardi*edproducts
4 ssem'le.to.order or ma1e.
to.stoc1 strategy
4 $elatiely higher olumes,
with flexi'le flows
transitioning to line flows
• sing system as catalyst for
continuous improement
4 Small lot si*es, consistent
quality, relia'le suppliers,
and flexi'le wor1force4 ssem'le.to.order or ma1e.
to.stoc1 strategy
4 8igh olumes and well.
'alanced line flows
"he most prominent systems now in use are the
material requirements planning #$P% system, the
9rum.:uffer.$ope #9:$% system, and lean systems!
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Material
Re$uirements Planning
Material requirements planning (MRP):
computeri*ed information system deeloped specifically to
help manufacturers manage dependent demand inentory and
schedule replenishment orders!
MRP explosion/ process that conerts the requirements
of arious final products into a material requirements plan that
specifies the replenishment schedules of all the
su'assem'lies, components, and raw materials needed to
produce final products!
Bill o materials (B!M): record of all the components
of an item, the parent;component relationships, and the
usage quantities deried from engineering and process
designs!
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MRP "nputs
Inventory
transactions
Inventory
records
!t"er
sources
o demand
#ut"ori$ed
master production
sc"edule
Bills o
materials
Engineering
and process
designs
Material
requirements
plan
MRPMRP
explosionexplosion
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%ill of Materials &erms
%sage quantity/ "he num'er of units of a
component that are needed to ma1e one unit of its
immediate parent!
Inventory items: End item/ "he final product sold to a customer!
Intermediate item/ n item that has at least one parent
and at least one component!
&u'assem'ly/ n intermediate item that is assem'led #as
opposed to 'eing transformed 'y other means% from more
than one component!
Purc"ased item/ n item that has one or more parents
'ut no components 'ecause it comes from a supplier!
Part commonality/ "he degree to which a
component has more than one immediate parent!
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%ill of Materials
&eat cus"ion
&eatrame
'oards
ront
legs #
*adder'ac+
c"air
Bac+
legs
*eg supports
Bac+ slats
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, (-)
&eatrame 'oards
I (.)
&eat cus"ion
/ (.)
&eat rame
0 (-)
Bac+ slats
(1)
Bac+ legs
C (.)&eat
su'assem'ly
D (1)ront
legs
B (.)*adder'ac+
su'assem'ly
E (-)*eg
supports
# *adder'ac+
c"air
%ill of Materials
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Master
Production Schedule
Master production sc"edule (MP&): part of the material
requirements plan that details how many end items will 'e
produced within specified periods of time!
*adder'ac+ c"air
2itc"en c"air
Des+ c"air
. 1
#pril May
3 - 4 5 6 7
#ggregateproduction planor c"air amily
188
568568
188
.48
.18
188
.48
188
.18
568568
MP& or a amily o c"airs
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Master Production
Scheduling Process
(perations must first create a prospectie PS to test
whether it meets the schedule with the resources!
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e'eloping a Master
Production Schedule
<orecast is less than
'oo1ed orders in wee1 =
pro-ected on.hand inentory
'alance > 55 ? 0 ; @A > =7!
<orecast exceeds 'oo1ed
orders in wee1 2 pro-ected on.hand inentory 'alance
> =7 ? 0 ; @0 > ;=@! "he
shortage signals a need to
schedule an PS quantity for
completion in wee1 2!
MPS for
(ee)s 1 * +
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A'aila#le,&o,Promise
"n'entory
#vaila'letopromise (#9P) inventory/ "he
quantity of end items that mar1eting can promise to
delier on specified dates!
&t is the difference 'etween the customer orders already'oo1ed and the quantity that operations is planning to
produce!
s new customer orders are accepted, the "P
inentory is reduced to reflect the commitment of
the firm to ship those quantities ctual inentory stays unchanged until the order is
remoed from inentory and shipped to the customer!
