Chapter 14
Roberta Russell & Bernard W. Taylor, III
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Resource Planning презентация
Содержание
- 1. Resource Planning
- 2. Copyright 2006 John Wiley & Sons, Inc.
- 3. Copyright 2006 John Wiley & Sons, Inc. 14-
- 4. Copyright 2006 John Wiley & Sons, Inc.
- 5. Copyright 2006 John Wiley & Sons, Inc. 14- Demand Characteristics
- 6. Copyright 2006 John Wiley & Sons, Inc. 14- Material Requirements Planning
- 7. Copyright 2006 John Wiley & Sons, Inc.
- 8. Copyright 2006 John Wiley & Sons, Inc.
- 9. Copyright 2006 John Wiley & Sons, Inc. 14- Master Production Schedule (cont.)
- 10. Copyright 2006 John Wiley & Sons, Inc. 14- Product Structure
- 11. Copyright 2006 John Wiley & Sons, Inc. 14- Product Structure Tree
- 12. Copyright 2006 John Wiley & Sons, Inc. 14- Intended BOM List
- 13. Copyright 2006 John Wiley & Sons, Inc.
- 14. Copyright 2006 John Wiley & Sons, Inc.
- 15. Copyright 2006 John Wiley & Sons, Inc. 14- Modular BOMs
- 16. Copyright 2006 John Wiley & Sons, Inc.
- 17. Copyright 2006 John Wiley & Sons, Inc. 14- Item Master File
- 18. Copyright 2006 John Wiley & Sons, Inc. 14- Item Master File (cont.)
- 19. Copyright 2006 John Wiley & Sons, Inc.
- 20. Copyright 2006 John Wiley & Sons, Inc. 14- MRP Matrix
- 21. Copyright 2006 John Wiley & Sons, Inc. 14- MRP: Example
- 22. Copyright 2006 John Wiley & Sons, Inc. 14- MRP: Example (cont.)
- 23. Copyright 2006 John Wiley & Sons, Inc. 14- MRP: Example (cont.)
- 24. Copyright 2006 John Wiley & Sons, Inc. 14- MRP: Example (cont.)
- 25. Copyright 2006 John Wiley & Sons, Inc. 14- MRP: Example (cont.)
- 26. Copyright 2006 John Wiley & Sons, Inc. 14- MRP: Example (cont.)
- 27. Copyright 2006 John Wiley & Sons, Inc. 14- MRP: Example (cont.)
- 28. Copyright 2006 John Wiley & Sons, Inc. 14- MRP: Example (cont.)
- 29. Copyright 2006 John Wiley & Sons, Inc. 14- MRP: Example (cont.)
- 30. Copyright 2006 John Wiley & Sons, Inc. 14- MRP: Example (cont.)
- 31. Copyright 2006 John Wiley & Sons, Inc. 14- MRP: Example (cont.)
- 32. Copyright 2006 John Wiley & Sons, Inc. 14- MRP: Example (cont.)
- 33. Copyright 2006 John Wiley & Sons, Inc. 14- MRP: Example (cont.)
- 34. Copyright 2006 John Wiley & Sons, Inc.
- 35. Copyright 2006 John Wiley & Sons, Inc.
- 36. Copyright 2006 John Wiley & Sons, Inc.
- 37. Copyright 2006 John Wiley & Sons, Inc.
- 38. Copyright 2006 John Wiley & Sons, Inc. 14- Planned Order Report
- 39. Copyright 2006 John Wiley & Sons, Inc. 14- MRP Action Report
- 40. Copyright 2006 John Wiley & Sons, Inc.
- 41. Copyright 2006 John Wiley & Sons, Inc. 14- CRP
- 42. Copyright 2006 John Wiley & Sons, Inc.
- 43. Copyright 2006 John Wiley & Sons, Inc.
- 44. Copyright 2006 John Wiley & Sons, Inc. 14- Initial Load Profile
- 45. Copyright 2006 John Wiley & Sons, Inc. 14- Adjusted Load Profile
- 46. Copyright 2006 John Wiley & Sons, Inc.
- 47. Copyright 2006 John Wiley & Sons, Inc.
- 48. Copyright 2006 John Wiley & Sons, Inc. 14- ERP Modules
- 49. Copyright 2006 John Wiley & Sons, Inc.
- 50. Copyright 2006 John Wiley & Sons, Inc. 14- Selected Enterprise Software Vendors
- 51. Copyright 2006 John Wiley & Sons, Inc.
- 52. Copyright 2006 John Wiley & Sons, Inc.
- 53. Copyright 2006 John Wiley & Sons, Inc.
- 54. Copyright 2006 John Wiley & Sons, Inc.
- 55. Copyright 2006 John Wiley & Sons, Inc.
- 56. Copyright 2006 John Wiley & Sons, Inc.
- 57. Copyright 2006 John Wiley & Sons, Inc.
