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Material Requirements Planning (MRP) and ERP: © 2014 Pearson Education
Material Requirements Planning (MRP) and ERP: © 2014 Pearson Education
Material Requirements Planning (MRP) and ERP: © 2014 Pearson Education
Planning (MRP)
and ERP
Largest manufacturer of
ambulances in the world
12 major ambulance designs
18,000 different inventory
items
6,000 manufactured parts
12,000 purchased parts
14 - 4
Dependent vs Independent
Demand
12-5
14 - 5
Dependent Demand
For any product, all
components of that product
are dependent demand
items.
Given a quantity for the
product, the demand for all
parts and components can
be calculated.
© 2011 Pearson Education, Inc. publishing as Prentice Hall 14 - 6
What is MRP
Material requirements planning (MRP)
is a dependent demand production
planning and inventory control
system.
MRP integrates data from production
schedules (MPS) with inventory
records, scheduled receipts and the
bill of materials (BOM) to determine
purchasing and production schedules
for the components required to build a
product.
14 - 8
Bill-of-Material
for Trumpet
14 - 9
MRP
A computer-based
information system that
translates master production
schedule (MPS) requirements
for end items into time-
phased requirements for
subassemblies, components,
and raw materials.
12-10
14 - 10
MRP
The MRP is designed to
answer three questions:
What is needed?
How much is needed?
When is it needed?
14 - 13
Overview of MRP
14 - 14
Master Production Schedule (MPS)
Time-phased plan specifying how many
and when the company plans to produce
each end item
Aggregate
Aggregate Plan
Plan
(Product
(Product Groups)
Groups)
MPS
(Specific End Items)
14 - 15
Master Production Schedule
(MPS)
MPS is established in terms of
specific products
The MPS is a statement of what is to
be produced, not a forecast of
demand
Must be in accordance with the
aggregate production plan
Before it is executed, MPS must be
tested for feasibility (Capacity
Requirements Planning)
© 2011 Pearson Education, Inc. publishing as Prentice Hall 14 - 16
MPS Example – 1
14 - 17
MPS Example – 2
Months January February
Aggregate Production Plan 1,500 1,200
(Shows the total
quantity of amplifiers)
Weeks 1 2 3 4 5 6 7 8
Master Production Schedule
(Shows the specific type and
quantity of amplifier to be
produced
240-watt amplifier 100 100 100 100
150-watt amplifier 500 500 450 450
75-watt amplifier 300 100
Figure 14.2
© 2011 Pearson Education, Inc. publishing as Prentice Hall 14 - 18
Bills of Material (BOM)
List of components,
ingredients, and materials
needed to make product
Provides product structure
Items above given level are
called parents
Items below given level are
called children
© 2011 Pearson Education, Inc. publishing as Prentice Hall 14 - 19
Assembly Diagram and
Product Structure Tree
12-20
14 - 20
BOM Example (Determine requirements for all
components to satisfy demand for 50 Awesome
Speaker Kits)
Level Product structure for “Awesome” (A)
0 A
Amp-booster
Amp-booster
B
2 weeks
E
A
2 weeks 1 week
E
2 weeks 1 week
G C
3 weeks
F
1 week
D
| | | | | | | |
1 2 3 4 5 6 7 8 Figure 14.4
Time in weeks
© 2011 Pearson Education, Inc. publishing as Prentice Hall 14 - 25
MRP Outputs: Primary
Planned orders
A schedule indicating the
amount and timing of
future
production and/or
purchasing orders
14 - 26
MRP Outputs: Secondary
Secondary Outputs
Performance-control reports
e.g., missed deliveries and
stockouts
Planning reports
Data useful for assessing future
material requirements
e.g., purchase commitments
Exception reports
excessive scrap rates,
14 - 27
MRP Processing
MRP processing takes the end
item requirements specified
by the master production
schedule (MPS) and
“explodes” them into time-
phased requirements for
assemblies, parts, and raw
materials offset by lead
times 14 - 28
MRP Record
Week Number 1 2 3 4 5 6
Gross Requirements
Scheduled Receipts
Projected on hand
Net requirements
Planned-order-
receipt
Planned-order
release
Gross requirements
• Total expected demand
Scheduled receipts
• Open orders scheduled to arrive
Projected On Hand
• Expected inventory on hand at the
beginning of each time period 14 - 29
MRP Record
Week Number 1 2 3 4 5 6
Gross Requirements
Scheduled Receipts
Projected on hand
Net requirements
Planned-order-
receipt
Planned-order
release
Net requirements
• Actual amount needed in each time period
Planned-order receipts
• Quantity expected to be received at the beginning
of the period offset by lead time
Planned-order releases
• Planned amount to order in each time period
14 - 30
MRP: Processing
The MRP is based on the product structure
tree diagram
Requirements are determined level by level,
beginning with the end item and working down
the tree
The timing and quantity of each
“parent” becomes the basis for
determining the timing and quantity of
the “children” items directly below it.