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MPS (or)sheet
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Item: *adder'ac+ c"air !rder Policy: .48 units
*ead 9ime: . ee+
. 1 3 - 4 5 6 7
#pril
orecast
Customer
orders 'oo+ed
Pro;ectedon"and
inventory
MP& quantity
MP& start
<uantity
on /and:
38
37
38
16
38
1-
38
7 8
34
8
34
8 8
3434
44
May
.6 .36 .86 66 -1 6 .11 76
8 .48 8 8 8 8 .48 8
.48 8 8 8 8 .48 8 8
#vaila'leto
promise (#9P)
inventory
.6 =. .48
MPSSchedule
with
A&P
"he total of customer orders 'oo1ed until the next PS receipt is @A
units! "he "P > 55 #on.hand% ? 0 #PS quantity% ; @A > =7!
"he total of customer orders 'oo1ed until the next PS receipt is 27
? 2B ? A > 5C units! "he "P > =50 #PS quantity% ; 5C > C= units!
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MPS for Product A Application 15-1
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MPS for Product A
Application 15-1
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"n'entory Record
Inventory record/ record that shows an items lot.si*e policy,lead time, and arious time.phased data!
0ross requirements/ "he total demand deried from all parentproduction plans!
&c"eduled Receipts #open orders% are orders that hae 'eenplaced 'ut not yet completed!
Pro;ected on"and inventory/ n estimate of the amount ofinentory aaila'le each wee1 after gross requirements hae
'een satisfied! Planned receipts/ (rders that are not yet released to the shop
or supplier!
Planned order release/ n indication of when an order for aspecified quantity of an item is to 'e issued!
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"n'entory Record
.,Period (or)sheet
"n entor Record
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"n'entory Record Shows an items lot.si*e policy, lead time, and arious time.phased data!
Item: C
Description: *adder'ac+ C"air &eat su'assem'ly
*ot &i$e: 138 units
*ead 9ime: 1 ee+s
0ross
requirements.48
.
138
..6
8
1
8
8
3
8
.18
-
8
4
8
.48
5
8
.18
6
8
7
8&c"eduled
receipts
Pro;ectedon"andinventory
Planned
receipts
Planned order
releases
36
>ee+
88
..6 ..6 116
138
138
116 66
138
.76
138
.76
0ross requirements/ "he total demand deried from all parent
production plans!&c"eduled Receipts #open orders% are orders that hae 'eenplaced 'ut not yet completed!
Pro;ected on"and inventory/ n estimate of the amount ofinentory aaila'le each wee1 after gross requirements hae
'een satisfied!
Planned receipts/ (rders that are not yet released to the shop
or the supplier!
Planned order release/ n indication of when an order for aspecified quantity of an item is to 'e issued!
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Item: C
Description: *adder'ac+ C"air &eat su'assem'ly
*ot &i$e: 138 units
*ead 9ime: 1 ee+s
0ross
requirements.48
.
138
..6
8
1
8
8
3
8
.18
-
8
4
8
.48
5
8
.18
6
8
7
8&c"eduled
receipts
Pro;ectedon"andinventory
Planned
receipts
Planned orderreleases
36
>ee+
88
..6 ..6 116
138
138
116 66
138
.76
138
.76
Dithout a planned receipt in wee1 B, a shortage of @ units will occur/ ==7 ? 0 ? 0
; =20 > ;@ units! dding the planned receipt 'rings the 'alance to ==7 ? 0 ? 138
; =20 > 227 units! (ffsetting for a 2.wee1 lead time puts the corresponding
planned order release 'ac1 to wee1 2!
"he first planned receipt lasts until wee1 7, when pro-ected inentory would drop
to 77 ? 0 ? 0 ; =20 > ;B@ units! dding the second planned receipt 'rings the
'alance to 77 ? 0 ? 138 ; =20 > =A7 units! "he corresponding planned order
release is for wee1 5 #or wee1 7 minus 2 wee1s%!
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Planning /actors
Planning lead time: n estimate of the time
'etween placing an order for an item and
receiing the item in inentory!
Setup timeProcessing time
aterials handling time 'etween
operationsDaiting time
*otsi$ing rules: rule that determines the
timing and si*e of order quantities!
