Self-Instructional Manual (SIM) For Self-Directed Learning (SDL)
Self-Instructional Manual (SIM) For Self-Directed Learning (SDL)
UNIVERSITY OF MINDANAO
Table of Contents
Production System 36
Production Model 37
Production system design 38
Classification of system 38
Capacity Planning 46
Types of capacity planning 46
Capacity measurement 47
Priority rules 47
Four types of capacity planning 47
Capacity planning technique 49
Aggregate planning 51
Aggregate planning strategies 53
Capacity measurement 56
Week 4 to Week 5
Material Management 60
Scope of material management 62
Material Requirement Planning Process 63
Four basic Purchasing activities 63
Five basic traffic activities 65
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Week 6 to Week 7
Material Requirement Planning (MRP) 80
Benefits of MRP 82
MRP Functions 83
MRP System Structure 84
Overview of Inventory Planning with MRP 85
Bill of Material 85
Email: [email protected]
Requisites: None
Credit: 3
CC’s Voice: Hello prospective HR Practitioner! Welcome to this course CBM 112: The
Business and School Curriculum. By now, we are confident that you really
wanted to become an HR and that you have visualized yourself already being
in front of the business world.
CO
Let us begin!
9
Big Picture
Metalanguage
Material Management - is a total concept having its definite organization to plan and
control all types of materials, its supply, and its flow from raw stage to finish stage. It
can be defined as the function of the business that is responsible for coordination of
planning, sourcing, purchasing, moving and storing materials
Sub-function:
1. Materials planning and control – materials required for any operations are
based on the sales forecast and production plans.
2. Purchasing – the job of a material manager is to provide to the user
departments right material at the right time in right quality at right price from
the right source.
3. Stores Keeping - refers to the safe custody of all items of raw materials,
supplies, finished parts, purchased parts etc. In the store room for which the
store keeper acts as a trustee. It is said to be the process of receiving and
distributing stores or supplies.
4. Inventory Control – one of the powerful ways of controlling the materials
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Essential Knowledge
To perform the aforesaid big picture (unit learning outcomes) from week 4 to week 5
of the course, you need to fully understand the following essential knowledge that will be laid
down in the succeeding pages. Please note that you are not limited to exclusively refer to
these resources. Thus, you are expected to utilize other books, research articles and other
resources that are available in the university’s library e.g. ebrary, search.proquest.com
etc.
Material Management
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Material management strives to ensure that the material cost component of the total cost
be the least.
Materials Planning
Purchasing
Store Keeping
Inventory Control
Receiving, Inspection and Dispatching
Value Analysis, Standardization and Variety Reduction
Materials Handling and Traffic
Disposal of Scrap and Surplus, Material Preservation
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Purchase System
Forward Buying – occurs when retailers purchase units during a particular period,
hold some of them in inventory, and then sell them in subsequent period.
Blanket Order System – which a customer places with its supplier to allow multiple
delivery dates over a period of time, often negotiated to take advantage of
predetermined pricing. It is normally used when there is a recurring need for
expendable goods.
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Zero Stock – no on-hand inventory stock / is to order the exact quantity that will be
sold, and receipt goods into stock when they are needed
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Oxford. Dictionary
Systems Contract – are exclusive contracts with designated suppliers for specific
commodities of goods or services, with pricing and others agreement.
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Stock Level - production parts and materials are checked against blueprints and
specifications. Non productions are also reviewed. Once it is as per the specification
given the goods will be accepted.
Non-Production Stores
Integrated Concept
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Better Accountability
Better Coordination
Better Performance
Adaptability to EDP
Miscellaneous Advantage
Municipal Solid Waste (MSW ) is a “clean” waste stream that requires less
procuring
Revenue for local governments from the sale of recyclable materials in the
commodities market.
Strengthening and expansion of both local and national economies.
Conservation of energy and natural resources, reduction of greenhouse gas
emissions and reduction in landfills and incineration disposal.
Growing the market for more environmentally responsible products
Comprehensive waste stream answers for central question about Municipal Solid
Waste (MSW) programs:
Based on the idea that “the polluter pays.” EPR Policies are designed to
share the cost of a product’s environmentally sustainable disposal with
manufacturers and/or consumers.
This can be achieved by integrating environmental costs into the final product
price, or holding manufacturers liable for end-of-life costs associated with reuse,
recycling, and disposal.
Selection of Suppliers
Sources of Suppliers
- Specialized trade directories.
- Assistance of professional bodies or consultant.
- The buyer’s guide or purchase handbook.
- The manufacturer’s or distributor’s catalogue
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- Advertisements in dailies
- Advertisement in specialized trade journals
- Trade fair exhibitions
Development of Approved List of Suppliers
Evaluation and Selection of the Supplier
Cost Factors
Delivery
Design and Specification Factors
Legal Factors
Vendor Rating
Human Engineering
1. To enhance the efficiency and effectiveness with which the activities (work) is carried
out so as to increase the convenience of use, reduced errors and increase in
productivity.
2. To enhance certain desirable human values including safety reduced stress and
fatigue and improved quality of life.
