material resourcess planning
TRANSCRIPT
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MATERIAL REQUIREMENT
PLANNING (MRP)
Dependent Demand Inventory
System
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Kompetensi Dasar
• Maasis!a dapat mem"#atperen$anaan materia% den&an sistemdependent demand
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MRP
Material requirements planning(MRP): 'omp#ter"ased inormation
system yan& mener*ema+an+e"#t#an master s$ed#%e padaend items men*adi +e"#t#an time
pased #nt#+ s#"assem"%ies,$omponents, and ra! materia%s-
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Materials RequirementsPlanning
Materia%s re.#irements p%annin& (MRP) isa means or determinin& te n#m"er oparts, $omponents, and materia%s neededto prod#$e a prod#$t (end item)
Dependent vs- independent demandMRP provides time s$ed#%in& inormation
spe$iyin& !en ea$ o tes#"assem"%ies, parts, and $omponents
so#%d "e ordered or prod#$ed/at, !en, o! many0
Dependent demand drives MRP
MRP is an inormation system
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Independent and Dependent
Demand
Independent Demand
A
B(4) C(2)
D(2) E(1) D(3) F(2)
Dependent Demand
Independent demand is uncertain.Dependent demand is certain.
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Dependent Demand
Dependent demand1 Demandpada s#"assem"%ies ata#$omponent yan& dina+an
pada prod#+si prod#+ a+ir-Se+a%i independent demanddi+eta#i, dependent demand"isa ditent#+an-
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Dependent vs Independent Demand
Time
Time Time
Time
D e m a n d
D e m a n d
Stable demand“Lumpy” demand
A m o u n t o n a n d
A m o u n t o
n a n d
Sa!ety stoc"
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MRP 2 Te System
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MRP Inputs MRP Processing MRP #utputs
Masterscedule
$ill o! materials
In%entoryrecords
MRP computerprograms
&anges
#rder releases
Planned'orderscedules
()ception reports
Planning reports
Per!ormance'
controlreports
In%entorytransaction
Primaryreports
Secondaryreports
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MPR Inp#ts
Master Prod#$tion S$ed#%e (MPS)3i%% o Materia%s (34M)
Inventory data"ase
P r o d u c t
S t r u c
t u r e
T r e e
L e a d
T i m e s
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Master Production Scedule *MPS+
MPS1 4ne o treeprimary inp#ts in MRP Timepased p%an
spe$iyin& how many andwhen te 5rm p%ans to
"#i%d ea$ end item Deve%oped "ydisa&&re&atin& te6aggregate plan7
Aggregate Plan(Product Groups)
Aggregate Plan
(Product Groups)
MPS
(Specific End Items)
/ee+
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P%annin& 8ori9on
, - / 0 1 2 3 4 ,5
Procurement
6abrication
Subassembly
Assembly
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3i%% o Materia%s (34M)
$#M7 a %istin& o a%% o te ra!
materia%s, parts, s#"assem"%ies,and assem"%ies needed to prod#$eone #nit o a prod#$t-
Product structure tree1 :is#a%depi$tion o te re.#irements in a"i%% o materia%s, !ere a%%$omponents are %isted "y %eve%s-
A simp%e .#estion1 ;or
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34M tree ormat and %o! %eve% $odin&Lo!%eve% $odin& re.#ires tat !en an identi$a% item
o$$#r on m#%tip%e %eve%s, ten it so#%d "e 6%o!ered7 to its%o!est %eve% or $omp#tationa% reasons- Te sot!are !i%%$omp%ete a%% %eve% = items 5rst, ten a%% %eve% < items, et$-
In te ori&ina% dia&ram (a) sin$e N appears on %eve%s < ? @
In te 5na% dia&ram (") (ater re$%assi5$ation) it is %o!ered to%eve% @-A%so, note tat S #nder P !as on %eve% , !i$ needed
to "e %o!ered to %eve% B
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Inventory Re$ords
Mer#pa+an sa%a sat# inp#t MRPMe%ip#ti inormasi stat#s setiap item
men#r#t periode !a+t#Gross re.#irements C +e"#t#an+otorS$ed#%ed re$eipts C pesanan tetapAmo#nt on and C persediaan di
tan&anLead time C !a+t# an$an&Lot si9e C #+#ran %ot
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Assem"%y Time 'art
, - / 0 1 2 3 4 ,5 ,,
Procurement o!