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!ot Si0ing Rules/ied Order 2uantity 3/O24
ixed order quantity (!<): rule that
maintains the same order quantity each time
an order is issued!
9ictated 'yEquipment capacity limits
uantity discount
"ruc1load capacityinimum purchase quantity
E(
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H1,A 6sing /O2 Application 15-+
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H1,A 6sing /O2
Application 15-+
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!ot Si0ing RulesPeriodic Order 2uantity 3PO24
Periodic order quantity (P!<): rule thatallows a different order quantity for eachorder issued 'ut tends to issue the order at
predetermined time interals!"he order quantity equals the amount of the item
needed to coers P wee1s worth of grossrequirements!
P!< lot si$e
to arrive in
ee+ t
9otal 0ross requirements
or P ee+s? including
ee+ t
Pro;ected on"and
inventory 'alance
at end o ee+ t .
@ A
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&he PO2 3P 7 84 Rule for the!adder,#ac) Chair Seat Su#assem#ly
Item: C
Description: *adder'ac+ C"air &eat su'assem'ly
*ot &i$e: P @ 3
*ead 9ime: 1 ee+s
0ross
requirements .48.48
.
138138
..6..6
1 3
.18.18
- 4
.48.48
5
.18.18
6 7
&c"eduled
receipts
Pro;ected
on"andinventory
Planned
receipts
Planned order
releases
36
>ee+
..6..6 ..6..6
.43.43
.48.48
.43.43
.48.48 88 88 88
.18.18
.18.18
#=20 ? 0 ? =50% . ==7 > =5@
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H1,A 6sing PO2 Application 15-8
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H1,A 6sing PO2
Application 15-8
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!ot,for,!ot
*otorlot (*-*) rule/ rule under which the lot si*eordered coers the gross requirements of a singlewee1!
"husP
> =, and the goal is to minimi*e inentoryleels!
"he pro-ected on.hand inentory com'ined withthe new order will equal *ero at the end of wee1 t !
*-* lot si$eto arrive in
ee+ t
0ross requirements
or ee+ t
Pro;ected on"andinventory 'alance at
end o ee+ t .
@ A
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&he !ot,for,!ot 3!9!4 Rule for the!adder,#ac) Chair Seat Su#assem#ly
Item: C
Description: *adder'ac+ C"air &eat su'assem'ly
*ot &i$e:
*ead 9ime: 1 ee+s
0ross
requirements .48.48
.
138138
..6..6
1 3
.18.18
- 4
.48.48
5
.18.18
6 7
&c"eduled
receipts
Pro;ected
on"andinventory
Planned
receipts
Planned order
releases
36
>ee+
..6..6 ..6..6
33
88
33
88 88 88 88
.18.18
.18.18
#=20 ? 0 ? 0% . ==7 > @
*-* Rule
.48.48
.48.48
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H1,A 6sing !9! Application 15-9
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H1,A 6sing !9!
Application 15-9
C i
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Comparing
!ot,Si0ing Rules
!<, P!<, and *-* rules affect inentory costs and setup andordering costs! &n the example, each rule too1 effect in wee1 B,when the first order was placed! comparison of pro-ected on.hand inentory aeraged oer wee1s
B through A of the planning hori*on for the ladder.'ac1 chair seatsu'assem'ly/
!</ #227?227?77?=A7?=A7%F5 > .7. units
P!</ #=50?=50?0?0?0%F5 > 58 units
*-*/ #0?0?0?0?0%F5 > 8 units
!< generates high inentory 'ecause it creates remnants!
P!< reduces on.hand inentory 'ecause it does a 'etter -o' ofmatching order quantity to requirements!
*-* minimi*es inentory inestment 'ut maximi*es the num'erof orders placed!
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Safety Stoc)
"he usual policy is to use safety stoc1 for end items and
purchased items to protect against fluctuating customer orders
and unrelia'le suppliers of components 'ut to aoid using it as
much as possi'le for intermediate items!
Schedule a planned receipt wheneer the pro-ected on.hand
inentory 'alance drops 'elow the desired safety stoc1 leel!
