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1SUCCESS IN SUCCESS OUTSUCCESS IN SUCCESS OUTI - 1

-- --

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1. 2. Inventory3. BOM4. MPS5. MRP6. CRP7. Scheduling




1-1.Reorder Point( )

(Order Point) = +

1.




1-2.MRP(Material Requirement Planning) :

- (What), (When), (How Much) .

MPS( )

MRP( )Inventory( ) BOM( ) BOM;Bill of Materials

MPS;Master Production Schedule




1-3.CLOSED LOOP MRP( MRP)- Feed back .

NO

YES

Closed Loop

MPS

MRPInventory( ) BOM

?




1-4.MRP II(Manufacturing Resource Planning) : - , , ,

.

MPS

Inventory BOM

CRP

RCCP

NO

YES

MRP

RCCP:

MPS;Master Production ScheduleRCCP;Rough-cut Capacity Plan,

, , ,

MRP;Material Requirements PlanBOM;Bill of MaterialsCRP;Capacity Requirements Plan

CRP:




1-5. MRP/ERP(Enterprise Resource Planning) : “ ”

- ( , , , , , , , ) , .

-1970 (MRP mrp: Material Requirement Planning),1980 (MRPII MRP: Manufacturing Resource Planning)

.

- .- 1980 , (Supply Chain) , ,

” .

- / ,- , , , Light Sizing

, ERP .

- , , , ,

(ABC Costing)” , ,

.




MRP/ERP

– MRP.

– MRP (BOM, Bi l l of Mat er i al s) ,

(Rout i ng Sheet ) ,

(MPS, Mast er Pr oduct i on Schedul e) ,

( I nvent or y Recor d)

) , , ,

. ”

MRP MRP II ERP




1-6.ERP(Enterprise Resource Planning)

MPS

MRP BOM

CRP

RCCP

NO

YES

( )




1-7. (Manufacturing Strategy)

Inventory

Engineering-To-Order( )

Make-To-Order( )

Assemble-To-Order( )

Make-To-Stock( )

1.1 Manufacturing strategy and lead time

(delivery lead time)

Design AssembleManufacturePurchase Ship




2-1. , , stocks Items

2-2. - Raw Materials (RAW)- Work in Process (WIP)- Finished Goods (FG) = end items- Maintenance, Repair, and Operating Supplies (MRO)

2-3.-Lot For Lot (L4L) : - : Fixed Order Quantity (FOQ) :

) FOQ = 1001 100 100101 100 200

- : Period Order Supply (POS) ; - (Minimum Order Quantity) - (EOQ : Economic Order Quantity)EOQ = (2AS) /( IC)

A = (Annual Usage)S = (Setup Cost)I = (Annual Carry Cost)C = (Unit Cost)

- (Reorder Point)- (Safety Stock) :

2. Inventory Management( )




2-4. (Lead Time : )

- LT

, ,

- LT :

- Queue + Setup + Run + Wait + MoveQueue Time : .Setup Time : Run Time : , , = Run Time X Lot SizeWait Time : , Move Time :

- Order Release :

Queue WaitRunSetup Queue WaitRunSetup

Queue WaitRunSetupQueue WaitRunSetup

Move

Move

Move

Move




2-4. (Lead Time : )

- (Operation Time) = (Setup Time) + (Run Time) = (Load)

- Lead Time Offset( )

- (Manufacturing Calendar)

(Day) , .

(Manufacturing or M-day Calendar). .

4 .




2-5. (Inventory Status Data)

- (On Hand) : , - (Scheduled Receipt)

(Release) Open Order( , ) . .

- (Scheduled Issue)- = + -- (Reservation)- (Allocation)

(Pick List) MRP

- (Backflush)

2-4.- 1 - 1

23

2 - 135

2-5. - (Cycle Counting) : , - (Physical Inventory)




2-4.Item Identification

•••••••• (Description)




3-1.BOM(Bill of Material) , ,

, 3-2.Level LLC

3-3.BOM

- , , , , , ,

3. BOM( :Bill of Material)

Ass’y Ass’y

Roll Ass’y

LEVEL 0

LEVEL 1

LEVEL 2

LEVEL 3




3-4. BOM( :Bill of Material)BOM

Job Shop

Repetitive

Flow Shop

One of AKind

One of A Kind Job Shop Repetitive Flow Shop

, , ,

BOM

(Project, One of a kind): build

Batch




3-5. BOM

BOM ,

?

?

?




A X

B C

)

. . )

(capaci t y)

* - (Single level)- (Multi-level, Indented)- (Explosion)- (Implosion) Where-used : .

- (Summarized)

-Pegging : , MRP (Explosion)

source.

