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Planeacion de Requerimientos de Los Materiales
Planeacion de Requerimientos de Los Materiales
OBJECTIVES
Material Requirements Planning (MRP) MRP Logic and Product Structure Trees Time Fences MRP Example MRP II and Lot Sizing
Lead Times A 1 day B 2 days C 1 day D 3 days E 4 days F 1 day Total Unit Demand Day 10 50 A Day 8 20 B (Spares) Day 6 15 D (Spares)
The McGraw-Hill Companies, Inc., 2004
First, the number of units of A are scheduled First, the number of units of A are scheduled backwards to allow for their lead time. So, in the backwards to allow for their lead time. So, in the materials requirement plan below, we have to place materials requirement plan below, we have to place an order for 50 units of A on the 9th day to receive an order for 50 units of A on the 9th day to receive them on day 10. them on day 10.
Day: A Required Order Placement 1 2 3 4 5 6 7 8 9 50 10 50
LT = 1 day
Next, we need to start scheduling the components that make up Next, we need to start scheduling the components that make up A. In the case of component B we need 4 Bs for each A. A. In the case of component B we need 4 Bs for each A. Since we need 50 As, that means 200 Bs. And again, we back Since we need 50 As, that means 200 Bs. And again, we back the schedule up for the necessary 2 days of lead time. the schedule up for the necessary 2 days of lead time.
Day : A B R e q u ire d O rd e r P la c e m e n t R e q u ire d O rd e r P la c e m e n t 1 2 3 4 5 6 7 8 9 50 200 10 50
20 20 200
Spares
4x50=200
Finally, repeating the process for all components, we have the Finally, repeating the process for all components, we have the final materials requirements plan: final materials requirements plan:
Day: A LT=1 B LT=2 C LT=1 D LT=3 E LT=4 F LT=1 Required Order Placement Required Order Placement Required Order Placement Required Order Placement Required Order Placement Required Order Placement 1 2 3 4 5 6 7 8 9 50 200 100 55 55 20 200 200 200 400 300 20 200 400 100 300 10 50
20 20 200
A
Part D: Day 6
C(2) F(2)
40 + 15 spares
10
15 Weeks
26
11
Determines exact unit numbers needed Determines the dates when orders for those materials should be released, based on lead times
12
Inventory transactions
From Exhibit 15.6 From Exhibit 15.6
Secondary reports
Primary reports Planned order schedule for inventory and production control Exception reports Planning reports Reports for performance control
The McGraw-Hill Companies, Inc., 2004
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Super BOM
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Pegging
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16
17
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MRP Example
X A(2) C(3) C(2) B(1) D(5)
Item X A B C D On-Hand Lead Time (Weeks) 50 2 75 3 25 1 10 2 20 2
Requirements include 95 units (80 firm orders and 15 forecast) of X Requirements include 95 units (80 firm orders and 15 forecast) of X in week 10 in week 10
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Day: 1 2 3 4 5 6 7 8 9 10 95 50 45 45
X LT=2 Onhand 50 A LT=3 Onhand 75 B LT=1 Onhand 25 C LT=2 Onhand 10 D LT=2 Onhand 20
A(2)
Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release
50 50
50
50
50
50
50
50
50
45 90 75 75 75 75 75 75 75 75 15 15 45 25 25 25 25 25 25 25 25 20 20
15
45 10 10 10 10 10 35 35 40
20 40
40 40 100
35
20 20
20
20
20
20
20 80 80
80
The McGraw-Hill Companies, Inc., 2004
20
Day: 1 2 3 4 5 6 7 8 9 10 95 50 45 45
X LT=2 Onhand 50 A LT=3 Onhand 75 B LT=1 Onhand 25 C LT=2 Onhand 10 D LT=2 Onhand 20
A(2)
B(1)
Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release
50 50
50
50
50
50
50
50
50
45 90 75 75 75 75 75 75 75 75 15 15 45 25 25 25 25 25 25 25 25 20 20
15
45 10 10 10 10 10 35 35 40
20 40
40 40 100
35
20 20
20
20
20
20
20 80 80
80
The McGraw-Hill Companies, Inc., 2004
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Day: 1 2 3 4 5 6 7 8 9 10 95 50 45 45
X LT=2 Onhand 50 A LT=3 Onhand 75 B LT=1 Onhand 25 C LT=2 Onhand 10 D LT=2 Onhand 20
A(2)
B(1)
C(3)
Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release
50 50
50
50
50
50
50
50
50
45 90 75 75 75 75 75 75 75 75 15 15 45 25 25 25 25 25 25 25 25 20 20
15
45 10 10 10 10 10 35 35 40
20 40
40 40 100
35
20 20
20
20
20
20
20 80 80
80
The McGraw-Hill Companies, Inc., 2004
22
Day: 1 2 3 4 5 6 7 8 9 10 95 50 45 45
X LT=2 Onhand 50 A LT=3 Onhand 75 B LT=1 Onhand 25 C LT=2 Onhand 10 D LT=2 Onhand 20
A(2)
B(1)
C(3)
C(2)
Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release
50 50
50
50
50
50
50
50
50
45 90 75 75 75 75 75 75 75 75 15 15 45 25 25 25 25 25 25 25 25 20 20
15
45 10 10 10 10 10 35 35 40
20 40
40 40 100
35
20 20
20
20
20
20
20 80 80
80
The McGraw-Hill Companies, Inc., 2004
23
Day: 1 2 3 4 5 6 7 8 9 10 95 50 45 45
X LT=2 Onhand 50 A LT=3 Onhand 75 B LT=1 Onhand 25 C LT=2 Onhand 10 D LT=2 Onhand 20
A(2)
B(1)
C(3)
C(2)
D(5)
Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release Gross requirements Scheduled receipts Proj. avail. balance Net requirements Planned order receipt Planner order release
50 50
50
50
50
50
50
50
50
45 90 75 75 75 75 75 75 75 75 15 15 45 25 25 25 25 25 25 25 25 20 20
15
45 10 10 10 10 10 35 35 40
20 40
40 40 100
35
20 20
20
20
20
20
20 80 80
80
The McGraw-Hill Companies, Inc., 2004
24
Yes
Execute: Capacity Plans Material Plans
25
26