13-1 MRP and ERP

William J. Stevenson

Operations Management

8th edition

13-2 MRP and ERP

CHAPTER13

MRP and ERP

McGraw-Hill/IrwinOperations Management, Eighth Edition, by William J. StevensonCopyright © 2005 by The McGraw-Hill Companies, Inc. All rights

reserved.

13-3 MRP and ERP

Material requirements planning (MRP): Computer-based information system that translates master schedule requirements for end items into time-phased requirements for subassemblies, components, and raw materials.

MRPMRP

13-4 MRP and ERP

Independent and Dependent DemandIndependent and Dependent Demand

Independent Demand

A

B(4) C(2)

D(2) E(1) D(3) F(2)

Dependent Demand

Independent demand is uncertain. Dependent demand is certain.

13-5 MRP and ERP

Dependent demand: Demand for items that are subassemblies or component parts to be used in production of finished goods.

Once the independent demand is known, the dependent demand can be determined.

Dependant DemandDependant Demand

13-6 MRP and ERP

Dependent vs Independent DemandDependent vs Independent Demand

Time

Time Time

Time

Dem

and

Dem

and

Stable demand“Lumpy” demand

Am

ou

nt

on

han

d

Am

ou

nt

on

han

d

Safety stock

Figure 13.1

13-7 MRP and ERP

MRP Inputs MRP Processing MRP Outputs

Masterschedule

Bill ofmaterials

Inventoryrecords

MRP computerprograms

Changes

Order releases

Planned-orderschedules

Exception reports

Planning reports

Performance-controlreports

Inventorytransaction

Primaryreports

Secondaryreports

Figure 13.2

13-8 MRP and ERP

Master Production Schedule Time-phased plan specifying timing and

quantity of production for each end item. Material Requirement Planning Process

Product Structure

Tree

Lead Times

MPR InputsMPR Inputs

13-9 MRP and ERP

Master ScheduleMaster Schedule

Master schedule: One of three primary inputs in MRP; states which end items are to be produced, when these are needed, and in what quantities.

Cumulative lead time: The sum of the lead times that sequential phases of a process require, from ordering of parts or raw materials to completion of final assembly.

13-10 MRP and ERP

Planning HorizonPlanning Horizon

1 2 3 4 5 6 7 8 9 10

Procurement

Fabrication

Subassembly

Assembly

Figure 13.4

13-11 MRP and ERP

Bill-of-MaterialsBill-of-Materials

Bill of materials (BOM): One of the three primary inputs of MRP; a listing of all of the raw materials, parts, subassemblies, and assemblies needed to produce one unit of a product.

Product structure tree: Visual depiction of the requirements in a bill of materials, where all components are listed by levels.

13-12 MRP and ERP

Product Structure TreeProduct Structure Tree

Chair

Seat

Legs (2) Crossbar

SideRails (2)

Crossbar

BackSupports (3)

LegAssembly

BackAssembly

Level 0

1

2

3

Figure 13.5

13-13 MRP and ERP

Inventory RecordsInventory Records

One of the three primary inputs in MRP Includes information on the status of each

item by time period Gross requirements Scheduled receipts Amount on hand Lead times Lot sizes And more …

13-14 MRP and ERP

Assembly Time ChartAssembly Time Chart

1 2 3 4 5 6 7 8 9 10 11

Procurement ofraw material D

Procurement ofraw material F

Procurement ofpart C

Procurement ofpart H

Procurement ofraw material I

Fabricationof part G

Fabricationof part E

Subassembly A

Subassembly B

Final assemblyand inspection

Figure 13.7

13-15 MRP and ERP

MRP ProcessingMRP Processing

Gross requirements

Schedule receipts

Projected on hand

Net requirements

Planned-order receipts

Planned-order releases

13-16 MRP and ERP

MPR ProcessingMPR Processing

Gross requirements

Total expected demand

Scheduled receipts

Open orders scheduled to arrive

Planned on hand

Expected inventory on hand at the beginning of each time period

13-17 MRP and ERP

MPR ProcessingMPR Processing

Net requirements

Actual amount needed in each time period

Planned-order receipts

Quantity expected to received at the beginning of the period

Offset by lead time

Planned-order releases

Planned amount to order in each time period

13-18 MRP and ERP

Updating the SystemUpdating the System

Regenerative system

Updates MRP records periodically

Net-change system

Updates MPR records continuously

13-19 MRP and ERP

MRP OutputsMRP Outputs

Planned orders - schedule indicating the amount and timing of future orders.