*adder'ac+ C"air
&eat su'assem'ly
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Material requirements plan
#ction notices• Releasing ne orders
• #d;usting due dates
Priority reports• Dispatc" lists
• &upplier sc"edules
Capacity reports• Capacity requirements planning
• inite capacity sc"eduling
• Inputoutput control
Manuacturing resources plan
Perormance reportsCost and
price data
Routings
and time
standards
MRP
explosion
MRP translates? or explodes? t"e MP& and other sources of demand
into the requirements needed for all of the su'assem'lies, components,
and raw materials the firm needs to produce parent items! "his process
generates the material requirements plan for each component item!
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==7
On hand Inventory + Scheduled receipts – Gross Requirements
==7 ==7
@00
LO! SI"# $ %&' (nits
SEAT SUBASSEMBLY L#A) !IM# $ % Wee*s
Wee*s + % & , - . / 0
1ross 2e3irements 150 120 150 120
Scheduled 2eceipts 230
Projected on4hand5 &/Planned 2eceipts
Planned order 2eleases
LO! SI"# $ &''
Seat Frames L#A) !IM# $ + Wee*
Wee*s + % & , - . / 0
1ross 2e3irements
Scheduled 2eceipts
Projected on4hand Inv6 $ ,'
Planned 2eceipts
Planned order 2eleases
LO! SI"# $ L,LSeat us!ions L#A) !IM# $ + 7ee*
Wee*s + % & , - . / 0
1ross 2e3irements
Scheduled 2eceipts
Projected on4hand Inv6 $ '
Planned 2eceipts
Planned order 2eleases
Material Requirements Plan
Gross Requirements
Gross Requirements
Gross Requirements
LO! SI"# %&' ( it
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==7 ==7 ==7
2@02@0227 227
@00
Requirements
LO! SI"# $ %&' (nits
SEAT SUBASSEMBLY L#A) !IM# $ % Wee*s
Wee*s + % & , - . / 0
1ross 2e3irements 150 120 150 120
Scheduled 2eceipts 230
Projected on4hand5 &/Planned 2eceipts
Planned order 2eleases
LO! SI"# $ &''
Seat Frames L#A) !IM# $ + Wee*
Wee*s + % & , - . / 0
1ross 2e3irementsScheduled 2eceipts
Projected on4hand Inv6 $ ,'
Planned 2eceipts
Planned order 2eleases
LO! SI"# $ L,L
Seat us!ions L#A) !IM# $ + 7ee*
Wee*s + % & , - . / 0
1ross 2e3irements
Scheduled 2eceipts
Projected on4hand Inv6 $ '
Planned 2eceipts
Planned order 2eleases
Material Requirements Plan
Gross Requirements
Gross Requirements
Gross Requirements
117 units is insufficient to meet gross requirements of 12 for
!ee" #$ so a planned order release of 2% must &e scheduled'
LO! SI"# %&' (nits
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==7 ==7 ==7 227 227
2@0
2@0=A7 =A7
@00
LO! SI"# $ %&' (nits
SEAT SUBASSEMBLY L#A) !IM# $ % Wee*s
Wee*s + % & , - . / 0
1ross 2e3irements 150 120 150 120
Scheduled 2eceipts 230
Projected on4hand5 &/Planned 2eceipts
Planned order 2eleases
LO! SI"# $ &''
Seat Frames L#A) !IM# $ + Wee*
Wee*s + % & , - . / 0
1ross 2e3irementsScheduled 2eceipts
Projected on4hand Inv6 $ ,'
Planned 2eceipts
Planned order 2eleases
LO! SI"# $ L,L
Seat us!ions L#A) !IM# $ + 7ee*
Wee*s + % & , - . / 0
1ross 2e3irements
Scheduled 2eceipts
Projected on4hand Inv6 $ '
Planned 2eceipts
Planned order 2eleases
