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Chapter 14 MRP to ERP

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Proceeds one level at a time (level-by-level) 'Nets' and plans action only when lowest level in any BOM is reached. Rev. 03/02/05 ... – PowerPoint PPT presentation

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Title: Chapter 14 MRP to ERP


1
Chapter 14 MRP to ERP
  • Independent vs. dependent demand, MRP inputs and
    processing, Closed-loop MRP, MRP II, ERP

2
Traditional I/C Problems
  • Reorder point (when to order)
  • Assumes known, linear demand (sawtooth)
  • Assumes rough knowledge of lead time
  • Uses safety stock (or safety time) as buffer
  • Each item planned independently
  • EOQ (how much to order)
  • Focuses on mechanics of formula
  • Assumes linear (constant) usage
  • Always results in inventory

3
MRP
  • Material Requirements Planning (MRP)
  • Father of MRP Joseph Orlicky (???? - ????)
  • Dependent vs. independent demand concept
  • Other requirements
  • Manufacturing Bill of Materials (BOM)
  • Accurate, well-managed Master Production
    Schedule (MPS) to drive MRP
  • Computer software to explode BOMs
  • Computer hardware speed and data capacity

4
Key MRP Inputs
  • Master Production Schedule (MPS)
  • Well managed Build Plan
  • Bill of Materials (or recipes)
  • Parent/child relationships
  • Single level vs. multi-level
  • Structured for manufacturing
  • On hand inventory (available to use)
  • Material on order (from supplier)

5
Key MRP Inputs
  • Planning factors
  • Lead time
  • Lot sizing algorithm or rule
  • Optional adjustments
  • Safety stock
  • Safety time
  • Yield
  • Shrinkage
  • etc.

6
MRP Processing
  • Answers both questions
  • When to order
  • How much to order
  • Proceeds one level at a time (level-by-level)
  • Nets and plans action only when lowest level in
    any BOM is reached

7
Lot Sizing Algorithms
  • Lot for lot
  • Seeks to balance supply and demand
  • Fixed order quantity
  • May have minimums, maximums, multiples
  • Economic Order Quantity (EOQ)
  • Variations are Least Unit Cost, Least Total Cost,
    Part Period Balancing
  • Period Order Quantity
  • Fixed Period Requirements
  • Wagner-Whitin

8
MRP Summary - 1
  • Big number-cruncher
  • Follows rules using built-in logic and tables
  • Predicts shortages
  • Gross requirements derived from planned order
    releases of parent items
  • Processes level-by-level
  • Nets requirements and plans for an item at lowest
    level of use in any BOM

9
MRP Summary - 2
  • First suggests pull-ins, push-outs, cancellations
  • Then creates planned orders (not released)
  • Provides action and/or exception messages
  • High-speed computers now mean process in minutes
    rather than hours
  • Planner needs to evaluate results before acting

10
Problems with MRP
  • Computer model
  • Decisions may be based on inaccurate data
  • Inventory-building features have crept in
  • Safety stock
  • Safety time
  • EOQ
  • Represents a push system

11
Resource Planning Systems
  • MRP
  • Closed loop MRP
  • MRP II
  • ERP
  • SCM
  • Next emphasis gt E-commerce

12
Closed Loop MRP and MRP II
  • Oliver Wight (???? 1983)
  • Sold concepts to American management
  • Closed Loop MRP
  • Feedback any changes in due dates and quantities
  • Must have accurate due dates
  • Manufacturing Resource Planning (MRP II)
  • Integrate Long Range, Intermediate Range, Short
    Range, and Real-time planning

13
ERP and SCM
  • Enterprise Resource Planning (ERP)
  • Coined by Gartner Group
  • Extends integrated planning to Customer Service,
    Forecasting, Quality, Human Resources,
    Accounting, Project Management
  • Supply Chain Management (SCM)
  • Extends planning to other organizations
  • Tightly couples suppliers and customers

14
ERP Software Vendors - 2001
  • Enterprise Resource Planning (ERP)
  • SAP
  • Oracle
  • Baan
  • PeopleSoft
  • J.D. Edwards

15
ERP Software Vendors - 2005
  • Enterprise Resource Planning (ERP)
  • SAP
  • Oracle
  • PeopleSoft
  • J.D. Edwards
  • Baan (financial and legal problems followed by
    acquisition)

16
ERP Software Vendors - 2008
  • Enterprise Resource Planning (ERP)
  • SAP
  • Oracle
  • Infor Global Solutions (SSA ERP - formerly Baan)
  • The Sage Group
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