Order releases - Authorization for the execution of planned orders.

Changes - revisions of due dates or order quantities, or cancellations of orders.

13-20 MRP and ERP

MRP Secondary ReportsMRP Secondary Reports

Performance-control reports

Planning reports

Exception reports

13-21 MRP and ERP

Other ConsiderationsOther Considerations

Safety Stock Lot sizing

Lot-for-lot ordering Economic order quantity Fixed-period ordering

13-22 MRP and ERP

Food catering service End item => catered food

Dependent demand => ingredients for each recipe, i.e. bill of materials

Hotel renovation Activities and materials “exploded” into

component parts for cost estimation and scheduling

MRP in ServicesMRP in Services

13-23 MRP and ERP

Benefits of MRPBenefits of MRP

Low levels of in-process inventories

Ability to track material requirements

Ability to evaluate capacity requirements

Means of allocating production time

13-24 MRP and ERP

Requirements of MRPRequirements of MRP

Computer and necessary software Accurate and up-to-date

Master schedules Bills of materials Inventory records

Integrity of data

13-25 MRP and ERP

Expanded MRP with emphasis placed on integration

Financial planning

Marketing

Engineering

Purchasing

Manufacturing

MRP IIMRP II

13-26 MRP and ERP

MarketMarketDemandDemand

ProductionProductionplanplan

Problems?Problems?

Rough-cutRough-cutcapacity planningcapacity planning

YesYes NoNo YesYesNoNo

FinanceFinance

MarketingMarketing

ManufacturingManufacturing

AdjustAdjustproduction planproduction plan

MasterMasterproduction scheduleproduction schedule

MRPMRP

CapacityCapacityplanningplanning

Problems?Problems?RequirementsRequirements

schedulesschedules

Ad

just

mas

ter

sch

edu

leA

dju

st m

aste

r sc

hed

ule

MRP IIMRP IIFigure 13.14

13-27 MRP and ERP

Capacity PlanningCapacity Planning

Capacity requirements planning: The process of determining short-range capacity requirements.

Load reports: Department or work center reports that compare known and expected future capacity requirements with projected capacity availability.

Time fences: Series of time intervals during which order changes are allowed or restricted.

13-28 MRP and ERP

Capacity PlanningCapacity Planning

Develop a tentativemaster production

schedule

Develop a tentativemaster production

schedule

Use MRP tosimulate material

requirements

Use MRP tosimulate material

requirements

Convert materialrequirements to

resource requirements

Firm up a portionof the MPS

Is shopcapacity

adequate?

Cancapacity be

changed to meetrequirements

Revise tentativemaster production

schedule

Changecapacity

Yes

No

Yes

No

Figure 13.15

13-29 MRP and ERP

Enterprise resource planning (ERP): Next step in an evolution that began with

MPR and evolved into MRPII Integration of financial, manufacturing, and

human resources on a single computer system.

ERPERP

13-30 MRP and ERP

ERP Strategy ConsiderationsERP Strategy Considerations

High initial cost High cost to maintain Future upgrades Training

13-31 MRP and ERP

Additional PowerPoint slides contributed by Geoff Willis, University of Central Oklahoma.

CHAPTER13

13-32 MRP and ERP

Bill of Materials – Part 1Bill of Materials – Part 1

A listing of all raw materials, parts, subassemblies, and assemblies needed to produce one unit

Product structure Tree

X

F(2)E(2)ED(3)

CB(2)

0

1

2

Level

13-33 MRP and ERP

How many more of each component is needed to make 15 Xs if there are 5 of each already in stock?

X

F(2)E(2)ED(3)

CB(2)

Bill of Materials – Part 2Bill of Materials – Part 2

13-34 MRP and ERP

ERP BenefitsERP Benefits

ERP2Summary

13-35 MRP and ERP

H&B SAP ApplicationH&B SAP Application

ERP7Plant Linkages at Hillerich & Bradsby

13-36 MRP and ERP

Bill of MaterialsBill of Materials

PT3Federal Signal