(Bi l l Of Mat er i al s)

3-5. BOM




3-5. BOM




3-6. BOM




BOM




BOM

•A/S




3-7.BOM

-Engineering BOM E-BOM BOM . (Function)

. , BOM . , A, . ,

EBOM Manufacturing BOM .

- ( )--

BOM Manufacturing BOM Production BOM . MRP BOM . M-BOM P-BOM . M-BOM

E-BOM . , Item.

-




3-7.BOM

- BOM (Planning BOM ; Planning Bills)

Planning BOM (Master Production Scheduling) . , . ,

BOM .

Planning BOM1) Modular BOM2) Common Part BOM ( or KIT BOM)3) Super Bill ( )

Table

Common Parts Legs Sides Tops

Leg A 40%

Leg B 35%

Leg C 25%

Side A 55%

Side B 30%

Side C 15%

Top A 45%

Top B 30%

Top C 25%

100%

3 X 3 X 3 = 27




Modular BOM ( BOM)

Modular BOM Feature/Option . Assemble-To-Order .

, . - :1800cc, 2000cc, 2500cc, 3000cc- : , Graphic Equalizer , CD - ABS- , +--- : , - Room Mirror . - 10- . (combination) BOM BOM .

, A 3 , B 10 , C 5 , D 5 , E 10 , 3 * 10 * 5 * 5 * 10 = 7500 BOM .

, , 3 + 10 + 5 + 5 + 10 = 33 BOM . Modular BOM(Common Parts) . Modular BOM , BOM

. , Master Production Scheduling Option, .

(Final Product) 7500, 33 Common Parts .




Common Part BOM ( or KIT BOM)( , ) BOM , BOM

Item (Pseudo) Item Number .

BOM ; Super Bill ( )- Modular BOM Common Parts BOM Child BOM- ( )Planning BOM . BOM .

) Color TV 14 , 15 , 17 Color TV , 20%, 30%, 50%, Modular BOM BOM .

1800cc 60%, 2000cc 40%, 30%, Graphic Equalizer 30%, CD Player 50% Modular BOM BOM .

(MPS) . BOM .

.

Planning BOM-------




BOM / , (tree). , ( )

. , BOM Inverted BOM . BOM (Parent Child Relationship) , Parent Item Child Item, (Cycle) .

(1) Multilevel BOM , BOM Display . BOM Parent Child , Child Child ( ) BOM Multilevel BOM

. , BOM Multilevel BOM Parent Child , BOM Indented BOM .

(2) Phantom BOM Phantom Item BOM . Phantom Item, Item . Phantom Item BOM Phantom BOM . ,

Phantom JIT MRP , Engineering BOM Manufacturing BOM. Phantom BOM blow-through, pseudo BOM, transient BOM . Pseudo BOM

Planning BOM , .

(5) BOM( BOM) , BOM BOM BOM(Add), BOM (Delete)

(6) Add/Delete BOM . Bill of Activity Bill of Process BOM, Routing , , /NC /

. .




3-6.BOM

---- (Phantom)- (Backflush)

3-7. BOM -- : ( )




4. MPS(Master Production Schedule; )

: 26K (Periods)

1 2 3 4 5 6 7 8Sales Forecast 150 160 180 180 180 150 160 160Interplant Order 10 10 20Special Engineering Needs 20 10Service Part Requirements 10 10 10Special Promotion( ) 50Safety Stock Increase 10 10Anticipation build up 10 10 10Total 170 230 200 210 190 170 170 180

MPS ( Sources of MPS Requirements)

* Anticipation build up : ( : )

= 80Lot size = 100

(Periods)

1 2 3 4 5 6 7 8Sales Forecast 60 60 60 60 60 60 60 60

20 60 0 40 80 20 60 0MPS 100 100 100 100

MPS




4-1. MPS (Schedule)

4-2. (Independent Demand, Dependent Demand)

4. MPS(Master Production Schedule; )

Make-to-Stock Make-to-Order Assemble-to-Order

(END ITEM) (End Product)

(Raw material)

MPS

MPS

MPS FASFAS

FAS ; Final assembly schedule

, , ,

, (Sub Ass’y),

(Raw Material)




4-3.

. Planning Horizon ( )MRP MRP

.

A

B C D

E F

G

(LT = 1)

(LT = 5) (LT = 2)

(LT = 3)

(LT = 6)

(LT = 6)

1 + 2 + 3 + 6 = 12 12 .




4-3.

. Time Bucket MRP 1 1

; daily time bucket, weekly time bucket

· Time Phased, Time Slotted, Time Series

· Time FenceDTF ; Demand Time Fence

(master schedule) ..

