COMPUTER INTEGRATED MANUFACTURING

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Presentation transcript:

COMPUTER INTEGRATED MANUFACTURING Unit – 2 / Topic :4 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

Materials Requirement Planning TOPICS TO BE DISCUSSED Materials Requirement Planning 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech 2

PRODUCTION PLANNING It is a pre-production activity. It is the pre-determination of manufacturing requirements such as manpower, machines and manufacturing process. Activities of Production Planning Aggregate production planning Master Production Schedule Material Requirement Planning(MRP) Capacity Planning materials, 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

Inputs & Outputs from APP 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

Master Production Schedule Intermediate planning stage next to Aggregate Production Planning The Aggregate plan is to be disaggregated (broke into parts) to include information about the different models of the product to be produced Master Production Schedule also known as MPS or Master Schedule is the result of disaggregation of an aggregate plan 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

Master Production Schedule Month Jan Feb Mar Apr May Jun Jul Aug Sep No. of Motors 75 60 80 40 50 55 MASTER PRODUCTION SCHEDULE AC 5 Hp 25 10 5 - AC 25 Hp 30 15 20 DC 20 Hp DC 10 Hp 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

Objectives of MPS To Schedule end items to be completed promptly and when promised to customers To avoid overloading or under loading the production facility so that production capacity is efficiently utilized and results in low production cost 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

Functions of MPS To translate aggregate plans into specific end terms To evaluate alternate schedules To generate material requirement To generate capacity requirements To facilitate information processing To maintain valid priorities To effectively utilize capacity 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

Materials Requirement Planning MRP-I converts the Master Schedule into a detailed schedule for the raw materials and parts used in the final products It identifies the quantities of each raw material and part items It indicates when each item must be ordered and delivered so as to meet the master schedule for the final products 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

Inputs to MRP Master Production Schedule Bill of materials file and Inventory record file 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

Bill of Materials Bill of Materials designates what items and how many of each are used to make up a specified final product BOM file is used to compute the raw materials and component requirement for each products listed in the master schedule Provides information on the product structure by listing the component parts and sub assemblies 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

BOM - Sample 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

Inventory Record file Item master data segment : provides item identification by part number and other data like lead time, cost and quantity Inventory status data: provides a time-phased record of inventory status Subsidiary data segment: provides subsidiary data like purchase orders, scrap or rejects, engineering changes etc 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

Inventory Record - Sample 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

MRP Output Report Primary Output Report: Order release notice Planned order release report Rescheduling notices Cancellation notices Report on inventory status Secondary Output Report: Performance report Inventory forecasts 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

Benefits of MRP Reduced inventory levels Better production schedule Reduced production lead time Reduced setup time & cost Reduced product changeover cost Improved product quality Quicker response to change in demand 8/1/2017 ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

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