Copyright 2006 John Wiley & Sons, Inc. 14- Lecture Outline Material Requirements Planning (MRP) Capacity Requirements Planning (CRP) Enterprise Resource Planning (ERP) Customer Relationship Management (CRM) Supply Chain Management (SCM) Collaborative
Слайд 1Copyright 2006 John Wiley & Sons, Inc.
Resource Planning
Operations Management - 5th
Edition
Слайд 2Copyright 2006 John Wiley & Sons, Inc.
14-
Lecture Outline
Material Requirements Planning (MRP)
Capacity
Requirements Planning (CRP)
Enterprise Resource Planning (ERP)
Customer Relationship Management (CRM)
Supply Chain Management (SCM)
Collaborative Product Commerce (CPC)
Enterprise Resource Planning (ERP)
Customer Relationship Management (CRM)
Supply Chain Management (SCM)
Collaborative Product Commerce (CPC)
Слайд 4Copyright 2006 John Wiley & Sons, Inc.
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Material Requirements
Planning (MRP)
Computerized inventory control
and production planning system
When to use MRP?
Dependent demand items
Discrete demand items
Complex products
Job shop production
Assemble-to-order environments
When to use MRP?
Dependent demand items
Discrete demand items
Complex products
Job shop production
Assemble-to-order environments
Слайд 7Copyright 2006 John Wiley & Sons, Inc.
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MRP Inputs and Outputs
Inputs
Master production
schedule
Product structure file
Item master file
Outputs
Planned order releases
Work orders
Purchase orders
Rescheduling notices
Product structure file
Item master file
Outputs
Planned order releases
Work orders
Purchase orders
Rescheduling notices
Слайд 8Copyright 2006 John Wiley & Sons, Inc.
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Master Production Schedule
Drives MRP process
with a schedule of finished products
Quantities represent production not demand
Quantities may consist of a combination of customer orders and demand forecasts
Quantities represent what needs to be produced, not what can be produced
Quantities represent end items that may or may not be finished products
Quantities represent production not demand
Quantities may consist of a combination of customer orders and demand forecasts
Quantities represent what needs to be produced, not what can be produced
Quantities represent end items that may or may not be finished products
Слайд 13Copyright 2006 John Wiley & Sons, Inc.
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Specialized BOMs
Phantom bills
Transient subassemblies
Never stocked
Immediately
consumed in next stage
K-bills
Group small, loose parts under pseudo-item number
Reduces paperwork
K-bills
Group small, loose parts under pseudo-item number
Reduces paperwork
Слайд 14Copyright 2006 John Wiley & Sons, Inc.
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Specialized BOMs (cont.)
Modular bills
Product assembled
from major subassemblies and customer options
Modular bill kept for each major subassembly
Simplifies forecasting and planning
X10 automobile example
3 x 8 x 3 x 8 x 4 = 2,304 configurations
3 + 8 + 3 + 8 + 4 = 26 modular bills
Time-phased bills
an assembly chart shown against a time scale
Modular bill kept for each major subassembly
Simplifies forecasting and planning
X10 automobile example
3 x 8 x 3 x 8 x 4 = 2,304 configurations
3 + 8 + 3 + 8 + 4 = 26 modular bills
Time-phased bills
an assembly chart shown against a time scale
Слайд 16Copyright 2006 John Wiley & Sons, Inc.
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Time-phased Bills
Forward scheduling: start at
today‘s date and schedule forward to determine the earliest date the job can be finished. If each item takes one period to complete, the clipboards can be finished in three periods
Backward scheduling: start at the due date and schedule backwards to determine when to begin work. If an order for clipboards is due by period three, we should start production now
Слайд 19Copyright 2006 John Wiley & Sons, Inc.
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MRP Processes
Exploding the bill of
material
Netting out inventory
Lot sizing
Time-phasing requirements
Netting out inventory
Lot sizing
Time-phasing requirements
Слайд 34Copyright 2006 John Wiley & Sons, Inc.
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Lot Sizing in MRP Systems
Lot-for-lot
ordering policy
Fixed-size lot ordering policy
Minimum order quantities
Maximum order quantities
Multiple order quantities
Economic order quantity
Periodic order quantity
Fixed-size lot ordering policy
Minimum order quantities
Maximum order quantities
Multiple order quantities
Economic order quantity
Periodic order quantity
Слайд 35Copyright 2006 John Wiley & Sons, Inc.
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Advanced Lot Sizing Rules: L4L
Total
cost of L4L = (4 X $60) + (0 X $1) = $240
Слайд 36Copyright 2006 John Wiley & Sons, Inc.
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Advanced Lot Sizing Rules: EOQ
Total
cost of EOQ = (2 X $60) + [(10 + 50 + 40) X $1)] = $220
Слайд 37Copyright 2006 John Wiley & Sons, Inc.
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Advanced Lot Sizing Rules: POQ
Total
cost of POQ = (2 X $60) + (20 X $1) = $180
Слайд 40Copyright 2006 John Wiley & Sons, Inc.