.

PTF ; Planning Time Fence (master schedule) .

..

0 3 days

Due date Demand Time Fence

PlanningTime Fence

7 days




4-3.

ATP (Available To Promise ; ) CTP (Capable TO Promise ; )

MPS ATP CTP .

,

.

ATP CTP.




4-3.

. ATP (Available to Promise; )

. .

ATP = ARCP – (ACO + DDURD)ARCP = Amount of the Receipt in the Current PeriodACO = All Customer orders up until the next Receipt is DueDDURD = Dependent Demand up until the next Receipt is Due

1 2 3 4 5

10 20 10 30 20

MPS 10 60 110

ATP 40 50




4-3.

. CTP (Capable To Promise)

ATP (Resource), . ATP MPS CTP

. .

APS(Advanced Planning Scheduling) .

. Planner ; MPS/MRP ,

Planner : - ( i.e. launch purchase order or shop order )- open order- System Planning Factor ,

( , , scrap allowances, )- , -- ( )




4-4. MPS/MRP

.

= ( + ) -

= (MPS)

= + (

)

: Lot Size

= –

= –




4-5. MPS

· PAB (Projected Available Balance; )

DTF( ) :PAB = PAB + MPS –

:PAB = PAB + MPS – ( > or )

: 78100 DTF( ) : 3: ( , ) PTF( ) : 8Size : 50 : 50 : 2 periods

Period

(Sales Plan, Forecast)

)

; PAB 50

Available-to-Promise

; MPS

1 2 3 4 5 6 7 8 9

20 22 21 25 24 23 21 21 25

19 17 15 11 9 5 2 1 0

31 14 49 24 0 27 6 35 10

50 50 50

Calculate the PAB & the MPS for period 1-9




4-5. MPS

(MPS) "Time-Phased Grid" "Time-Slotted", "Time-Series", "Tableau" . MPS MRP (Time Bucket) , (Planning

Horizon) .

MPS SourceMPS (MTS ; Make To Stock) (Forecast), (MTO ; Make To Order)

(Customer Order) . (Interplant Order),

(Special Engineering Needs), (Service Part Requirements) .

, MPS . , , (Special Promotion)

MPS . (Stock Out)(Safety Stock Increase) , ,

(Anticipation Build Up) , MPS .

MPSMPS (Gross Requirements) . (Release)

(Scheduled Receipts) . (Bucket) (Net Requirements) . ,

.(Lot Sizing) (Planned Order

Receipts) . (Scheduled Receipts) (Planned Order Receipts) MRP MPS .

MRP MPS , RCCP MRP MPS .




MPS

(Engineering To Order), (Make To Order), (Assemble To Order), (Make To Stock) . (ETO)

(Critical Path) . , , MRP (Project Management) , (MTO) MPS

. (MTO) MPS(MTO) . MPS .

(Backlog) , MPS . , .

(MTO) , MPS (Planning Horizon) ., BOM .

, MPS .

(MTS) MPS,

. MPS , (Forecast)MPS .

, . .

BOM , .

(ATO) MPS,

. , .

1 , 2 . 1 MPS , 2 MPS

. 2 (FAS:Final Assembly Schedule). (Modular BOM)

.




5. MRP

:MRP (Right Time), ( Right Place), (Right

Part), (Right Amount) .

MRP

– MPS( )– BOM( :Bill of Material)– Routing( )– IR( ;Inventory Record)

:

“ MPS( : Master Production Schedule),

.”

MRP 4




1.MRP -Net Change( , )

-Regeneration( , )

2.LLC

3.MRP - , , , , ,

4.

-GR(Gross Requirement) :

-NR(Net Requirement) :

-Scheduled Receipt( )

-Projected Available( )

-Planned Order( )Planned order release( ) : Lead Time Offset Planned order receipt( ) : Lot Size

-Firm Planned Order( )Planned Order

5. MRP




5.-MPS (GR)- = - -- = - GR + -NR = - (Lot Size) - Offset -BOM

6.-A 7/15 7/20 100

B 1 , .: 100, : 50, 3 , Lot for Lot

-B : 100: 100 - 50 = 50: 50 - 100 = -50: 50

- 50 (Planned order receipt)-7/15 50 3 , 7/12

- 7/12 50 (Planned order release)

7.MRP 3--- (Exception message)




MRP

1. (Gross Requirements) 2. (Inventory)

- (Scheduled Receipts)-- (Projected On Hand)

3. (Net Requirements)

4. (Planned Order Receipts) - (Lot Size)

5. (Planned Order Releases) - (Lead Time Offset)

6. MRP (Part Explosion Procedure)--

Level 1 ( ) After Service (

) .,

..

