MANUFACTURING PLANNING & CONTROL SYSTEM

Slides:



Advertisements
Similar presentations
MANAJEMEN PRODUKSI DAN OPERASI
Advertisements

Production Planning Devaki Nadkarni Production Planning Annual demand by item and by region Monthly demand for 15 months by product type Monthly demand.
Manufacturing’s Objectives
To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Resource Planning Chapter 14.
Omercan Barut Dokuz Eylul University Industrial Engineering.
Master Production Scheduling (MPS) – Basic Techniques pom
The Fundamentals of Enterprise Resource Planning Olayele Adelakun (Ph.D) Assistant Professor CTI Office: Room 735 CTI 7th Floor Phone: Fax:
Rev. 03/09/05SJSU Bus David Bentley1 Chapter 12 – Aggregate Planning Planning levels (long, intermediate and short ranges and real time control);
Material Requirements Planning (MRP)
Production Planning & Control
POM - J. Galván 1 PRODUCTION AND OPERATIONS MANAGEMENT Ch. 15: Material Requirements Planning (MRP)
Materials Requirement Planning (MRP)
MRP.
Materials Requirements Planning (MRP) Material Requirement Planning (MRP)  MRP determines the number of components and raw material required and their.
Production Planning (Aggregate Planning). SOM 464: Manufacturing Resource Planning Study of the efficient allocation of resources (material, equipment,
Copyright © 2011 by The McGraw-Hill Companies, Inc. All rights reserved. McGraw-Hill/Irwin Manufacturing Planning and Control MPC 6 th Edition Chapter.
DOM 301 : Operations Management Practice
Manufacturing Production Control Systems Dr. Ron Tibben-Lembke SCM 461.
Operations Planning Horizons
1 Chapter 15 MRP and ERP. 2 Dependent demand: Demand for items that are subassemblies or component parts to be used in production of finished goods. Dependant.
MRP, MRP II, and ERP.
Material Requirements Planning
MRP Material Requirements Planning. MRP …is a planning and scheduling technique used for batch production of assembled items. … is a computer-based information.
© 2004 by Prentice Hall, Inc. Upper Saddle River, N.J Operations Management Material Requirements Planning (MRP) & ERP Chapter 14.
MATERIAL REQUIREMENTS PLANNING (MRP) AND ERP Chapter 14 1.
Production Planning and Control Introduction
© The Delos Partnership 2007 page 1 Creating the visibility to manage the crisis Developing a proper Demand Planning and Management process.
Manufacturing Planning and Control
Operations Management Contemporary Concepts and Cases Chapter Sixteen Material Requirements Planning and ERP Copyright © 2011 by The McGraw-Hill Companies,
Material Requirements Planning (MRP) Computer-based information system for ordering and scheduling of dependent-demand inventories, i.e. what is needed,
Aggregate Planning and Resource Planning Chapters 13 and 14.
Resource Planning Chapter 14. MGMT 326 Foundations of Operations Introduction Strategy Managing Projects Quality Assurance Facilities & Work Design Products.
13-1MRP and ERP. 13-2MRP and ERP  Material requirements planning (MRP): Computer-based information system that translates master schedule requirements.
1 Example: MRP Schedule LocoMopeds is a manufacturer of off-road mopeds. The following product structure diagram represents the bill of materials for.
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render) © 2001 by Prentice Hall, Inc. Upper Saddle River, N.J Material.
Introduction to Materials Management
Master Scheduling Chapter 3.
MRP Systems MRP – Material Requirements Planning Commonly used method in industry to coordinate the production scheduling of end items and their associated.
Dependent demand lumpy MRP DETAILED SCHEDULE FOR RAW MATERIALS & COMPONENTS USED IN THE END PRODUCTS MASTER SCHEDULE FOR END ITEMS.
Arnold, Chapman, & Clive: Intro Materials Management, 6 th ed. © 2008 Pearson Education, Upper Saddle River, NJ All Rights Reserved. Operation Management.
Chapter 15 MRP and ERP.
Introduction to Materials Management
1 MRP: Based on Dependent Demand u This chapter explores: –Master production schedule –Material Requirements Planning (MRP) »System structure »Example.
Aggregate Planning and Resource Planning Chapters 13 and 14.
P RODUCTION PLANNING What do we need to produce? Process Machinery & Equipment Labor Skills Material 1.
Advanced Manufacturing Laboratory Department of Industrial Engineering Sharif University of Technology Session #15.
1 Forecasting, Planning and Scheduling
Lecture 3 Production Planning System Books Introduction to Materials Management, Sixth Edition, J. R. Tony Arnold, P.E., CFPIM, CIRM, Fleming College,
1 Slides used in class may be different from slides in student pack Managerial Briefing 13 Enterprise Resource Planning Systems  Enterprise Resource Planning.
Enterprise Resource planning. Example Imagine that you organize a party by next month to celebrate your birthday, and analyze the things you do for that.
Murat Kaya, Sabancı Üniversitesi 1 MS 401 Production and Service Systems Operations Spring Master Production Scheduling (MPS) Slide Set #9.
SchedulingProducingControllingSchedulingProducingControlling.
Production Planning (Aggregate Planning). SOM 464: Manufacturing Resource Planning Study of the efficient allocation of resources (material, equipment,
Production management Content – Core work process – 6 W – Production classification – EOQ – Lean Manufacturing – Systems of Management production.
Copyright © 2011 by The McGraw-Hill Companies, Inc. All rights reserved. McGraw-Hill/Irwin Manufacturing Planning and Control MPC 6 th Edition Chapter.
EVOLUTION OF ERP 1960’s - Systems Just for Inventory Control 1970’s - MRP – Material Requirement Planning (Inventory with material planning & procurement)
CH-8-Resource Planning Assist Prof Banu OZKESER December, 2015.
MRP and ERP  Material Requirements Planning (MRP) is a software based production planning and inventory control system used to manage manufacturing processes.
Enterprise Resources Planning (ERP) Definition 1 Enterprise Resource Planning A method for the effective planning and controlling of ALL these sources.
XII. PERENCANAAN KEBUTUHAN MATERIAL (MATERIAL REQUIREMENT PLANNING)
Master Production Scheduling (MPS)
Facility Inventory Old Facilities Modern Facilities Classroom Size
Common Learning Blocks
MRP and ERP.
Chapter 5 Master Production Scheduling
Introduction to Materials Management
King Saud University College of Engineering IE – 462: “Industrial Information Systems” Fall – 2018 (1st Sem H) Introduction (Chapter 1) part.
Chapter 6 The Master Budget and Responsibility accounting
Manufacturing’s Objectives
Materials Management Systems
Presentation transcript:

MANUFACTURING PLANNING & CONTROL SYSTEM Make the right goods at the right time at top quality and do so as economically as possible.

Manufacturing Planning and Control (MPC) Manufacturing Planning and Control is responsible for the planning and control of the flow of material through the manufacturing process The primary activities carried out are as follows: Production planning Implementation and Control Inventory Management

A good planning system What are we going to make ? What does it take to make it ? What do we have ? What do we need ?

PRIORITY-CAPACITY RELATIONSHIP (Demand) Capacity (Resources) Priority relates to what product are needed, how many are needed, and when they are needed. Capasity is the capability of manufacturing to produce goods and services. Eventally it depends on the resources of the company : the machinery, labor, and financial resource , and the availability of material from suppliers.

MPC 5 Mayor level : - Strategic business plan - Production Plan - Master Production Schedule - Material Requirements Plan - Purchasing and Production Activity Control

STRATEGIC BUSSINESS PLAN Production Plan Financial Plan Marketing Plant Engineering Plan

Strategic business plan Master Plan Production plan Planning Master prod schedule Material req plan Manufacturing Planning and Control system implementation Prod activity cont. & puchasing

PRODUCTION PLAN Quantity of each product group that must be produced in each period Desired Inventory levels Resources of equipment, labor, and material needed in each period Availability of the resources needed

Master Production Schedule Plan for the production of individual end items. Level of detail for the MPS is higher than for the production plan

Material Requirements Plan Plan for Production and Purchase of the components used in making the items in the master production schedule. The levels of detail is high

Purchasing and Production Activity Control Represent the implementation and control phase of the production planning and control system. Purchasing is responsible for establishing and controlling the flow of raw materials into factory. Production and Activity Control is responsible for planning and controlling the flow of work through the factory.

Capacity Management At each level in the manufacturing planning and control system, the priority plan must be tested against the available resources and capacity of the manufacturing system.

Perencanaan Kapasitas Perencanaan Prioritas STRAG BIS RRP Manajemen Permintaan Perencanaan. Produksi RCCP MPS CRP MRP Purchasing Ops. Seq PAC I/O Cont. RRP = Resource Requirement Planning RCCP = Rough-Cut Capacity Planning CRT = Capacity Requirement Planning

Performance Measurement MRP II System Business Planning Marketing Planning Production Planning Master Production Scheduling Material Requirement Planning Production Activity Control Order release Operation scheduling Dispatching Expediting Production reporting Performance Measurement Purchasing Vendor selection Order placement Vendor scheduling Order follow-up Demand Management - Forecasting - Distribution Requirement - Order Entry Final Assembly Resource Planning Rough-Cut Capacity Capacity Requirement Operation Management Execution Top Management Operation

MANUFACTURING RESOURCE PLANNING ( MRP II ) MRP II provides coordination between marketing and production, marketing, finance, and production agree on a total workable plan expressed in the production plan. Fully integrated planning and control system.

