1. Chapter 5 生產製造循環 (II) 淡江大學資訊管理學系 徐煥智整理編撰

2. 物料需求計劃 (Material Requirements Planning) 對衍生需求的優先次序規劃 對車子的需求 衍生出 對輪胎的需求

3. 物料需求計劃 (Material Requirements Planning) What to order How much to order When to order When to schedule delivery Note: MRP 用來規劃所有資源的未來需求.

4. 物料需求計劃 (Material Requirements Planning) MRP MPS BOM Inventory Records 工令 請購單

5. 物料需求計劃 (Material Requirements Planning) Bill of Material Structure 1. 彙總式 (Summarized Parts List) 2. 多階式 (Multilevel Bill) 3. 單階式 (Single-Level Bill) 4. 規劃料表 (Planning Bill)

6. 物料需求計劃 (Material Requirements Planning) 彙總式 (Summarized Parts List) 項目 A Product Tree

7. 物料需求計劃 (Material Requirements Planning) 多階式 (Multilevel Bill)

8. 物料需求計劃 (Material Requirements Planning) 單階式 (Single-Level Bill)

9. 物料需求計劃 (Material Requirements Planning) 規劃料表 (Planning Bill) - Used to simplify forecasting (MPS, MRP) Leg A 40% Leg B 35% Leg C 25% Side A 55% Side B 30% Side C 15% Top A 45% Top B 30% Top C 25% 100%

10. 物料需求計劃 (Material Requirements Planning) 用途表 (Where-Used Report) 與 BOM 相關表格 溯源報表 (Pegging Report) Where-used reports give the same information as a BOM, but the where-used report gives the parents for a component whereas the BOM gives the components for a parent. A pegging report is similar to where-used report. However, the pegging report shows only those parents for which there is an existing requirement.

11. 物料需求計劃 (Material Requirements Planning) 溯源報表 (Pegging Report) Pegged Requirements Source of Requirements

12. 物料需求計劃 (Material Requirements Planning) MRP Process Exploding and Offsetting Gross and Net Requirements Releasing Orders

13. 物料需求計劃 (Material Requirements Planning) Exploding and Offsetting - Example Planned Order (MPS)

14. 物料需求計劃 (Material Requirements Planning) Gross and Net Requirement - Example

15. 物料需求計劃 (Material Requirements Planning) Released Order - Scheduled Receipt The scheduled receipts row shows the quantities ordered and when they are expected to be completed and available. Note: Net Requirement = Gross Requirement - Scheduled Receipts - Available Inventory

16. 物料需求計劃 (Material Requirements Planning) MRP 不安定性 高階項目的小改變造成低階項目的大改變。 MRP 系統做出的排程若經常改變將傷害 MRP 的可信度。 變化的原因： MPS 變化、供應商遲交、品質 問題、記錄錯誤、意外的異動。

17. 物料需求計劃 (Material Requirements Planning) Fundamental Wrong with MRP MRP Flawed Model Note: Lead times are not affected by the status of the plant

18. MRP II Hierarchy Demand Forecast Aggregate Planning Resource Planning MPS Rough-Cut Capacity Planning MRP Job Pool Job Release Job Dispatching Capacity Requirement Planning BOM Inventory Status Routing Data Long-Range Planning Intermediate-Range Planning Short-Term Planning

19. CRP Planned Order Releases Open Orders Routing Data Capacity and lead Time for Process Centers Shop Calendar Work Center Load Report 產能需求規劃 (Capacity Requirement Planning)

20. 產能需求規劃 (Capacity Requirement Planning) Part Name: Gear Shaft Part Number: SG123 Drawing Number: D123X Operation Work S/U Time Run Time/Piece No. Center (Standard Hours) (Standard Hours) Operation 10 12 1.50 0.2 Turn Shaft 20 14 0.50 0.25 Mill Slot 30 17 0.30 0.05 Drill Hole 40 03 0.45 0.10 Grind 50 Stores Inventory Routing Data

21. 產能需求規劃 (Capacity Requirement Planning) Work Center File

22. 產能需求規劃 (Capacity Requirement Planning) Ex: A work center has the following open orders and planned orders for week 20. Calculate the total standard time required (load) on this work center in week 20. Order 222 is already in progress, and there are 100 remaining to run. Order Quantity Setup Time Run Time Released Orders Planned Orders 222 333 100 150 0 1.5 0.2 444 555 200 300 3 2.5 0.25 0.15

23. 產能需求規劃 (Capacity Requirement Planning) Work Center Load Report

24. 結論