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    MRP Planner Tasks: Release Reschedule Analyze and Update Reconcile Identify Problems Solve Shortages Enhance

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    ajeng.saraswati
    The document outlines various tasks involved in MRP planning including generating purchase and production orders, rescheduling orders, analyzing and updating data, reconciling errors, and addressing problems like material shortages. It also discusses exception codes to separate vital issues from trivial ones and bottom-up replanning using pegging data to guide efforts in solving shortages.

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    MRP Planner Tasks: Release Reschedule Analyze and Update Reconcile Identify Problems Solve Shortages Enhance

    Uploaded by

    ajeng.saraswati
    70 views10 pages
    The document outlines various tasks involved in MRP planning including generating purchase and production orders, rescheduling orders, analyzing and updating data, reconciling errors, and addressing problems like material shortages. It also discusses exception codes to separate vital issues from trivial ones and bottom-up replanning using pegging data to guide efforts in solving shortages.

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    The document outlines various tasks involved in MRP planning including generating purchase and production orders, rescheduling orders, analyzing and updating data, reconciling errors, and addressing problems like material shortages. It also discusses exception codes to separate vital issues from trivial ones and bottom-up replanning using pegging data to guide efforts in solving shortages.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    70 views10 pages

    MRP Planner Tasks: Release Reschedule Analyze and Update Reconcile Identify Problems Solve Shortages Enhance

    Uploaded by

    ajeng.saraswati
    The document outlines various tasks involved in MRP planning including generating purchase and production orders, rescheduling orders, analyzing and updating data, reconciling errors, and addressing problems like material shortages. It also discusses exception codes to separate vital issues from trivial ones and bottom-up replanning using pegging data to guide efforts in solving shortages.

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    MRP Planner Tasks

    • Purchase orders
    Release • Shop floor (production) orders

    Reschedule • Change due dates of existing orders (when desirable)

    • Set lot sizes and lead times


    Analyze and Update • Adjust scrap allowances and safety stocks

    Reconcile • Identify errors and inconsistencies and eliminate their root causes

    Identify Problems • Take action now to prevent future crises

    Solve Shortages • Adjust records and system parameters to prevent recurrence

    Enhance • Identify system enhancements to improve performance


    Exception Codes

    Separating the vital few from the


    trivial many
    Requirements
    Part numbers that cannot be
    Orders with
    with planned satisfied
    unsatisfactory
    orders in the within system
    timing or
    immediate parameters
    quantity
    period (management
    input needed)
    Bottom-Up Replanning
    • Using pegging data to guide efforts to solve
    material shortages
    – Pegging data allows the planner to take action
    only when actual customer orders are impacted
    MRP System Output
    Part number and description MRP system data

    MRP planning data

    Exception messages
    MRP System Dynamics

    MRP System Issues


    Procedural
    Rescheduling– Complex
    Transactions inadequacies–
    moving the transactions–
    during a situations the
    due date of inventory
    period– system
    an order to adjustments,
    unexpected wasn’t
    an earlier or service parts,
    changes designed to
    later date etc.
    handle
    System Dynamics
    An MRP is not a static document
    As time goes by
    Some orders get completed
    Other orders are near completion
    New orders will have been entered
    Existing orders will have been altered
    Quantity changes
    Delays
    Missed deliveries
    – See Figure 6.11,6.12,6.13
    Principles

    • Effective use of an MRP system allows development of a


    forward-looking approach to managing material flows.
    • The MRP system provides a coordinated set of linked product
    relationships, which permits decentralized decision making for
    individual part numbers.
    • All decisions made to solve problems must be implemented
    within the system, and transactions must be processed to reflect
    the resultant changes.
    • Effective use of exception messages allows attention to be
    focused on the “vital few” rather than the “trivial many.”
    10. XYZ Company
    Item A; Lot Size = 150; LT = 1, SS = 0. Average Inventory = ?

    Period 1 2 3 4 5 6 7 8 9 10

    Gross Requirements 71 46 49 55 52 47 51 48 56 51

    Scheduled Receipts

    Proj. Available Bal. 150

    Planned Order Rel.

    Item B; Lot Size = 150; LT = 1, SS = 0. Average Inventory = ?

    Period 1 2 3 4 5 6 7 8 9 10

    Gross Requirements 77 83 90 22 10 10 16 19 27 79

    Scheduled Receipts

    Proj. Available Bal. 150

    Planned Order Rel.


    10. XYZ Company
    Item A; Lot Size = 3 weeks supply (P=3); LT = 1, SS = 0. Average Inventory = ?
    Period 1 2 3 4 5 6 7 8 9 10

    Gross Requirements 71 46 49 55 52 47 51 48 56 51

    Scheduled Receipts

    Proj. Available Bal. 150

    Planned Order Rel.

    Item B; Lot Size = 3 weeks supply (P=3); LT = 1, SS = 0. Average Inventory = ?

    Period 1 2 3 4 5 6 7 8 9 10

    Gross Requirements 77 83 90 22 10 10 16 19 27 79

    Scheduled Receipts

    Proj. Available Bal. 150

    Planned Order Rel.


    14. ABC Manufacturing Company
    a. Component C (Q=40, LT=2, SS=0)

    1 2 3 4 5 6

    Gross Requirements

    Scheduled Receipts

    Projected Available Balance

    Planned Order Release

    b. Component C (Q=40, LT=2, SS=0)

    1 2 3 4 5 6

    Gross Requirements

    Scheduled Receipts

    Projected Available Balance

    Planned Order Release

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