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Evolution and Development of MRP / MRPII / ERP Systems

Evolution and Development of MRP / MRPII / ERP Systems. MPS - Master Production Scheduling BOM - Bill of Materials Product structure INV - Inventory Transaction Inventory status PUR - Purchasing Control SFC - Shop Flow Cont rol Production Activity Control. DEM. Forcasts.

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Evolution and Development of MRP / MRPII / ERP Systems

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  1. Evolution and Development of MRP / MRPII / ERP Systems

  2. MPS - Master Production Scheduling BOM - Bill of MaterialsProduct structure INV - Inventory TransactionInventory status PUR - Purchasing Control SFC - Shop Flow Control Production Activity Control DEM • Forcasts • Orders BOM INV MRP – Material Requirements Planning The basic module of the system Material resources • MPS • MRP PUR SFC

  3. DEM • Forcasts • Orders BOM INV CL MRP – Closed Loop Material Requirements Planning CRP - Capacity Requirements Planning I/OC - Input/Output ControlLoad of Work Centers SOP - Sales and Operations Planning Production planning Capacity planning • SOP • MPS • MRP • CRP PUR SFC • I/OC

  4. DEM • Forcasts • Orders BOM INV MRP II – Manufacturing Resource Planning Marketing resources Finance resources DEM - Demand Management RCCP - Rough Cut Capacity Planning RRP - Resource Requirements Planning Interface with marketing area (distribution resources) and finance area Production planning Capacity planning • SOP • RRP • MPS • RCCP • MRP • CRP PUR SFC • I/OC

  5. DEM Demand Management Forcasts and Orders SOP Sales &Operation Planning RP Resource Planning RCCP - Rough-Cut Capacity Planning MPS Master Production Scheduling MRP Material Requirements Planning CRP - Capacity Requirements P. FPS Final Product Schedule PAC Production Activity Control Input /Output Control PUR Purchasing Control MANUFACTURING RESOURCES PLANNING SYSTEM MRP II

  6. MRP II Standard System APICS 1989 SOP - (Sales and Operations Planning) DEM - (Demand Management) MPS - (Master Production Scheduling) MRP - (Material Requirements Planning) BOM - (Bill of Material Subsystem) INV - (Inventory Transaction Subsystem) SRS - (Scheduled ReceiptsSubsystem) SFC - (Shop Floor Control, Production Activity Control) CRP - (Capacity Requirements Planning) I/OC - (Input/Output Control) PUR - (Purchasing) DRP - (Distribution Requirements Planning) TPC - (Tooling Planning and Control) FPI - (Financial Planning Interfaces) SYM - (Simulation) PMT - (Performance Measurement)

  7. DEM • Forcasts • Orders BOM INV ERP (MRP III)Enterprise Resource Planning Marketing resources Finance resources TOTAL MANAGEMENT INTEGRATION • Integration of all functions in enterprise • Total Enterprise Resources Management (Inter Functional Management ) • Integrated Organization Production planning Capacity planning • SOP • RRP • MPS • RCCP • MRP • CRP PUR SFC • I/OC

  8. Benefits of MRPII/ERP system implementation in an organisation • Reduced Inventory with fewer (none) shortages • Improved Customer Service • Improved Direct Labour Productivity • Reduced Purchasing Cost • Reduced Obsolescence • Reduced Overtime • Plan for future capacity needs

  9. MRP • DRP • LRP • CL MRP • MRP II • DRP II • ERP • LIS Development of MRP system 1960 1970 1980 1990 2000 Production management integration Enterprise management integration Supply chain management integration MRP - Material Requirements Planning CL MRP - Closed Loop Material Requirements Planning MRP II - Manufacturing Resource Planning ERP - Enterprise Resource Planning DRP - Distribution Requirements Planning LRP - Logistics Requirements Planning DRP II - Distribution Resource Planning LIS - Logistics InformationSystem

  10. Dokładność, bezbłędność, aktualność i niezawodność danych: • Kartoteka strukturalna - 99% • Kartoteka rodzajowa - 99% • Kartoteka procesów technologicznych - 95% • Kartoteka stanowisk roboczych - 95% Rygor i dyscyplina w kontroli przepływu materiałów: • Zapasy - 99% • Zlecenia produkcyjne - 99% • Zlecenia nabycia - 99% • Zamówienia klientów - 99% Realny, wykonalny ze względu na zdolności produkcyjne Główny Plan Produkcji Zaangażowanie kierownictwa oraz jego uczestnictwo i zrozumienie: • Arbitraż w kwestiach spornych między • Marketingiem • Produkcją • Finansami Szkolenia pracowników: • 80% przeszkolonej i poinformowanej załogi • Kierownik projektu wdrożenia systemu MRPII System MRPII/ERP jest bezużyteczny jeżeli nie przestrzega się wysokiej dyscypliny w zarządzaniu zapasami Kontrola zapasów według klasyfikacji ABC: • Codzienna kontrola – klasa A pozycje rodzajowe o dużej wartości na wyjściu • Comiesięczna kontrola – klasa C pozycje o małej wartości na wyjściu Wymogi efektywnego wdrożenia i funkcjonowania zintegrowanego systemu zarządzania klasy MRPII/ERP

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