Material Requirements Plan
2@02@0
77
Gross Requirements
Gross Requirements
Gross Requirements
77 units is insufficient to meet gross requirements of 1( for
!ee" )$ so a planned order release of 2% must &e scheduled'
LO! SI"# %&' (nitsM t i l R i t Pl
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2@0 2@0
2@0 2@0
LO! SI"# $ %&' (nits
SEAT SUBASSEMBLY L#A) !IM# $ % Wee*s
Wee*s + % & , - . / 0
1ross 2e3irements 150 120 150 120
Scheduled 2eceipts 230
Projected on4hand5 &/Planned 2eceipts
Planned order 2eleases
LO! SI"# $ &''
Seat Frames L#A) !IM# $ + Wee*
Wee*s + % & , - . / 0
1ross 2e3irementsScheduled 2eceipts
Projected on4hand Inv6 $ ,'
Planned 2eceipts
Planned order 2eleases
LO! SI"# $ L,L
Seat us!ions L#A) !IM# $ + 7ee*
Wee*s + % & , - . / 0
1ross 2e3irements
Scheduled 2eceipts
Projected on4hand Inv6 $ '
Planned 2eceipts
Planned order 2eleases
Material Requirements Plan
==7 ==7 ==7
2@0
2@0227 227 77
2@02@0=A7 =A7
@00
Gross Requirements
Gross Requirements
Gross Requirements
LO! SI"# $ %&' (nitsM t i l R i t Pl
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2@0 2@0
==7 ==7 ==7
2@0
2@0227 227 77
2@02@0=A7 =A7
2@0 2@0@00
B0 on.hand is carried from preious plan to wee1 one!
B0
B0 on hand plus @00 in receipts minus demand of 2@0 > ==0
==0
==0 is carried in inentory until wee1 5 when more is needed!
==0 ==0
3ot of @00 must 'e scheduled to start production in wee1 B and
arries as planned receipt in wee1 5!
@00@00
LO! SI"# $ %&' (nits
SEAT SUBASSEMBLY L#A) !IM# $ % Wee*s
Wee*s + % & , - . / 0
1ross 2e3irements 150 120 150 120
Scheduled 2eceipts 230
Projected on4hand5 &/Planned 2eceipts
Planned order 2eleases
LO! SI"# $ &''
Seat Frames L#A) !IM# $ + Wee*
Wee*s + % & , - . / 0
1ross 2e3irementsScheduled 2eceipts
Projected on4hand Inv6 $ ,'
Planned 2eceipts
Planned order 2eleases
LO! SI"# $ L,L
Seat us!ions L#A) !IM# $ + 7ee*
Wee*s + % & , - . / 0
1ross 2e3irements
Scheduled 2eceipts
Projected on4hand Inv6 $ '
Planned 2eceipts
Planned order 2eleases
Material Requirements Plan
Gross Requirements
Gross Requirements
Gross Requirements
LO! SI"# %&' (nitsM t i l R i t Pl
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@00@00
=A0 =A0 =A0 =A0
LO! SI"# $ %&' (nits
SEAT SUBASSEMBLY L#A) !IM# $ % Wee*s
Wee*s + % & , - . / 0
1ross 2e3irements 150 120 150 120
Scheduled 2eceipts 230
Projected on4hand5 &/Planned 2eceipts
Planned order 2eleases
LO! SI"# $ &''
Seat Frames L#A) !IM# $ + Wee*
Wee*s + % & , - . / 0
1ross 2e3irementsScheduled 2eceipts
Projected on4hand Inv6 $ ,'
Planned 2eceipts
Planned order 2eleases
LO! SI"# $ L,L
Seat us!ions L#A) !IM# $ + 7ee*
Wee*s + % & , - . / 0
1ross 2e3irements
Scheduled 2eceipts
Projected on4hand Inv6 $ '
Planned 2eceipts
Planned order 2eleases
Material Requirements Plan
2@0
2@02@0
2@0==7 ==7 ==7 227 227 77 =A7 =A7
2@0 2@0@00
B0 ==0 ==0 ==0
2@0 2@0
Gross Requirements
Gross Requirements
Gross Requirements
(n.8and for wee1 5 is @00 ? ==0 . 2@0 > =A0"he =A0 in inentory is carried until the next gross
requirements!
