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Maximizing Efficiency with Material Requirements Planning (MRP)

Learn about Material Requirements Planning (MRP) including inputs, processing, outputs, benefits, and its evolution into MRP II and Enterprise Resource Planning (ERP). Gain insights into the MRP process, product structure tree, inventory records, and MRP II benefits. Discover how MRP enhances production planning, capacity requirements evaluation, and inventory management. Explore the integration of financial, manufacturing, and human resources in ERP systems.

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Maximizing Efficiency with Material Requirements Planning (MRP)

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  1. MRP and ERP

  2. MRP • Material requirements planning (MRP): Computer-based information system that translates master schedule requirements for end items into time-phased requirements for subassemblies, components, and raw materials.

  3. MRP Inputs MRP Processing MRP Outputs Changes Order releases Master schedule Planned-order schedules Primary reports Exception reports Bill of materials Planning reports MRP computer programs Secondary reports Performance- control reports Inventory records Inventory transaction Figure 13.2

  4. MPR Inputs • Master Production Schedule • Time-phased plan specifying timing and quantity of production for each end item. • Material Requirement Planning Process Product Structure Tree Lead Times

  5. Master Schedule Master schedule: One of three primary inputs in MRP; states which end items are to be produced, when these are needed, and in what quantities. Cumulative lead time: The sum of the lead times that sequential phases of a process require, from ordering of parts or raw materials to completion of final assembly.

  6. Bill-of-Materials Bill of materials (BOM): One of the three primary inputs of MRP; a listing of all of the raw materials, parts, subassemblies, and assemblies needed to produce one unit of a product. Product structure tree: Visual depiction of the requirements in a bill of materials, where all components are listed by levels.

  7. Level 0 Chair Leg Assembly Back Assembly 1 Seat Cross bar Side Rails (2) Cross bar Back Supports (3) Legs (2) 2 3 Product Structure Tree Figure 13.5

  8. Inventory Records • One of the three primary inputs in MRP • Includes information on the status of each item by time period • Gross requirements • Scheduled receipts • Amount on hand • Lead times • Lot sizes • And more …

  9. Procurement of raw material D Fabrication of part E Subassembly A Procurement of raw material F Final assembly and inspection Procurement of part C Procurement of part H Subassembly B Fabrication of part G Procurement of raw material I 6 7 1 2 3 4 5 8 9 10 11 Assembly Time Chart Figure 13.7

  10. MRP Processing • Gross requirements • Schedule receipts • Projected on hand • Net requirements • Planned-order receipts • Planned-order releases

  11. MPR Processing • Gross requirements • Total expected demand • Scheduled receipts • Open orders scheduled to arrive • Planned on hand • Expected inventory on hand at the beginning of each time period

  12. MPR Processing • Net requirements • Actual amount needed in each time period • Planned-order receipts • Quantity expected to received at the beginning of the period • Offset by lead time • Planned-order releases • Planned amount to order in each time period

  13. Updating the System • Regenerative system • Updates MRP records periodically • Net-change system • Updates MPR records continuously

  14. MRP Outputs • Planned orders - schedule indicating the amount and timing of future orders. • Order releases - Authorization for the execution of planned orders. • Changes - revisions of due dates or order quantities, or cancellations of orders.

  15. MRP Secondary Reports • Performance-control reports • Planning reports • Exception reports

  16. Other Considerations • Safety Stock • Lot sizing • Lot-for-lot ordering • Economic order quantity • Fixed-period ordering

  17. Benefits of MRP • Low levels of in-process inventories • Ability to track material requirements • Ability to evaluate capacity requirements • Means of allocating production time

  18. MRP II • Expanded MRP with emphasis placed on integration • Financial planning • Marketing • Engineering • Purchasing • Manufacturing

  19. Master production schedule Market Demand Finance Manufacturing Marketing Production plan MRP Adjust master schedule Rough-cut capacity planning Capacity planning Adjust production plan No Yes Requirements schedules No Yes Problems? Problems? MRP II Figure 13.14

  20. ERP • Enterprise resource planning (ERP): • Next step in an evolution that began with MPR and evolved into MRPII • Integration of financial, manufacturing, and human resources on a single computer system.

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