Level 1 Level 2 .




A

B

E

D

C

Period1 2 3 4 5

Gross requirement 20Scheduled receiptsOn hand 6 6 6 36 36 36Planned order releases 50

Period1 2 3 4 5

Gross requirement 50Scheduled receipts 25On hand 30 55 5 5 5 5Planned order releases

A

B

C

Lead time=2Lot size = 20



Period1 2 3 4 5

Gross requirement 10 20Scheduled receipts 5On hand 5 5 10 0 0 0Planned order releases 20

MRP

: 5

: 6

: 30




< >

A

C

ED

B

(1) (2)

(1) (1)

LT

A 200 0 L4L 1 10/30

B 30 FOQ(100 ) 10

C 0 L4L 2

D 30 POS(10 ) 5

E 100 FOQ(200) 20

POS : Period of Supply FOQ : Fixed Order Quantity




MRP

MRP .

1 BOM ,( ) 1 .

2 = ( / ) * ( BOM ) +

3 =- ( )

MRP.

, , .4




6-1.

-Load( ) : ,

-Capa.( ) : .

-Backward( ) ( )

-Forward( )

-Infinite( ) : , ,

-Finite( ) : ,

- (Shop Calendar or Shop Planning Calendar) : Gregorian calendar,

- (Work Center)

6. CRP




MONTH WEEK MON. TUES. WED. THURS. FRI. SAT. SUN

27

28

JULY29

30

31

2 3 5 6 123 124 125 126

9 10 11 12 13 127 128 128 130 131

16 17 18 19 20 21 22

132 133 134 135 136

23 24 25 26 27 28 29

137 138 139 140 141

30 31 1 2 3

142 143 144 145 146

2123

JULY WORK DAY 123

• (DEFINES NON-WORK DAYS)

(Shop Planning Calendar)




010 020 030

Lead Time

BACKWARD SCHEDULING

Lead Time

FORWARD SCHEDULING

010 020 030

(Scheduling Techniques)




6-2 CRP

: MPS

RCCP :




6-3.CRP Input

- (Routing), , ,

( ) (Routing Sheet Operation Sheet)

- (Work Center)or , , , shift, Utilization( ), Efficiency( )

* Shift : * Utilization( ) = / , 1 * Efficiency( ) = / , 1

: Pin : 12-562: 1020 C.R.S : 12-562-D

: ST-100 : 07-12-4 : N:

Set-up

Drill.

Grind

LT 100

DR 132

GR 83

V-200

-

40

20

30

0.01

0.10

0.30

10

20

30




6-4.CRP flow

(( , , ))

, ,

//

1Utilization

Routing Routing

BOM BOM

(tool)(fixture)

((Loa

d)

Loa

d)

((Cap

acity

) C

apac

ity)




4.CAPA

- 6, 8hr, 2 , 85%, 90%, 6-

Capa = 6 * 8 * 2 * 0.85 * 0.9 * 6 = 440.64 hr

5.Load

A Hr Hr 10 A 0.5 0.1 10 0.5 + 1.0 = 1.5 20 B 1.0 0.1 10 1.0 + 1.0 = 2.0

B 10 C 0.5 0.5 20 0.5 + 10.0 = 10.520 A 1.0 0.2 20 1.0 + 4.0 = 5.0

A = 1.5 + 5 = 6.5 HrB = 2.0HrC = 10.5Hr




•.

• ,.

3/30 A 38.8 3/29 A 15.2 . WC1 A 3/29 ~ 3/30

B 23.6 B 3/28 ~ 3/293/28 B 5.4

3. : J001 3/30 1 , J002 3/30 2

7. Scheduling

J001 A 100 10 WC1 4hr 0.5 4+0.5 * 100 = 54hr2. 20 - 0.01 0.01 * 100 = 1hr

J002 B 50 10 WC1 4hr 0.5 4+0.5 * 50 = 29hr20 - 0.01 0.01 * 50 = 0.5hr

WC1 = 54 + 29 = 83hr= 1 + 0.5 = 1.5hr

1. CAPA : 3 , 2 , 1 8hr 85%, 100%.1 CAPA = 3 * 2 * 8 * 0.85 * 1 = 38.8 hr




1

WC1

28 29 30

38.8 Hr

38.8 Hr

J001

J002 15.2 Hr

23.6 Hr

5.4 Hr




INFINITE ( )

OVER OVER OVER

CAPACITY(120 HRS)

FINTE ( )

OVER

CAPACITY(120 HRS)

&




Backward, Finite

BOM

Yes

No

BOM



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