chapter 14 – resource planning operations management

Chapter 14 – Resource Planning

Operations Managementby

R. Dan Reid & Nada R. Sanders2nd Edition © Wiley 2005

PowerPoint Presentation by R.B. Clough - UNH

Types of Demand There are two types of demand. Independent Demand

Is the demand for finished products Does not depend on the demand of other products Needs to be forecasted

Dependent Demand Is the demand derived from finished products Is the demand for component parts based on the

number of end items being produced and is managed by the MRP system

Evolution of Material Planning Systems

Back in the sixties, manufacturing planning systems were reorder point systems that simply determined when and how much to order

First MRP systems translated a master schedule of final products into time-phased net requirements for subassemblies, assemblies, and parts

Closed-loop MRP included production planning, master scheduling, and capacity requirements

In mid 1970’s, MRPII systems added functionality to plan and execute all internal functions

An Overview of MRP

MRP uses the concept of backward scheduling to determine how much and when to order and replenish

The MPS module contains the authorized schedule

The BOM module contains the product structure for each unique product

The Inventory Record module keeps track of the inventory status for each item in the database

MRP output includes schedules for all internal activities and parts as well as orders for all supply chain items

Input/Output - MRP Process

Objectives of MRP

Determines the quantity and timing of material requirements Determines what to order (checks BOM), how

much to order (lot size rules), when to place the order (need date minus lead time), and when to schedule delivery (on date needed)

Maintain priorities In a changing environment, MRP reorganizes

priorities to keep plans current and viable

Building a CD Cabinet With MRP

A Product Structure Tree

MRP Inputs-Bills of Material

A BOM lists all of the items needed to produce one CD cabinet

The BOM is exactly like a recipe for baking a cake

The BOM’s must be complete and accurate and can only be changed by an ECN

MRP BOM’s are indented bills of materials

Table 14-5 Indented BOM Part Number Description Quantity Required CD1001-01 CD cabinet 1 CD1001T-01 Cabinet top 1 CD1001B-01 Cabinet bottom 1 CD1001F-01 Feet 4 CD1001D-01 Cabinet door 1 CD1001DM-01 Door magnet 1 CD1001DH-01 Door hinges 2 CD1001DK-01 Door handle 1 CD1001DS-01 Screws 8 CD1001LS-01 Cabinet left side 1 CD1001RS-01 Cabinet right side 1 CD1001SC-01 Door catch 1 CD1001DS-01 Screws 2 CD1001SH-01 Cabinet shelf 4 CD1001SS-01 Shelf holder 16

MRP Inputs - Authorized MPS

From the authorized MPS, we calculate when we need to have replenishment orders of CD cabinets; when we need a new MPS order.

Table 14-1 Initial MPS Record for CD CabinetItem: CD CabinetLot size rule: FOQ=100Lead time: 1 week

1 2 3 4 5 6 7 8 9 10 11 12Gross Requirements: 25 25 25 25 30 30 30 30 35 35 35 35Projected Available: 80 55 30 5 -20MPS

Table 14-2 Updated MPS Record for CD CabinetItem: CD CabinetLot size rule: FOQ=100Lead time: 1 week

1 2 3 4 5 6 7 8 9 10 11 12Gross Requirements: 25 25 25 25 30 30 30 30 35 35 35 35Projected Available: 80 55 30 5 80 50 20 90 60 25 90 55 20MPS 100 100 100

MRP Inputs-Inventory Records

System checks the inventory record for each BOM item to see if inventory is available or if a replenishment order is needed to build the cabinets.Table 14-3 First Inventory Record for CD CabinetItem: CD CabinetLot size rule: L4LLead time: 1 week

1 2 3 4 5 6 7 8 9 10 11 12Gross Requirements: 0 0 0 100 0 0 100 0 0 100 0 0Scheduled Receipts:Projected Available: 0 0 0 0 -100Planned Orders

Table 14-4 Updated Inventory Record for CD CabinetItem: CD CabinetLot size rule: L4LLead time: 1 week

1 2 3 4 5 6 7 8 9 10 11 12Gross Requirements: 0 0 0 100 0 0 100 0 0 100 0 0Scheduled Receipts:Projected Available: 0 0 0 0 0 0 0 0 0 0 0 0 0Planned Orders 100 100 100

The MRP Explosion Process

Using table 14-6 and the product structure tree, we will work through an example of how the MRP explosion process would calculate the requirements for building a CD cabinet. On the next slide we start with the cabinet top to illustrate how MRP calculates the gross requirements for this component.