LO! SI"# %&' (nitsM t i l R i t Pl
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2@0
2@0
2@0
2@00 0 0 0 0 0 0 0
2@0
2@02@0
2@0
2@0 2@0@00
B0 ==0 ==0 ==0
@00@00=A0 =A0 =A0 =A0
==7 ==7 ==7 227 227 77 =A7 =A7
LO! SI"# $ %&' (nits
SEAT SUBASSEMBLY L#A) !IM# $ % Wee*s
Wee*s + % & , - . / 0
1ross 2e3irements 150 120 150 120
Scheduled 2eceipts 230
Projected on4hand5 &/Planned 2eceipts
Planned order 2eleases
LO! SI"# $ &''
Seat Frames L#A) !IM# $ + Wee*
Wee*s + % & , - . / 0
1ross 2e3irementsScheduled 2eceipts
Projected on4hand Inv6 $ ,'
Planned 2eceipts
Planned order 2eleases
LO! SI"# $ L,L
Seat us!ions L#A) !IM# $ + 7ee*
Wee*s + % & , - . / 0
1ross 2e3irements
Scheduled 2eceipts
Projected on4hand Inv6 $ '
Planned 2eceipts
Planned order 2eleases
Material Requirements Plan
2@0 2@0
Gross Requirements
Gross Requirements
Gross Requirements
Planned order releases are si*ed to gross requirements!Pro-ected on.hand inentory remains at *ero!"wo planned order releases of 2@0 units are scheduled!
LO! SI"# $ %&' (nitsM t i l R i t Pl
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LO! SI"# $ %&' (nits
SEAT SUBASSEMBLY L#A) !IM# $ % Wee*s
Wee*s + % & , - . / 0
1ross 2e3irements 150 120 150 120 0
Scheduled 2eceipts 230
Projected on4hand5 &/ 11" 11" 11" 22" 22" "" 1#" 1#"Planned 2eceipts 230 230
Planned order 2eleases 230 230
LO! SI"# $ &''
Seat Frames L#A) !IM# $ + Wee*
Wee*s + % & , - . / 0
1ross 2e3irements 230 230Scheduled 2eceipts 300
Projected on4hand Inv6 $ ,' $0 110 110 110 1#0 1#0 1#0 1#0
Planned 2eceipts 300
Planned order 2eleases 300
LO! SI"# $ L,L
Seat us!ions L#A) !IM# $ + 7ee*
Wee*s + % & , - . / 0
1ross 2e3irements 230 230
Scheduled 2eceipts
Projected on4hand Inv6 $ ' 0 0 0 0 0 0 0 0
Planned 2eceipts 230 230
Planned order 2eleases 230 230
Material Requirements Plan
Gross Requirements
Gross Requirements
Gross Requirements
Gross requirements for seat.frame 'oards will 'e =200 units #or B x @00% in
wee1 @!
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Other
"mportant Reports
#ction notice/ computer.generated memo
alerting planners a'out releasing new orders and
ad-usting the due dates of scheduled receipts!
Capacity requirements planning (CRP)/ technique used for pro-ecting time.phased capacity
requirements for wor1stations its purpose is to
match the material requirements plan with the
capacity of 1ey processes! Manuacturing resource planning (MRP II)/
system that ties the 'asic $P system to the
companys financial system and to other core and
supporting processes!
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"tem A:s MPS and %OM Application 15-5
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"n'entory ata Application 15-5
"t
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"tem Application 15-5
"t %
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"tem % Application 15-5
"t C
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"tem C Application 15-5
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rum,%uffer,Rope System
DrumBuerRope (DBR)/ planning and control
system that regulates the flow of wor1.in.process
materials at the 'ottlenec1 or the capacity
constrained resource #66$% in a productie system!
ar1et 9emand
H50 unitsFwee1
9rum.:uffer.$ope System with a 6apacity 6onstrained $esource #66$%
% ff R S t
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rum,%uffer,Rope System
in Practice
"he %& Marine Corps Maintenance Center in
l'any, Georgia, oerhauls and repairs ehicles
used 'y the 6orps!
