7 Manufacturing Resource Planning Dr Ron TibbenLembke pp
7 - Manufacturing Resource Planning Dr. Ron Tibben-Lembke pp. 222 -234, 236 -7, 240
How do we account for LT? l System for organizing WIP releases l l Consider LT for each item Look at BOM to see what parts needed Release so they will arrive just as needed Example Figure 7. 2 l l l Order quantity is 50 units LT is one week I’ve added “Net requirements” and “scheduled releases” rows to Figure for clarity
Fig 7. 2 6 units short
Fig 7. 2 Order 50 units week earlier
Fig 7. 2 Ending inventory
Terminology l Projected Available balance l l l Not on-hand (that may be greater) Tells how many will be available (in ATP sense) Planned order releases ≠ scheduled receipts l l l Only when material has been committed to their production Move to scheduled receipts as late as possible Preserves flexibility
Figure 7. 3 1605 Snow Shovel 314 scoop assembly 118 Shaft (wood) 14127 Rivet (4) 048 Scoop-shaft connector 062 Nail (4) 13122 Top Handle Assy
314 scoop assembly 019 Blade (steel) 2142 Scoop (aluminum) 14127 Rivet (6)
13122 Top Handle Assembly 11495 Welded Top handle bracket Assembly 457 Top handle (wood) 1118 Top handle Coupling (steel) 129 Top Handle Bracket (steel) 082 Nail (2)
BOM Explosion l Process of translating net requirements into components part requirements Take into account existing inventories l Consider also scheduled receipts l
BOM Explosion Example l Need to make 100 shovels l We are responsible for handle assemblies.
13122 Top Handle Assembly 11495 Welded Top handle bracket Assembly 457 Top handle (wood) 1118 Top handle Coupling (steel) 129 Top Handle Bracket (steel) 082 Nail (2)
Net Requirements Part Description Top handle assy Top handle Nail (2 required) Bracket Assy Top bracket Top coupling Inv 25 22 4 27 15 39 Sch Gross Rec Req -100 25 50 --15 Net Req 75
Figure 7. 5 Part Description Top handle assy Top handle Nail (2 required) Bracket Assy Top bracket Top coupling Inv 25 22 4 27 15 39 Sch Rec -25 50 --15 Gross Req 100 75 150 75 Net Req 75 28 96 48
13122 Top Handle Assembly 11495 Welded Top handle bracket Assembly 457 Top handle (wood) 1118 Top handle Coupling (steel) 129 Top Handle Bracket (steel) 082 Nail (2)
Figure 7. 5 Part Description Top handle assy Top handle Nail (2 required) Bracket Assy Top bracket Top coupling Sch Inv 25 22 4 27 15 39 Gross Rec Req -100 25 75 50 150 -75 -48 15 48 Net Req 75 28 96 48 33 --
Timing of Production l This tells us how many of each we need Doesn’t tell when to start l Start as soon as possible? l Dependent events (oh no, not that!) l l (We ignore statistical fluctuations) Front schedule Cutting approach (Fig. 7. 6) p. 231 l Back schedule Fig. 7. 7 p. 232 l
Fig 7. 8 – 13122 Top Handle Assy p. 233
Fig 7. 8 – 13122 Top Handle Assy -2
13122 Top Handle Assembly X 13122 Top Handle Assembly 11495 Welded Top handle bracket Assembly 457 Top handle (wood) 1118 Top handle Coupling (steel) 129 Top Handle Bracket (steel) 082 Nail (2)
457 Top Handle One handle for Each assembly
457 Top Handle
457 Top Handle
13122 Top Handle Assembly X 13122 Top Handle Assembly 11495 Welded Top handle bracket Assembly 457 Top handle (wood) 1118 Top handle Coupling (steel) 129 Top Handle Bracket (steel) 082 Nail (2)
13122 Top Handle Assembly X 13122 Top Handle Assembly 11495 Welded Top handle bracket Assembly X 457 Top handle (wood) 1118 Top handle Coupling (steel) 129 Top Handle Bracket (steel) 082 Nail (2)
082 Nail (2 required) Two nails for Each assembly
082 Nail (2 required)
082 Nail (2 required)
082 Nail (2 required)
13122 Top Handle Assembly X 13122 Top Handle Assembly 11495 Welded Top handle bracket Assembly XX 457 Top handle (wood) 1118 Top handle Coupling (steel) 129 Top Handle Bracket (steel) 082 Nail (2)
11495 Bracket Assembly One bracket for Each assembly
11495 Bracket Assembly One bracket for Each assembly
11495 Bracket Assembly One bracket for Each assembly
11495 Bracket Assembly
13122 Top Handle Assembly X 11495 Welded Top handle bracket Assembly 13122 Top Handle Assembly X XX 457 Top handle (wood) 1118 Top handle Coupling (steel) 129 Top Handle Bracket (steel) 082 Nail (2)
129 Top Bracket
129 Top handle bracket
13122 Top Handle Assembly X 11495 Welded Top handle bracket Assembly 13122 Top Handle Assembly X 1118 Top handle Coupling (steel) X 129 Top Handle Bracket (steel) XX 457 Top handle (wood) 082 Nail (2)
1118 Top handle coupling
1118 Top handle coupling
1118 Top handle coupling
Other considerations l Safety stock if uncertainty in demand or supply quantity l Don’t let available go down to 0 l Safety supply l Place order earlier than necessary l Order l LT if uncertainty in arrival time of quantities EOQ, Lot-For-Lot, Periodic Order quantity, more to come in ch. 14
Homework l DQ: 3, 7 l Problems: 3, 5, 6, 7
- Slides: 43