implementing mrp with advanced repetitive
DESCRIPTION
Implementing MRP with Advanced Repetitive. Sean Donahue – RFBP Nadia Truxell – Logan Consulting. Introduction – Sean Donahue. - PowerPoint PPT PresentationTRANSCRIPT
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Implementing MRP with Advanced Repetitive
Sean Donahue – RFBPNadia Truxell – Logan Consulting
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Introduction – Sean Donahue
•15 years experience in the MFG/PRO & QAD environment in the food industry. Activities included purchasing, logistics, inventory management, advanced repetitive scheduling, MRP and master scheduling.
• Have also assisted with MRP implementations/training, software and policy upgrades, MRP support, development support of custom programs within QAD as well as integration support of third party software with QAD.
•Positions held: Shipping and Receiving , S&R leader, Plant Scheduler and Master Scheduler.
•Education: Grand Valley State University APICS
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Introduction – Nadia Truxell
• Operations/Materials Manager – Scherdel Sales & TechnologyAutomotive Supplier of Springs and StampingsImplemented QAD
• Project Manager – Logan ConsultingQAD Implementations and Business Process ConsultingAutomotiveFood & BeverageConsumer GoodsIndustrial Products
• Education: Grand Valley State University APICS
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MRP– Introduction
• Introduction
•MRP Implementation Approach at RFBP
•Elements of MRP Process
•Advanced Repetitive Aspects
•Lessons Learned
•Questions
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Introduction – RFBP
Bread, Griddle, and Cookie products for Industrial, Foodservice, and Retail markets
11 Manufacturing plants across the US and Canada Advanced Repetitive processing
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Implementation Approach
Prerequisites to MRP:
•Accurate BOMS
•Accurate Inventory
•Accurate Demand
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Implementation Approach
1) Define Goals and Benefits of Project
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Implementation Approach
• A common understanding of planning processes and a common set of terms and definitions used in planning throughout the division
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Implementation Approach
• A single, repeatable process throughout the organization
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Implementation Approach
• Easier transfer of planning methodology to new planners and new plants.
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Implementation Approach
• Better decisions on what SKU’s to produce and in what quantities to fulfill customer orders and meet forecast demand.
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Implementation Approach
• Reduction possibilities in overall inventory with minimal shortages and expedites
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Implementation Approach
• Improvement in Customer Service (reduction in SO leadtime and improvement in fill rate, on-time delivery)
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Implementation Approach
• Reduction opportunities in obsolescence (both FG and Ingredient SKUs)
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Implementation Approach
• Reduction in overtime, improvement in direct labor productivity
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Implementation Approach
• Accountability throughout the organization based on a single set of criteria
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Implementation Approach
2) Organize TeamDefine Roles and Responsibilities
Project SponsorProject ManagerSubject Matter ExpertCore Team (from Plant)End Users
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Implementation Approach
3) Conduct Kickoff Meeting, Current State Assessment and Gap Analysis at each plant site
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Implementation Approach
Gap Analysis
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Implementation Approach
4) Core Team Training
Onsite Training with Core Team members
Train the Trainer approach
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Implementation Approach
5) Process Design
Work with SME and Core Team to resolve identified gaps to evolve the end state processes.
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Elements of MRP Process
6) Data Cleansing
Work with core team to update static data (master data, planning parameters) and clean up dynamic data (PO, DO, SO, WO).
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Elements of MRP Process
7) User Acceptance Testing
Execute processes in a test database environment to gain approval from the users that the process meets the expected goals
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Elements of MRP Process
8) End User Training
Core Team trains End Users with support from SME and Project Manager
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Elements of MRP Process
• 9) Data Conversion and Go Live
Conduct upload of master data changes and finalize static data cleansing
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Elements of MRP Process
10) Support Plant during live processing
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Elements of MRP Process
Supply Planning Model
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Elements of MRP Process
Forecast Feedback Process
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Elements of MRP ProcessMaster Scheduling Process
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Elements of MRP Process
Plant Scheduling Process
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Elements of MRP Process
• ABC Stratification
Item Sales Ranking80/20 Rule Applied to determine Period Order Quantity
A= POQ 7B= POQ 14C= POQ 28
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Elements of MRP Process
Item Site Planning
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Elements of MRP Process
MRP Control File
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Elements of MRP Process
MRP Net Change/Regen
Set to run through batch processMRP Regen – WeeklyMRP Net Change – Nightly
End User Access restricted – Master Schedulers can execute upon request
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Elements of MRP Process
• MRP Planned Order Browse
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Elements of MRP Process
• MRP Action Message Browse
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Advanced Repetitive
32Soft Schedule Upload Tool
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Advanced Repetitive
Line Schedule Workbench
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Advanced Repetitive
Line Schedule Workbench
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Advanced RepetitiveLine Schedule Workbench
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KPI-Results
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Lessons Learned
MRP Implementation Challenges• Mindset that “MRP Doesn’t Work”• Data integrity• Plants “have always done it this way” and fall
back into old habits• Major struggles with Operational vs
Production Forecast accuracy
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Questions
Questions?