Table 14-6 Updated Inventory Record for CD CabinetItem: CD Cabinet Parent: noneLot size rule: L4L Children: Top, bottom, door, left side, right side, shelves, shelf supportsLead time: 1 week

1 2 3 4 5 6 7 8 9 10 11 12Gross Requirements: 0 0 0 100 0 0 100 0 0 100 0 0Scheduled Receipts:Projected Available: 0 0 0 0 0 0 0 0 0 0 0 0 0Planned Orders: 100 100 100

Inventory Records - Components

It was noted on the previous slide that the parent item (CD Cabinet) has planned orders in periods 3, 6, and 9.

Its children (top, bottom, door, left & right side, shelves, and supports) have gross requirements in periods 3, 6, and 9.

Table 14-8a Inventory Record for Cabinet TopItem: Cabinet Top Parent: CD CabinetLot size rule: FOQ=144 Children: noneLead time: 3 weeks

1 2 3 4 5 6 7 8 9 10 11 12Gross Requirements: 0 0 100 0 0 100 0 0 100 0 0 0Scheduled Receipts:Projected Available: 120 120 120 20 20 20 64 64 64 108 108 108 108Planned Orders: 144 144

Inventory Records - Components

Table 14-8b Inventory Record for Cabinet BottomItem: Cabinet Bottom Parent: CD CabinetLot size rule: FOQ=144 Children: FeetLead time: 3 weeks

1 2 3 4 5 6 7 8 9 10 11 12Gross Requirements: 0 0 100 0 0 100 0 0 100 0 0 0Scheduled Receipts: 144Projected Available: 20 20 20 64 64 64 108 108 108 8 8 8 8Planned Orders: 144

Table 14-8c Inventory Record for Cabinet DoorItem: Cabinet Door Parent: CD CabinetLot size rule: FOQ=144 Children: Magnet, hinge, handle, screwsLead time: 4 weeks


Table 14-8d Inventory Record for Cabinet Left SideItem: Left Side Parent: CD CabinetLot size rule: FOQ=144 Children: noneLead time: 3 weeks

1 2 3 4 5 6 7 8 9 10 11 12Gross Requirements: 0 0 100 0 0 100 0 0 100 0 0 0Scheduled Receipts: 144Projected Available: 0 0 144 44 44 44 88 88 88 132 132 132 132Planned Orders: 144 144

Inventory Records– Components (cont.)

Table 14-8e Inventory Record for Cabinet Right SideItem: Right Side Parent: CD CabinetLot size rule: FOQ=144 Children: Door catch, door screwsLead time: 3 weeks

1 2 3 4 5 6 7 8 9 10 11 12Gross Requirements: 0 0 100 0 0 100 0 0 100 0 0 0Scheduled Receipts: 144Projected Available: 0 0 144 44 44 44 88 88 88 132 132 132 132Planned Orders: 144 144

Table 14-8f Inventory Record for Cabinet ShelvesItem: Shelf Parent: CD CabinetLot size rule: L4L Children: noneLead time: 2 weeks

1 2 3 4 5 6 7 8 9 10 11 12Gross Requirements: 0 0 400 0 0 400 0 0 400 0 0 0Scheduled Receipts:Projected Available: 0 0 0 0 0 0 0 0 0 0 0 0 0Planned Orders: 400 400 400

Table 14-8g Inventory Record for Shelf SupportsItem: Shelf Supports Parent: CD CabinetLot size rule: FOQ=2500 Children: noneLead time: 1 week


Inventory Records – Remaining Components

Table 14-9a Inventory Record for Door MagnetItem: Door Magnet Parent: Cabinet DoorLot size rule: FOQ=250 Children: noneLead time: 2 weeks


Table 14-9b Inventory Record for Door HingeItem: Door Hinge Parent: Cabinet DoorLot size rule: FOQ=500 Children: noneLead time: 4 weeks


Table 14-9c Inventory Record for Door HandleItem: Handle Parent: Cabinet DoorLot size rule: FOQ=144 Children: noneLead time: 3 weeks


Inv. Records – Remaining Components (cont.)

Table 14-9d Inventory Record for Door ScrewsItem: Screw Parent: Cabinet Door, Cabinet Right SideLot size rule: FOQ=1000 Children: noneLead time: 1 week


Table 14-9e Inventory Record for Door CatchItem: Door Catch Parent: Cabinet Right SideLot size rule: FOQ=144 Children: noneLead time: 1 week


Table 14-9f Inventory Record for FeetItem: Foot Parent: Cabinet BottomLot size rule: L4L Children: noneLead time: 4 weeks

1 2 3 4 5 6 7 8 9 10 11 12Gross Requirements: 0 0 576 0 0 0 0 0 0 0 0 0Scheduled Receipts: 576Projected Available: 0 0 0 0 0 0 0 0 0 0 0 0 0Planned Orders:

MRP Action Notices Action Notices:

Indicate items that need a production planner’s attention

Are created when a planned order needs to be released, due dates need to be adjusted, or when there is insufficient lead time for normal replenishment

Often require planners to rush or expedite orders Action Bucket:

Is the current period where we take actions such as releasing, rescheduling, or canceling orders

A positive quantity in current period’s planned order row means that an order must be released

Lot Sizing Rules Rules are used to change the

frequency of replenishment orders & set the quantity of each order (balance holding & ordering costs to reduce total costs)

Common rules: Fixed Order Quantity (FOQ) Lot-for-Lot (L4L) Periodic Order Quantity (POQ)

Comparing Lot Size Rules

Table 14-10 Inventory Records Comparing Lot Size Rules

Table 14-10a Inventory Record Using Fixed-Order QuantityItem: CD CabinetLot Size Rule: FOQ=144

Lead Time: 1 week1 2 3 4 5 6 7 8 9 10 11 12 13 Holding $ Order $

Gross requirements 0 25 25 40 40 0 60 60 60 0 60 60 60Scheduled receiptsProjected available 0 0 119 94 54 14 14 98 38 122 122 62 2 86 82.50 100.00Planned orders 144 144 144

Table 14-10b Inventory Record Using Lot-for-LotItem: CD CabinetLot Size Rule: L4L


Gross requirements 0 25 25 40 40 0 60 60 60 0 60 60 60Scheduled receiptsProjected available 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00 250.00

Planned orders 25 25 40 40 60 60 60 60 60 60

Table 14-10c Inventory Record Using Period Order QuantityItem: CD CabinetLot Size Rule: POQ=4 periods


Gross requirements 0 25 25 40 40 0 60 60 60 0 60 60 60Scheduled receiptsProjected available 0 0 105 80 40 0 0 120 60 0 0 120 60 0 58.50 75.00

Planned orders 130 180 180

Rough Cut Capacity Example: The CRP module uses data from MRP. We calculate workloads for critical work centers based on open shop orders and planned shop orders. These shop orders are translated into hours of work by work center and by time period.Table 14-11 show items scheduled for work Center 101.

Available = 4 machines x 2 shifts x 10 hours x 5 days x 0.85 utiliza- x 0.95 effi- Capacity per shift per wk. tion ciency Available = 323.0 standard hours Capacity

123456789

1011121314151617

A B C D E F GTable 14-11 Workload for Work Center 101

Run Time Total Setup per Unit in Item Weekly

Item Time Standard Time WorkloadPeriod Number Quantity (hours) Hours (hours) (hours)

4 DN100 250 3.0 0.20 53.0DP100 250 5.0 0.18 50.0DS119 150 2.5 0.30 47.5DT136 400 3.5 0.27 111.5 262.0

5 EQ555 1000 8.0 0.08 88.0ER616 500 4.0 0.22 114.0ES871 100 2.0 0.35 37.0 239.0

6 FA314 250 3.0 0.30 78.0FF369 100 1.5 0.12 13.5FR766 50 0.5 0.15 8.0FS119 200 3.0 0.35 73.0FY486 500 6.0 0.27 141.0 313.5

Workload Graph for Work Center 101: CRP enables a company to evaluate both the feasibility of the MRP system and how well the company is using its critical work centers.

Enterprise Resource Planning

What Is ERP? Software designed for organizing and

managing business processes Modules share information across all

business functions Can share customer sales data with the

supply chain to help with global replenishment

All modules are fully integrated and use a common database – some PC based

Integration of ERP

ERP Modules-4 Categories Finance and accounting

Investment, cost, asset, capital, and debt management Budgets, profitability analysis, and performance reports

Sales and marketing Handles pricing, availability, orders, shipments, & billing

Production and materials management Process planning, BOM, product costing, ECN’s, MRP,

allocates resources, schedules, PO’s, & inventory Human resources

Workforce planning, payroll & benefits, & org. charts

Benefits of ERP Implementation

ERP presents a holistic view of the business functions from a single information and IT architecture

Increases organizational information flow Increases ability to incorporate better management

control, speedier decision making, and cost reductions Allows replacement of disparate systems e.g. ExxonMobile used ERP to replace 300 different

systems A study of ERP implementations reports that benefits

typically start 8 months after implementation with median annual savings of $1.6 million

Cost and Implementation Issues

Major suppliers are SAP, Peoplesoft, Oracle, and Baan. Also smaller PC based suppliers.

Costs for larger ERP systems range from hundreds of thousands to several million dollars.

Outside consultants are usually involved in selection, configuration, and implementation.

Consultant costs can run up to 3 times the cost of the system itself according to a Gartner Group study.

Added costs also include additional people, new computer hardware, and the cost to develop a new, integrated database

Successful implementation requires leadership and top management commitment to a vision for the business

Homework

Problems1 – 5, 11 – 18.

chapter 14 – resource planning operations management

Documents

business functions

cd cabinet

inventory

gross requirements

authorized

mrp inputs

work center

finished products