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Material Requirement Planning (MRP)

Material Requirement Planning (MRP). 物 ( 材）料需求規劃. Outline. 定義與發展歷史沿革 MRP 架構 重要概念與名詞解釋 BOM Lead Time Reorder Point (ROP) 再訂購點 Safety Stock 安全存量 經濟訂購量 Economic Order Quantity (EOQ). MRP Definition. The planning of components based on the demand for high-level assemblies.

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Material Requirement Planning (MRP)

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  1. Material Requirement Planning (MRP) 物 (材）料需求規劃 IT/S in Manufacturing

  2. Outline • 定義與發展歷史沿革 • MRP架構 • 重要概念與名詞解釋 • BOM • Lead Time • Reorder Point (ROP)再訂購點 • Safety Stock安全存量 • 經濟訂購量Economic Order Quantity (EOQ) IT/S in Manufacturing

  3. MRP Definition The planning of components based on the demand for high-level assemblies. American Society for Production and Inventory Control (APICS) • 根據需求規劃零件組裝 IT/S in Manufacturing

  4. 發展歷史沿革 • 材料需求規劃(MRP)是計劃材料需求的工具. • 製造資源規劃(MRP II)計劃全廠的各項資源. • 企業資源規劃(ERP)計劃整個企業(不止一個廠)的各項資源 IT/S in Manufacturing

  5. MRP IT/S in Manufacturing

  6. MRP IT/S in Manufacturing

  7. MRP輸入資料 • 主生產排程(Mater Production Scheduling; MPS)：完成品的生產預定量及時間． • 材料表(Bill of Material; BOM)：又叫產品結構表（product structure)做成一個父件的所有子件． • 庫存狀態 (Inventory)：在庫量(on-hand)，在途量(scheduled receipt)，保留量(allocated). • 材料主檔：件號，前置時間，安全存量，批量法則，最低階碼等． • 工作曆：以時段(time bucket)將連續的時間分成斷續的時間，有以週為單位的(00-99)也有以日為單位的(000-999)． IT/S in Manufacturing

  8. IT/S in Manufacturing

  9. IT/S in Manufacturing

  10. BOM一例 IT/S in Manufacturing

  11. BOM一例 IT/S in Manufacturing

  12. Order model of control定單控制模式 • Sales銷售 • 顧客、地址、產品、數量、價格、時間等 • Purchase採購 • 供應商、料品、料量、運送時間、地址等 • Works生產: Manufacturing order製造命令 • 產品、數量、交期及其他指示 IT/S in Manufacturing

  13. Order model of control定單控制模式 （前置時間） IT/S in Manufacturing

  14. When should order be launched?何時下訂單　 • Reorder Point (ROP)再訂購點：庫存量降低至某一水準即發出某個數量訂單 倉儲大小 安全存量 平均需求量 前置時間 IT/S in Manufacturing

  15. Reorder Point (ROP)再訂購點之限制 • Orders arrive late.訂單常遲到 • Material consumed discontinuously.物料消耗不聯貫 • The value of average demand does not represent future consumption.目前之需求平均不能代表未來之消耗量 IT/S in Manufacturing

  16. IT/S in Manufacturing

  17. Safety Stock安全存量 To buffer the planning system to against uncertainty in demand緩衝需求不確定之影響 平均值　　　　　標準差　　　　　　　　　平均絕對差 IT/S in Manufacturing

  18. Forecast Errors預測錯誤 IT/S in Manufacturing

  19. 計算安全存量1─絕對差 IT/S in Manufacturing

  20. 計算安全存量1&2 IT/S in Manufacturing

  21. 倉儲大小與訂單頻率關係 IT/S in Manufacturing

  22. 經濟訂購量Economic Order Quantity (EOQ) 單位產品庫存一年持有成本 生產成本率 準備作業時間 倉儲大小 流程時間 年度需求量 最佳倉儲大小 IT/S in Manufacturing

  23. EOQ之概念圖示 IT/S in Manufacturing

  24. Service level IT/S in Manufacturing

  25. 物料需求的本質 • 獨立需求(Independent demand) • 產品或零件的需求和其他產品或零件的需求並沒有關係，也就是此種產品或零件的需求不會受到其他產品或零件需求的影響。 • 依賴需求(Dependent demand) • 產品或零件的需求是來自其他產品或零件的需求，後者是前者的父件(parent item)，前者是後者的子件(component item)。 IT/S in Manufacturing

  26. 獨立及依賴需求 • 有些材料同時具有獨立及依賴需求特性，如用來裝配成完成品的零件也可以維修零件銷售． • 依賴需求零件的生產計畫要能達成獨立需求零件的生產計畫． IT/S in Manufacturing

  27. 物料之特性 • Cost: represents a small portion of total value of assembly成本比例 • Volume: used in large quantities使用量 • Commonality: used on several different assemblies普遍性 • Non-critical: alternative items can be used緊急性 • Availability: available from a variety of sources at short notice存在性 IT/S in Manufacturing

  28. Pareto curve for components in an assemblies 80-20原則 IT/S in Manufacturing

  29. MRP計算 IT/S in Manufacturing

  30. MRP計算（續） IT/S in Manufacturing

  31. Homework 1 選擇一小組要生產製造之簡單產品，分析其零件物料，繪出此產品之物料表(Bill of Material; BOM)或產品結構表（product structure) ，如頁8至11。 IT/S in Manufacturing

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