material resourcess planning

8/16/2019 Material Resourcess Planning

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MATERIAL REQUIREMENT

PLANNING (MRP)

Dependent Demand Inventory

System


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Kompetensi Dasar

• Maasis!a dapat mem"#atperen$anaan materia% den&an sistemdependent demand


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MRP

Material requirements planning(MRP): 'omp#ter"ased inormation

system yan& mener*ema+an+e"#t#an master s$ed#%e padaend items men*adi +e"#t#an time

pased #nt#+ s#"assem"%ies,$omponents, and ra! materia%s-


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Materials RequirementsPlanning

Materia%s re.#irements p%annin& (MRP) isa means or determinin& te n#m"er oparts, $omponents, and materia%s neededto prod#$e a prod#$t (end item)

Dependent vs- independent demandMRP provides time s$ed#%in& inormation

spe$iyin& !en ea$ o tes#"assem"%ies, parts, and $omponents

so#%d "e ordered or prod#$ed/at, !en, o! many0

Dependent demand drives MRP

MRP is an inormation system


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Independent 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.


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Dependent Demand

Dependent demand1 Demandpada s#"assem"%ies ata#$omponent yan& dina+an

pada prod#+si prod#+ a+ir-Se+a%i independent demanddi+eta#i, dependent demand"isa ditent#+an-


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Dependent vs Independent Demand

Time

Time Time

Time

D e m a n d

D e m a n d

Stable demand“Lumpy” demand

A m o u n t o n a n d

A m o u n t o

n a n d

Sa!ety stoc"


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MRP 2 Te System


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MRP Inputs MRP Processing MRP #utputs

Masterscedule

$ill o! materials

In%entoryrecords

MRP computerprograms

&anges

#rder releases

Planned'orderscedules

()ception reports

Planning reports

Per!ormance'

controlreports

In%entorytransaction

Primaryreports

Secondaryreports


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MPR Inp#ts

Master Prod#$tion S$ed#%e (MPS)3i%% o Materia%s (34M)

Inventory data"ase

P r o d u c t

S t r u c

t u r e

T r e e

L e a d

T i m e s


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Master Production Scedule *MPS+

MPS1 4ne o treeprimary inp#ts in MRP Timepased p%an

spe$iyin& how many andwhen te 5rm p%ans to

"#i%d ea$ end item Deve%oped "ydisa&&re&atin& te6aggregate plan7

Aggregate Plan(Product Groups)

Aggregate Plan

(Product Groups)

MPS

(Specific End Items)

/ee+


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P%annin& 8ori9on

, - / 0 1 2 3 4 ,5

Procurement

6abrication

Subassembly

Assembly


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3i%% o Materia%s (34M)

$#M7 a %istin& o a%% o te ra!

materia%s, parts, s#"assem"%ies,and assem"%ies needed to prod#$eone #nit o a prod#$t-

Product structure tree1 :is#a%depi$tion o te re.#irements in a"i%% o materia%s, !ere a%%$omponents are %isted "y %eve%s-

A simp%e .#estion1 ;or


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34M tree ormat and %o! %eve% $odin&Lo!%eve% $odin& re.#ires tat !en an identi$a% item

o$$#r on m#%tip%e %eve%s, ten it so#%d "e 6%o!ered7 to its%o!est %eve% or $omp#tationa% reasons- Te sot!are !i%%$omp%ete a%% %eve% = items 5rst, ten a%% %eve% < items, et$-

In te ori&ina% dia&ram (a) sin$e N appears on %eve%s < ? @

In te 5na% dia&ram (") (ater re$%assi5$ation) it is %o!ered to%eve% @-A%so, note tat S #nder P !as on %eve% , !i$ needed

to "e %o!ered to %eve% B


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Inventory Re$ords

Mer#pa+an sa%a sat# inp#t MRPMe%ip#ti inormasi stat#s setiap item

men#r#t periode !a+t#Gross re.#irements C +e"#t#an+otorS$ed#%ed re$eipts C pesanan tetapAmo#nt on and C persediaan di

tan&anLead time C !a+t# an$an&Lot si9e C #+#ran %ot


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Assem"%y Time 'art

, - / 0 1 2 3 4 ,5 ,,

Procurement o!

ra8 material D

Procurement o! ra8 material 6

Procurement o! part &

Procurement o! part 9

Procurement o! ra8 material I

6abricationo! part :

