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MRP, CRP, and ERP

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Fabrication 1. Fabrication 2. Tier II Supplier 1. Tier II ... LOW-LEVEL CODING. Determines order of MRP calculations. Each BOM level is assigned a number ... – PowerPoint PPT presentation

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Title: MRP, CRP, and ERP


1
MRP, CRP, and ERP
  • Bills of Materials
  • The MRP Record
  • The MRP Explosion
  • Vertical Linkage of MRP Records
  • Validating the Mps
  • Capacity Requirements Planning

2
ERP
ENTERPRISE RESOURCE PLANNING
3
CORE MRP II
MANUFACTURING RESOURCE PLANNING
4
THE ORIGINAL MRP (Material Requirements Planning)
  • In the beginning (pre-1970's)
  • There were no computers
  • Material planning was done independently for each
    component
  • Then there were computers
  • And MRP (I) became possible
  • Then there were faster computers
  • And MRP II became possible
  • Then there were even faster computers
  • And ERP became possible

5
BILLS OF MATERIALS
  • BOM's show how parts are combined to create
    product
  • Representation may be graphical or indented
    text
  • X
  • A
  • B (2)
  • A
  •  Y
  • A

6
THE MRP RECORD
  • Objective is to determine future purchasing or
    production schedule for a component part
  • Gross Requirements demand for part
  • Scheduled Receipts planned completion times for
    batches of parts which have been already ordered

7
THE MRP RECORD
  • Objective is to determine future purchasing or
    production schedule for a component part
  • Objective is to determine future purchasing or
    production schedule for a component part
  • Gross Requirements demand for part
  • Scheduled Receipts planned completion times for
    batches of parts which have been already ordered

8
THE MRP RECORD
  • Objective is to determine future purchasing or
    production schedule for a component part
  • Objective is to determine future purchasing or
    production schedule for a component part
  • Gross Requirements demand for part
  • Scheduled Receipts planned completion times for
    batches of parts which have been already ordered

9
THE MRP RECORD
  • Objective is to determine future purchasing or
    production schedule for a component part
  • Objective is to determine future purchasing or
    production schedule for a component part
  • Gross Requirements demand for part
  • Scheduled Receipts planned completion times for
    batches of parts which have been already ordered

10
THE MRP RECORD
  • Objective is to determine future purchasing or
    production schedule for a component part
  • Planned Order Receipt planned completion times
    for batches of parts which have not yet been
    ordered
  • Planned Order Release planned start times for
    batches of parts which have not yet been ordered

11
THE MRP RECORD
  • Objective is to determine future purchasing or
    production schedule for a component part
  • Planned Order Receipt planned completion times
    for batches of parts which have not yet been
    ordered
  • Planned Order Release planned start times for
    batches of parts which have not yet been ordered

12
THE MRP RECORD
  • During Period 1
  • 10 units are disbursed

13
THE MRP RECORD
  • During Period 1
  • 10 units are disbursed
  • The scheduled receipt is completed

14
THE MRP RECORD
  • During Period 1
  • 10 units are disbursed
  • The scheduled receipt is completed
  • The planned order release is released

15
THE MRP RECORD
  • During Period 1
  • 10 units are disbursed
  • The scheduled receipt is completed
  • The planned order release is released

16
VERTICAL LINKAGE OF MRP RECORDS
  • Objective find material plans planned order
    releases for all parts
  • Data requirements
  • MPS
  • BOMs
  • Inventory records file
  • Gross requirements are ultimately derived from
    MPS
  • But in calculations, the gross requirements for a
    part depend only on the planned order releases of
    the parent parts

17
LOW-LEVEL CODING
  • Determines order of MRP calculations
  • Each BOM level is assigned a number
  • Products are at level 0
  • Each part is assigned the number of the lowest
    level at which it appears in any BOM
  • Calculate plans for level 0 first, then level 1,
    etc. . . .

18
MRP EXAMPLE
  • Start with MPS for products X and Y

19
MRP EXAMPLE
  • Start with MPS for products X and Y

20
MRP EXAMPLE
  • Planned order releases for X serve as basis for
    gross requirements for part B

21
MRP EXAMPLE
  • Part Bs record is then completed

22
MRP EXAMPLE
  • Part Bs record is then completed

23
MRP EXAMPLE
  • Part Bs record is then completed

24
MRP EXAMPLE
  • Part Bs record is then completed

25
MRP EXAMPLE
  • Part Bs record is then completed

26
MRP EXAMPLE
  • Part As gross requirements depend on planned
    order releases for X, Y, and B

27
MRP EXAMPLE
  • Part As record is then completed

28
MRP EXAMPLE
  • Part As record is then completed

29
MRP EXAMPLE
  • Part As record is then completed

30
CAPACITY REQUIREMENTS PLANNING
  • Should be used as a final check on the mps
  • More accurate than RCCP
  • May be too expensive for routine "what-if"
    analysis
  • Determine incremental run times and setup times
    for each part in each workcenter
  • Apply incremental run times and setup times from
    (1) to planned order releases to determine
    capacity requirements per period for each
    workcenter

31
THE ROUTING
  • The routing for a product or part lists
  • Where it is processed
  • Resources needed
  • Per batch or per setup
  • Per unit after workcenter is setup

32
CRP
  • The routing is applied to the planned order
    releases to obtain the capacity plan

33
CRP
  • The routing is applied to the planned order
    releases to obtain the capacity plan

34
CRP
  • The routing is applied to the planned order
    releases to obtain the capacity plan

35
CRP
  • The routing is applied to the planned order
    releases to obtain the capacity plan

36
CRP
  • The routing is applied to the planned order
    releases to obtain the capacity plan

37
CRP
  • The routing is applied to the planned order
    releases to obtain the capacity plan

38
CRP
  • The routing is applied to the planned order
    releases to obtain the capacity plan
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