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物料需求規劃 Material Requirement Planning (MRP)

物料需求規劃 Material Requirement Planning (MRP). 覃崇耀 Chung Y. Ching 世新大學傳管系副教授. 大綱. 有關 MRP 的參考書籍、期刊、網站 不同觀點 看 MRP 的定義 MRP 的演進 MRP 的邏輯 MRP 的實施 MRP 的檢討. 有關 MRP 的 參考書籍 、網站、期刊. Orlicky, J. A., Material Requirements Planning ,New York: McGraw-Hill, 1975

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物料需求規劃 Material Requirement Planning (MRP)

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  1. 物料需求規劃Material Requirement Planning (MRP) 覃崇耀 Chung Y. Ching 世新大學傳管系副教授

  2. 大綱 • 有關MRP的參考書籍、期刊、網站 • 不同觀點看MRP的定義 • MRP的演進 • MRP的邏輯 • MRP的實施 • MRP的檢討

  3. 有關MRP的參考書籍、網站、期刊 • Orlicky, J. A., Material Requirements Planning,New York: McGraw-Hill, 1975 • Plossl, G. W., Orlicky’s Material Require-ments Planning,(2nd edition) New York : McGraw-Hill, 1994 • Browne, J., J. Harhen, and J. Shivnan, Production Management Systems:An Integrated Perspective, New York : McGraw-Hill, 1994 • 有關生管的教科書

  4. 有關MRP的參考書籍、網站、期刊 http://www.google.com (browse: erp or mrp) http://www.itbp.com/opsmanagement/iebm/material_requirements.htm http://www.vaihome.com/s2000mrp.htm http://www.inventorysolutions.org/def_mrp.htm

  5. 有關MRP的參考書籍、網站、期刊 1. Production and Inventory Management Journal. 2. Journal of Operations Management. 3. International Journal of Production Research. 4. International Journal of Production Economic. 5. International Journal of Production Research. 6. Computer and IE 7.等等.

  6. 不同觀點看 MRP的定義

  7. 生產是： • What is to be made? • How many, and when are they needed? • What resources are required to do this? • Which are already available? • Which others will be available in time? • What more will be need?

  8. M R P的 定 義 • 生產管理系統的觀點 • Part of the Production Management Systems • Focus on Manufacturing Planning

  9. Figure 1 The hierarchy of PMS

  10. Part of the Production Management Systems (I)

  11. Part of the Production Management Systems (II)

  12. M R P的 定 義 • 管理資訊系統的觀點 • Part of the Computerized Integrated Manufacturing Information Systems • Focus on Manufacturing Planning and Control

  13. M R P的 定 義 • 生產計畫與管制的觀點 • Computerized Planning and Control Systems • Focus on Manufacturing Information Flow

  14. Master Production Schedule Planning MRP System Purchasing Scheduling Scheduling Scheduling Control Scheduling Scheduling Scheduling Scheduling

  15. M R P的 定 義 • 存貨管理系統的觀點 • Reorder point • Economic Ordering Quantity (EOQ) • Exposition and time-phased Inventory System

  16. M R P的 定 義 • 產能管理系統的觀點 • Infinite capacities • Push system • Equal weighted item priority

  17. Independent item demand Master production schedule Inventory transactions Inventory Status records MRP system Product structure record Inventory order action Priority planning Priority integrity Planned-order schedules To capacity requirements planning system Performance control Exception reports

  18. Figure. MPC Classification Schema CPM/PERT Number of subparts MRP Just-in-time Repetitive Flow Seconds Minutes Days Weeks Months Examples: Oil, food, drugs, watches, TV, trucks, planes, houses, ships

  19. Production Planning Resource Planning Demand Management Master Production Scheduling Front end Detail Material Planning Inventory status data Routing file Bills of material Detail CapacityPlanning Material and Capacity Plans Engine Shop-floor System Vendor System Back end Timed-phased Requirement (MRP) records Manufacturing Planning and Control System

  20. Contributors to MRP • Joseph Orlicky (mrp) • George Plossl (mrp) • Oliver Wight (mrp II) • American Production and Inventory Control Society (APICS)

  21. What is MRP?不同觀點看MRP • Computerized Inventory Control • Production Planning System • Management Information System • Manufacturing Control System

  22. When to use MRP • Job Shop Production • Complex Products • Assemble-to-Order Environments • Discrete and Dependent Demand Items

  23. Reduce Inventory Levels Reduce Component Shortages Improve Shipping Performance Improve Customer Service Improve Productivity Simplified and Accurate Scheduling Reduce Purchasing Cost Improve Production Schedules Reduce Manufacturing Cost Reduce Lead Times Less Scrap and Rework Higher Production Quality What can MRP do?

  24. Improve Communication Improve Plant Efficiency Reduce Freight Cost Reduction in Excess Inventory Reduce Overtime Improve Supply Schedules Improve Calculation of Material Requirements Improve Competitive Position What can MRP do?

  25. Three Basic Steps of MRP • Identifying Requirements • Running MRP – Creating the Suggestions • Firming the Suggestions

  26. Step 1: Identifying the Requirements • Quantity on Hand • Quantity on Open Purchase Order • Quantity in/or Planned for Manufacturing • Quantity Committed to Existing Orders • Quantity Forecasted

  27. Step 1: Important InformationMRP is….. • Company Sensitive • Location Sensitive • Date Sensitive

  28. Step 2: Running MRP – Creating the Suggestions • Critical Items • Expedite Items • Delay Items

  29. Step 3: Firming the Suggestions • Manufacturing Orders • Purchasing Orders • Various Reports

  30. Overview of the MRP System Product Structure File Master Production Schedule Inventory Master File Material Requirements Planning Purchase Orders Manufacturing Orders Various Reports

  31. MRP Inputs • Product Structure File • Master Production Schedule • Inventory Master File

  32. Product Structure File • Bill of Materials

  33. Master Production Schedule • Schedule of Finished Products • Represents Production, not Demand • Combination of Customer Orders and Demand Forecasts • What Needs to be Produced

  34. Inventory Master File • On-Hand Quantities • On-Order Quantities • Lot Sizes • Safety Stock • Lead Time • Past-Usage Figures

  35. MRP Process • Schedules the Production of all items using an MRP Matrix MRP Matrix

  36. Terms Defined • Item– name or number for the item being scheduled • Low-Level Code– the lowest level of the item on the product structure file • Lot Size– order multiples of quantity • Lead Time– the time from when an order is placed to when it is received • PD– Past Due Time Bucket, orders behind schedule

  37. Terms Defined • Gross Requirements– demand for an item by time period • Scheduled Receipts– material already ordered • Projected on Hand– expected ending inventory • Net Requirements– number of items to be provided and when • Planned Order Receipts– net requirements adjusted for lot size • Planned Order Releases– planned order receipts offset for lead times

  38. Example of the MRP Process

  39. Example of the MRP Process

  40. MRP Outputs • Manufacturing Orders • Purchasing Orders • Various Reports

  41. Hubbell Lighting Case • Manufactures Industrial Lighting Products • Good-Quality Products • Poor at Meeting Due Dates • Work is Specialized for Each Customer • Job Shop Environment • Complex Products

  42. Before MRP Implementation Less than 75% of orders completed on time After MRP Implementation 97% of orders completed on time 2% of orders completed with 1 to 2 days after due date Hubbell Lighting Case

  43. Summary of MRP MRP is a….. • Computerized Inventory Control • Production Planning System that….. • Schedules Component Items as Needed which will….. • Track Inventory and….. • Help you in many other aspects of business

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