6abricationo! part (

Subassembly A

Subassembly $

6inal assembly

and inspection


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MRP Pro$essin&

Gross re.#irementsS$ed#%e re$eipts

Pro*e$ted on and

Net re.#irements

P%annedorder re$eipts

P%annedorder re%eases


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MPR Processing

Gross re.#irements

Tota% epe$ted demand

S$ed#%ed re$eipts4pen orders s$ed#%ed to arrive

P%anned on and

Epe$ted inventory on and atte "e&innin& o ea$ time period


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MPR ProcessingNet re.#irements

A$t#a% amo#nt needed in ea$ time period

P%annedorder re$eipts

Q#antity epe$ted to re$eived at te"e&innin& o te period

4set "y %ead time

P%annedorder re%easesP%anned amo#nt to order in ea$ time period

l i


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Mulai

Masukan MRP:

- JIP

- Struktur produk

- Status persediaan

NETTING

Perhitungan kebutuhan bersih

yang dimulai dari leel !

"#TTING

Penentuan besarnya ukuran lot$

ukuran pemesanan

#%%SETTING

Penentuan &aktu pemesanan

barang

E'P"#(ING

)langi proses untuk leel

berikutnya

"eel terakhir

*E")+R+N MRP

- Ren,ana pemesanan kera

- Pesanan kera beralan

SE"ES+I

No

.es


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Updatin& te System

Re&enerative systemUpdates MRP re$ords periodi$a%%y

Net$an&e system

Updates MPR re$ords $ontin#o#s%y


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MRP #utputs

Planned orders to "e re%eased at a#t#re time-#rder release notices to ee$#te tep%anned orders-&anges in due dates o open ordersd#e to res$ed#%in&-&ancellations or suspensions o openorders d#e to $an$e%%ation or s#spensiono orders on te master prod#$tion

s$ed#%e-In%entory status data. P%anned orderre%eases


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MRP Secondary Reports

Perorman$e$ontro%reports

P%annin& reports

E$eption reports


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#ter &onsiderations

Saety Sto$+Lot si9in&

Lotor%ot orderin&

E$onomi$ order .#antity;iedperiod orderin&


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MRP in Ser%ices

;ood $aterin& servi$eEnd item F $atered ood

Dependent demand F in&redients

or ea$ re$ipe, i-e- "i%% o materia%s8ote% renovation

A$tivities and materia%s 6ep%oded7

into $omponent parts or $ostestimation and s$ed#%in&


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$ene;ts o! MRP

Lo! %eve%s o inpro$essinventories

A"i%ity to tra$+ materia%re.#irements

A"i%ity to eva%#ate $apa$ity

re.#irementsMeans o a%%o$atin& prod#$tiontime


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Requirements o! MRP

'omp#ter and ne$essary sot!areA$$#rate and #ptodate

Master s$ed#%es

3i%%s o materia%sInventory re$ords

Inte&rity o data


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MRP II

Epanded MRP !it empasisp%a$ed on inte&ration

;inan$ia% p%annin&

Mar+etin&En&ineerin&

P#r$asin&

Man#a$t#rin&


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Mar"etDemand

Productionplan

Problems<

Roug'cutcapacity planning

=es >o =es>o

6inance

Mar"eting

Manu!acturing

Ad?ustproduction plan

Masterproductionscedule

MRP

&apacityplanning

Problems<Requirements

scedules

A d ? u s t m a s t e r s c e d u l e

MRP II

;ire


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MRP Eamp%e

So%ved pro"%em


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Lot Si9in& in MRP

Pro&rams Te dea#%t order si9e is Lotor%ot (LBL)8o!ever, or p#r$ased items or or te$ni$a% reasons,

tere may "e minim#m or maim#m order si9esP#r$ased itemsCs#"assem"%ies may re.#ire m#%tip%es

o predetermined amo#nts (e-&-, m#%tip%es o J=)An eamp%e1 Pro"%em 5- E$e% time-'ommon %otsi9in& metods are1E$onomi$ order .#antity (E4Q)Least tota% $ost (LT')Least #nit $ost (LU')/i$ one to #se0 Te one tat is %east $ost%y


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Reerensi

3ed!ort, Inte&rated Prod#$tion 'ontro% Systems, on

/i%ey ? Son,

material resourcess planning

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