$epairs to equipment can ary tremendously at the!S! arine 6orps aintenance 6enter in l'any,
Georgia!
"he center struggled to 1eep up with its repairs until
managers implemented the simplified form of adrum.'uffer.rope system!
"he resultI $epair times fell from =H7 days to -ust
5A days, on aerage!
R Pl i f
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Resource Planning for
Ser'ice Pro'iders
Dependent demand for serices
$estaurant
irlines8ospitals
8otels
Bill o Resources/ record of a firms
parent.component relationships and all of
the materials, equipment time, staff, and
other resources!
Level 1
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Disc"arge
Level 2
Intermediate care
Level 3
Postoperative care
(&tep don)
Level 4
Postoperative care
(Intensive)
Level 7
Preoperative care
(9esting)
Level 5
&urgery
Level 6
Preoperative care
(#ngiogram)
urse
(5 "r)
MD
(. "r)
9"erapy
(. "r)
Bed
(1- "r)
*a'
(3 tests)
2itc"en
(. meal)
P"armacy
(.8
medicines)
Level 6
Preoperative care
(#ngiogram)
Bill o Resources (B!R) record of a serice firms parent;
component relationships and all of thematerials, equipment time, staff, andother resources associated with them,including usage quantities!
BOR for Treating an Aneurysm
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Sol'ed Pro#lem 1
*9 @ 1*9 @ 1 *9 @ 3*9 @ 3
*9 @ 3*9 @ 3
#
B (3) C (.)
*9 @ .*9 @ .
0 (.)
*9 @ 3*9 @ 3 *9 @ 5*9 @ 5
*9 @ 3*9 @ 3
*9 @ .*9 @ .
D (.)D (.) E (1) (.)
&f there is no existing
inentory, how many
units of items G, E, and
9 must 'e purchased to
produce fie units of end
item I
5 units of item G
@0 units of item E
20 units of item 93" > 3ead time
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Sol'ed Pro#lem 8
#
B (.) C (1)
D (.)
*9 @ 1*9 @ 1
*9 @ .*9 @ . *9 @ 1*9 @ 1
*9 @ 3*9 @ 3
I9EM
D#9# C#9E0!R B C D
*otsi$ing rule P!< (P@3) *-* !< @ 488 units
*ead time . ee+ 1 ee+s 3 ee+s
&c"eduled receipts one 188 (ee+ .) one
Beginning (on"and) 18 8 -14
inventory
"he PS for product calls for the assem'ly
department to 'egin final assem'ly according
to the following schedule/ =00 units in wee1 2
200 units in wee1 B =20 units in wee1 H =A0
units in wee1 7 and H0 units in wee1 A!9eelop a material requirements plan for the
next eight wee1s for items :, 6, and 9!
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Item: B *ot si$e: P!< (P @ 3)Description: *ead time: . ee+
0ross
requirements .88.88
.
1818
1 3 - 4 5 6 7
&c"eduled
receipts
Pro;ectedon"and
inventoryPlanned
receipts
Plannedorderreleases
18
>ee+
188188 188188
188
8 8 1-8 58 8
178
= .8
.18 .78 58
8 8
358
178 358
Sol'ed Pro#lem 8
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Item: C *ot si$e: *-*Description: *ead time: 1 ee+s
0ross
requirements 188188
.
188188
1 3 - 4 5 6 7
&c"eduled
receipts
Pro;ectedon"and
inventoryPlanned
receipts
Plannedorderreleases
8
>ee+
88 88
-88
188
8 8 8 8 8
-88
= .8
1-8 358 .18
8 8
1-8 358 .18
-88 1-8 358 .18
Sol'ed Pro#lem 8
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Item: D *ot si$e: !< @ 488 unitsDescription: *ead time: 3 ee+s
0ross
requirements -88-88
.
-14-14
1 3 - 4 5 6 7
&c"eduled
receipts
Pro;ectedon"and
inventoryPlanned
receipts
Plannedorderreleases
-14
>ee+
1414 1414
1-8
174 -14 384
488
= .8
358 .18
488
358384 384 384
488 488
Sol'ed Pro#lem 8