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Capacity Requirements Planning (CRP)
Creates a
load profile
Identifies under-loads and over-loads
Inputs
Planned order releases
Routing file
Open orders file
Identifies under-loads and over-loads
Inputs
Planned order releases
Routing file
Open orders file
Слайд 42Copyright 2006 John Wiley & Sons, Inc.
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Leveling Under-load Conditions
Acquire more work
Pull
work ahead that is scheduled for later time periods
Reduce normal capacity
Reduce normal capacity
Слайд 43Copyright 2006 John Wiley & Sons, Inc.
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Reducing Over-load Conditions
Eliminating unnecessary requirements
Rerouting
jobs to alternative machines, workers, or work centers
Splitting lots between two or more machines
Increasing normal capacity
Subcontracting
Increasing efficiency of the operation
Pushing work back to later time periods
Revising master schedule
Splitting lots between two or more machines
Increasing normal capacity
Subcontracting
Increasing efficiency of the operation
Pushing work back to later time periods
Revising master schedule
Слайд 46Copyright 2006 John Wiley & Sons, Inc.
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Relaxing MRP Assumptions
Material is not
always the most constraining resource
Lead times can vary
Not every transaction needs to be recorded
Shop floor may require a more sophisticated scheduling system
Scheduling in advance may not be appropriate for on-demand production.
Lead times can vary
Not every transaction needs to be recorded
Shop floor may require a more sophisticated scheduling system
Scheduling in advance may not be appropriate for on-demand production.
Слайд 47Copyright 2006 John Wiley & Sons, Inc.
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Enterprise Resource Planning (ERP)
Software that
organizes and manages a company’s business processes by
sharing information across functional areas
integrating business processes
facilitating customer interaction
providing benefit to global companies
sharing information across functional areas
integrating business processes
facilitating customer interaction
providing benefit to global companies
Слайд 49Copyright 2006 John Wiley & Sons, Inc.
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Organizational Data Flows
Source: Adapted from
Joseph Brady, Ellen Monk, and Bret Wagner, Concepts in Enterprise Resource Planning (Boston: Course Technology, 2001), pp. 7–12
Слайд 51Copyright 2006 John Wiley & Sons, Inc.
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ERP Implementation
Analyze business processes
Choose modules
to implement
Which processes have the biggest impact on customer relations?
Which process would benefit the most from integration?
Which processes should be standardized?
Align level of sophistication
Finalize delivery and access
Link with external partners
Which processes have the biggest impact on customer relations?
Which process would benefit the most from integration?
Which processes should be standardized?
Align level of sophistication
Finalize delivery and access
Link with external partners
Слайд 52Copyright 2006 John Wiley & Sons, Inc.
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Customer Relationship Management (CRM)
Software that
Plans
and executes business processes
Involves customer interaction
Changes focus from managing products to managing customers
Analyzes point-of-sale data for patterns used to predict future behavior
Involves customer interaction
Changes focus from managing products to managing customers
Analyzes point-of-sale data for patterns used to predict future behavior
Слайд 53Copyright 2006 John Wiley & Sons, Inc.
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Supply Chain Management
Software that plans
and executes business processes related to supply chains
Includes
Supply chain planning
Supply chain execution
Supplier relationships
Distinctions between ERP and SCM are becoming increasingly blurred
Includes
Supply chain planning
Supply chain execution
Supplier relationships
Distinctions between ERP and SCM are becoming increasingly blurred
Слайд 54Copyright 2006 John Wiley & Sons, Inc.
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Collaborative Product Commerce (CPC)
Software that
Incorporates
new product design and development and product life cycle management
Integrates customers and suppliers in the design process though the entire product life cycle
Integrates customers and suppliers in the design process though the entire product life cycle
Слайд 55Copyright 2006 John Wiley & Sons, Inc.
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ERP and Software Systems
Source: Adapted
from George Shaw, “Building the Lean Enterprise: Reducing Time to Market.” Industry Week (Webcast, June 14, 2001), http://www.industryweek.com/Events/TimeToMarket/ pent0614.html
Слайд 56Copyright 2006 John Wiley & Sons, Inc.
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Connectivity
Application programming interfaces (APIs)
give other
programs well-defined ways of speaking to them
Enterprise Application Integration (EAI) solutions
EDI is being replaced by XML
Enterprise Application Integration (EAI) solutions
EDI is being replaced by XML
Слайд 57Copyright 2006 John Wiley & Sons, Inc.
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Copyright 2006 John Wiley &
Sons, Inc.
All rights reserved. Reproduction or translation of this work beyond that permitted in section 117 of the 1976 United States Copyright Act without express permission of the copyright owner is unlawful. Request for further information should be addressed to the Permission Department, John Wiley & Sons, Inc. The purchaser may make back-up copies for his/her own use only and not for distribution or resale. The Publisher assumes no responsibility for errors, omissions, or damages caused by the use of these programs or from the use of the information herein.