ra8 material D
Procurement o! ra8 material 6
Procurement o! part &
Procurement o! part 9
Procurement o! ra8 material I
6abricationo! part :
6abricationo! part (
Subassembly A
Subassembly $
6inal assembly
and inspection
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MRP Pro$essin&
Gross re.#irementsS$ed#%e re$eipts
Pro*e$ted on and
Net re.#irements
P%annedorder re$eipts
P%annedorder re%eases
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MPR Processing
Gross re.#irements
Tota% epe$ted demand
S$ed#%ed re$eipts4pen orders s$ed#%ed to arrive
P%anned on and
Epe$ted inventory on and atte "e&innin& o ea$ time period
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MPR ProcessingNet re.#irements
A$t#a% amo#nt needed in ea$ time period
P%annedorder re$eipts
Q#antity epe$ted to re$eived at te"e&innin& o te period
4set "y %ead time
P%annedorder re%easesP%anned amo#nt to order in ea$ time period
l i
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Mulai
Masukan MRP:
- JIP
- Struktur produk
- Status persediaan
NETTING
Perhitungan kebutuhan bersih
yang dimulai dari leel !
"#TTING
Penentuan besarnya ukuran lot$
ukuran pemesanan
#%%SETTING
Penentuan &aktu pemesanan
barang
E'P"#(ING
)langi proses untuk leel
berikutnya
"eel terakhir
*E")+R+N MRP
- Ren,ana pemesanan kera
- Pesanan kera beralan
SE"ES+I
No
.es
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Updatin& te System
Re&enerative systemUpdates MRP re$ords periodi$a%%y
Net$an&e system
Updates MPR re$ords $ontin#o#s%y
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MRP #utputs
Planned orders to "e re%eased at a#t#re time-#rder release notices to ee$#te tep%anned orders-&anges in due dates o open ordersd#e to res$ed#%in&-&ancellations or suspensions o openorders d#e to $an$e%%ation or s#spensiono orders on te master prod#$tion
s$ed#%e-In%entory status data. P%anned orderre%eases
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MRP Secondary Reports
Perorman$e$ontro%reports
P%annin& reports
E$eption reports
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#ter &onsiderations
Saety Sto$+Lot si9in&
Lotor%ot orderin&
E$onomi$ order .#antity;iedperiod orderin&
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MRP in Ser%ices
;ood $aterin& servi$eEnd item F $atered ood
Dependent demand F in&redients
or ea$ re$ipe, i-e- "i%% o materia%s8ote% renovation
A$tivities and materia%s 6ep%oded7
into $omponent parts or $ostestimation and s$ed#%in&
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$ene;ts o! MRP
Lo! %eve%s o inpro$essinventories
A"i%ity to tra$+ materia%re.#irements
A"i%ity to eva%#ate $apa$ity
re.#irementsMeans o a%%o$atin& prod#$tiontime
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Requirements o! MRP
'omp#ter and ne$essary sot!areA$$#rate and #ptodate
Master s$ed#%es
3i%%s o materia%sInventory re$ords
Inte&rity o data
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MRP II
Epanded MRP !it empasisp%a$ed on inte&ration
;inan$ia% p%annin&
Mar+etin&En&ineerin&
P#r$asin&
Man#a$t#rin&
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Mar"etDemand
Productionplan
Problems<
Roug'cutcapacity planning
=es >o =es>o
6inance
Mar"eting
Manu!acturing
Ad?ustproduction plan
Masterproductionscedule
MRP
&apacityplanning
Problems<Requirements
scedules
A d ? u s t m a s t e r s c e d u l e
MRP II
;ire
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MRP Eamp%e
So%ved pro"%em
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Lot Si9in& in MRP
Pro&rams Te dea#%t order si9e is Lotor%ot (LBL)8o!ever, or p#r$ased items or or te$ni$a% reasons,
tere may "e minim#m or maim#m order si9esP#r$ased itemsCs#"assem"%ies may re.#ire m#%tip%es
o predetermined amo#nts (e-&-, m#%tip%es o J=)An eamp%e1 Pro"%em 5- E$e% time-'ommon %otsi9in& metods are1E$onomi$ order .#antity (E4Q)Least tota% $ost (LT')Least #nit $ost (LU')/i$ one to #se0 Te one tat is %east $ost%y
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Reerensi
3ed!ort, Inte&rated Prod#$tion 'ontro% Systems, on
/i%ey ? Son,