Seven Wastes
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Codification
Objectives of Codification:
Value Analysis
An organized creative approach which has its objective, the efficient identification of
unnecessary cost which provides neither quality nor use nor life nor appearance nor
customer features.
Value is not inherent in a product, it is a relative term, and value can change with
time and place.
STORE MANAGEMENT
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Functions of store
To receive raw materials, components, tools, equipment and other items and
account for them.
To provide adequate and proper storage and preservation to the various
items.
To meet the demands of the consuming departments by proper issues and
account for the consumption.
To minimize obsolescence, surplus, and scrap through proper codification,
preservation, and handling.
To highlight stock accumulation, discrepancies, and abnormal consumption
and effective control measures
To ensure good housekeeping so that material handling, preservation,
stocking, receipt and issue can be done adequately
To assist in verification and provide supporting information for effective
purchase action
Forum / Discussion
Let’s Check
Activity 1
1. Which a customer places with its supplier to allow multiple delivery dates over a
period of time?
A. Zero Stock
B. Blanket Order System
C. Value Analysis
D. None of the choices
A. Purchasing
B. Stores
C. Inventory control
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A. Purchasing
B. Stores
C. Inventory control
4. Basically the job of materials manager is to provide the user department right
materials at the right time in right quantity of right quality at right price from the right
source.
A. Purchasing
B. Stores
C. Inventory control
A. Miscellaneous advantage
B. Better accountability
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C. Better performance
D. Better coordination
7. Under a Centralized material Manager, a team spirit is inculcated and this result in
better morale and cooperation.
A. Miscellaneous advantage
B. Better accountability
C. Better performance
D. Better coordination
8. Create initiatives that divert all reusable materials into a form that is most efficient
for next use.
A. Reduce
B. Reuse
c. Recycle
D. None of these
A. Reduce
B. Reuse
C. Recycle
D. None of these
A. Ergonomics
B. Reciprocity
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C. Purchasing
D. All of the choices
Let’s Analyze
Activity 2
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2. What is codification?
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In a Nutshell
Activity 3
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Is also called the idle resource of an enterprise. Is the supervision of non-capitalized assets?
Or inventory, stock items, as a component of supply chain. Supervise the flow of goods from
manufactures to warehouse and from these facilities to pint of sale.
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• To stabilize Production
• To Take Advantage of Price Discounts
• To Meet the Demand during the Replenishment Period
• To Prevent Loss of Orders
• To Keep Pace with Changing Market Conditions
Inventory Control - is a planned approach of determining what to order, when to order and
how much to order and how much to stock so that costs associated with buying and storing
are optimal without interrupting production and sales.
Problems:
Scientific Inventory System - strikes the balance between the loss due to non-availability
of an item and cost of carrying the stock of an item
Scientific Inventory Control - maintaining optimum level of stock of goods required by the
company at minimum cost to the company
ABC Analysis
ABC Classification
A-Item: Very tight control, the items being of high value. The control need to be
exercised at higher level of authority
B-Item: Moderate control, the items being of moderate value. The control need to be
exercised at middle level of authority
C-Item: The items being low value, the control can be exercised at gross root level of
authority by respective user department managers
HML Analysis
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The classification of existing inventory is based on unit price of the items. They are
classified as high price, medium price and low cost items.
VED Analysis
The classification of existing inventory is based on criticality of the items. They are
classified as vital, essential and desirable items.
FSN Analysis
The classification of existing inventory is based consumption of the items. They are
classified as fast moving, slow moving and non-moving items.
SDE Analysis
GOLF Analysis
The classification of existing inventory is based sources of the items. They are classified as
Government supply ,ordinarily available, local availability and foreign source of supply items
SOS Analysis
The classification of existing inventory is based nature of supply of items. They are
classified as seasonal and off-seasonal items.
Inventory Model
Deals with idle resources like men, machines, money and materials. These models are
concerned with two decisions: HOW MUCH TO ORDER and WHEN TO ORDER so as to
minimize the total cost. Economic order is calculated by balancing the two costs.
1. Tabulation Method – data presentation which clear and attractive manner that easily
understood and analyzed.
Textual presentation –reading the data
Tabular presentation – present a chart of data that many variables. Function
by using computer program have been developed employing this algorithm.
Diagram presentation - tool for scheduling activities in a project plan. Using
boxes refers to a node of activities.
2. Algebraic Method – used to solve a pair of linear equations with two variables.
Includes substitution, elimination and graphing.
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Forum / Discussion
Let’s Check
Activity 1
A. TRUE B. FALSE
1. The B-item: Very tight control, the items being of high value.
2. The HML analysis, the classification of existing inventory is based on unit price of the items.
3. The VED analysis, the classification of existing inventory is based consumption of the items.
4. The FSN analysis, the classification of existing inventory is based on the items.
5. The CSR policies are based on the idea that “the polluter pays”.
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7. A typical manufacturing plant has number of diverse activities interacting with each other.
8. Building, dams, bridge and roads are sample of fixed position layout.
9. Service which employ process layout comprise hospital, bank, auto repair, libraries and
universities.
10. Offices are designed to be distasteful and to reflect the organization’s approach to business
dealing.
Let’s Analyze
Activity 2
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In a Nutshell
Activity 3
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