ENTERPRISE RESOURCE PLANNING ( ERP ) ERP is similar to the MRP II system except it dose not dwell on manufacturing. The whole enterprise is teken into account. APICS : An accounting oriented information system for identifying and palnning the enterprise – wide resources needed to make, ship, and account for customer orders.

Demand Management Four mayor activities : Forecasting. Order Processing. Making delivery promises. Interfacing between manufacturing planning & control and the marketplace.

Forecasting Forecasting adalah sebuah prediksi mengenai apa yang akan terjadi di masa yang akan datang. Tiga Kategori Forecasting : Qualitative Extrinsic Intrinsic

Qualitative techniques Projections based on judgement, intuition and informed opinions. By their nature, they are subjective.

Extrinsic Techniques Projection based on external indicators which relate to the demand for company’s products. Example : sales of automobile tires are proportional to gasoline comsumption.

Intrinsic Techniques A 12-month demand history January 92 July 84 February 83 August 81 March 66 September 75 Aprill 74 October 63 May November 91 June December

Intrinsic Techniques Based on single month : Demand this month will be the same as last month  84 Demand this month wil be the same as demand the same month last year  92

Intrinsic Techniques Avarage demand :  79 Moving avarages, exp 3-month moving average, Forecast January (63+91+84)/3 = 79 Suppose that January demand turned out to be 90 instead of 79, Forecast February (91+84+90)/3 = 88

Rata-rata Bergerak Tertimbang Misal untuk bulan Oktober (90), September (110) dan Agustus (130); diberi bobot tertimbang masing-masing 3, 2, 1 maka ramalan pada bulan Nopember adalah : (3(90) + 2(110) + 1(130) )/ (3 + 2 + 1) = 103.3

Intrinsic Techniques Exponensial Smoothing Perioda Bulan Pesanan Ramalan α = 0.1 α = 0.3 1 Januari 120 --- 2 Februari 90 120.0 3 Maret 100 117.0 111.0 4 April 75 115.3 107.7 5 Mei 110 111.3 97.9 6 Juni 50 111.2 101.5 7 Juli 105.1 86.1 8 Agustus 130 102.1 82.8 9 September 104.9 97.0 10 Oktober 105.4 100.9 11 November -- 103.9 97.6

Penghalusan Eksponensial Exponensial Smoothing Penghalusan Eksponensial Permintaan bulan Februari D2 = 90 Ramalan bulan Februari F2 = 120 F3 = α D2 + (1-α) F2 = (0.1) (90) + (0.9) (120) = 117 F4 = α D3 + (1-α) F3 = (0.1) (100) + (0.9) (117) = 115.3 (

Seasional Index Seasional sales history Year Quarter 1 2 3 4 Total 122 108 81 90 401 130 100 73 96 399 132 98 71 99 400 Average 128 102 75 95

Seasional Index Seasional Index = (period avg demand) / (avg demand for all periods) SI = 128 / 100 = 1.28 untuk kwartal-1 SI = 102 / 100 = 1.02 untuk kwartal-2 SI = 75 / 100 = 0.75 untuk kwartal-3 SI = 95 / 100 = 0.95 untuk kwartal-4 The company forecast an annual demand next year of 420 units

Seasional Index Forecast average quarterly demand = 420 / 4 = 105 units Expected first-quarter demand = 1.28 x 105 = 134.4 units Expected second-quarter demand = 1.02 x 105 = 107.1 units …

STRATEGI PERENCANAAN PRODUK LEVEL METHOD CHASE STRATEGY HYBRID / COMPROMISE SUBCONTRACTOR

CHASE

LEVELING PRODUCTION

HYBRID / COMPROMISE

Permintaan Produksi Inventori PERIODA 1 2 3 4 5 6 7 8 9 10 11 12 PERMINTAAN TOTAL   15 25 35 INVENTORY 30

Permintaan Produksi Inventori

Total Cost If the cost of carrying inventory is $5 per case per periode based on ending inventory, what is the total of carrying inventory If the cost changing production level is $20, What is the total cost of the plan

PROBLEM A Company wants to produce 10,000 units of an item over teh nest three months at a level rate. The first month has 20 working days, the second, 21 working days, and the third, 12 working days because of an annual shutdown. On the average, how much should the company produce each day to level production?

PROBLEM Amalgamated Fish Sinkers makes a product group of fresh fish sinkers and wants to develop a production plan for them. The expected opening inventory is 100 cases, and they want to reduce that to 80 cases by the end of the planning period. The number of working days is the same for each period. There are no back orders. The expected demand for the fish sinkers per period is as follows: 110, 120, 130. 120, 120. a. How much should be produced each period? b. What is the ending inventory for each period? c. If teh cost of carrying inventory is $5 per case per period based on ending inventory, what is the total cost of carrying inventory? d. What will be the total cost of the plan?

end of section