The “children” items then become the
“parent” items for the next level, and so
on 12-31
14 - 31
Example MRP
Shutter
Wood
Frames (2)
sections (4)
12-32
14 - 32
Example MRP
14 - 33
Updating the MRP System
An MRP is not a static document
As time passes
Some orders get completed
Other orders are nearing completion
New orders will have been entered
Existing orders will have been altered
Quantity changes
Delays
Missed deliveries
14 - 34
Updating the System
Two basic systems
Regenerative system: MRP records are
updated periodically
Essentially a batch system that
compiles all changes that occur within
the time interval and periodically
updates the system
Net-change system: MRP records are
updated continuously
The production plan is modified to
reflect changes as they occur
12-35
14 - 35
Safety Stock
Theoretically, MRP systems should not require
safety stock
Variability may necessitate the strategic use of
safety stock
A bottleneck process or late delivery of
raw materials may cause shortages in
downstream operations
When lead times are variable, the concept
of safety time is often used
Safety time: Scheduling orders for arrival
or completions sufficiently ahead of their
need so that the probability of shortage is
eliminated or significantly reduced
12-36
14 - 36
Lot Sizing Rules
Lot-for-Lot (L4L) ordering
The order or run size is set equal to the demand for that
period
Minimizes investment in inventory
It results in variable order quantities
A new setup is required for each run
Economic Order Quantity (EOQ)
Can lead to minimum costs if usage of item is fairly uniform
This may be the case for some lower-level items that are
common to different ‘parents’
Periodic Order Quantity (POQ): Provides coverage for some
predetermined number of periods
12-37
14 - 37
Lot-for-Lot Example
1 2 3 4 5 6 7 8 9 10
Gross
35 30 40 0 10 40 30 0 30 55
requirements
Scheduled
receipts
Projected on 35 0 0 0 0 0 0 0 0 0 0
hand
Net
0 30 40 0 10 40 30 0 30 55
requirements
Planned order 30 40 10 40 30 30 55
receipts
Planned order
30 40 10 40 30 30 55
releases
14 - 46
POQ Lot Size Example
WEEK 1 2 3 4 5 6 7 8 9 10
Gross
35 30 40 0 10 40 30 0 30 55
requirements
Scheduled
receipts
Projected on 35 0 0 40 0 0 70 30 0 0 55
hand
Net
0 30 0 0 10 0 0 30 0
requirements
Planned order 70 80 0 85 0
receipts
Planned order
70 80 85
releases
Lot-for-lot $700
EOQ $730
POQ $495
e y ie ld e d a
i n w ou l d h av
a gne r- W h it f $ 455
W t otal c o st o
plan w i t h a
Amp-booster
Table 14.3
© 2011 Pearson Education, Inc. publishing as Prentice Hall 14 - 53
Determining Gross
Requirements
Starts with a production schedule for the
end item – 50 units of Item A in week 8
Using the lead time for the item,
determine the week in which the order
should be released – a 1 week lead time
means the order for 50 units should be
released in week 7
This step is often called “lead time
offset” or “time phasing”
Gross
Allocations
requirements +
Total requirements
On Scheduled Net
– hand + receipts = requirements
Available inventory
© 2011 Pearson Education, Inc. publishing as Prentice Hall 14 - 57
Allocations
Allocated items refer to the number
of units in inventory that have been
assigned to specific future
production but not yet used or
issued from the stock room.
The following slide illustrates how
allocated items increase gross
requirements
14 - 58
Awesome Speaker Kits
ERP
14 - 66
Closed-Loop MRP
Production Planning
Master Production Scheduling
Material Requirements Planning
Capacity Requirements Planning
No
Realistic? Feedback
Feedback
Yes
Execute:
Capacity Plans
Material Plans
14 - 67
Manufacturing Resource Planning
(MRP II)
Goal: Plan and monitor all
resources of a manufacturing
firm (closed loop):
manufacturing
marketing
finance
engineering
14 - 69
Typical ERP System
14 - 70
Enterprise Resource
Planning (ERP)
ERP modules include
Basic MRP
Finance
Human resources
Supply chain management (SCM)
Customer relationship management
(CRM)
72 14 - 72
ERP Products
SAP: largest ERP vendor
modules can be integrated or used
alone
J.D. Edwards
flexibility: users can change features;
less of a pre-set structure than SAP’s
73 14 - 73
ERP Products
Oracle
tailored to e-business focus
PeopleSoft
open, modular architecture allows rapid
integration with existing systems
Baan
use of “best-of-class” applications
74 14 - 74
Leading ERP Vendors
Worldwide
SAP
Oracle
PeopleSoft
Sage
J.D.Edwards
Lawson
Microsoft Dynamics AX
Great Plains/Solomon
Invensys (BaaN)
IFS
© 2011 Pearson Education, Inc. publishing as Prentice Hall 14 - 75
Leading ERP Vendors in
Turkey
SAP
Oracle
GlobalSoft
IAS-CANIAS
NETSİS
LOGO BUSINESS SOLUTIONS
Microsoft Navision
IFS
© 2011 Pearson Education, Inc. publishing as Prentice Hall 14 - 76
Advantages of ERP
Systems
1. Provides integration of the
supply chain, production, and
administration
2. Creates commonality of
databases
3. Improves information quality
4. May provide a strategic
advantage
© 2011 Pearson Education, Inc. publishing as Prentice Hall 14 - 77
ERP Drawbacks
1. Very expensive to purchase and even more
so to customize
2. Implementation may require major
changes- Resistance to change
3. So complex that many companies cannot
adjust to it
4. Involves an ongoing, possibly never
completed, process for implementation
5. Training is an on-going activity