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Enterprise resource planning
Published in Andrew Greasley, Absolute Essentials of Operations Management, 2019
MRP is an information system used to calculate the requirements for component materials needed to produce end items. These components have what is called dependent demand. A dependent demand item has a demand that is relatively predictable because it depends on other factors. For example, a fireplace mantel consists of two legs and one shelf. If daily demand for the mantel, derived from the production schedule, is 50 mantels, then a daily demand of 100 legs and 50 shelves can be predicted. Thus, a dependent demand item can be classified as having a demand that can be calculated as the quantity of the item needed to produce a scheduled quantity of an assembly that uses that item. MRP systems manage dependent demand items by calculating the quantity needed and the timing required (taking into account purchasing and manufacturing lead times) of each item. The components of an MRP system that use and process this information are shown in Figure 14.1, and each component of the MRP system is now described.
Applying Theory of Constraints to a Complex Manufacturing Process
Published in Kaushik Kumar, Divya Zindani, J. Paulo Davim, Digital Manufacturing and Assembly Systems in Industry 4.0, 2019
Vishal Naranje, Srinivas Sarkar
Yet, the factory still lacks sophisticated (not necessarily very expensive) systems for MRP. Apart from being able to make the right components and parts readily available to factory workers, an MRP system also helps organizations maintain low levels of inventory. Oftentimes, one of the key results of a TOC implementation at a manufacturing setup is reduced inventory. An MRP can be used in production planning, scheduling, and controlling inventory. This makes it a valuable resource for the procurement team of any manufacturing setup. It ensures that the right amount of inventory is available for use. People, mainly managers, tend to take shortcuts that may affect the process integrity when resources are scarce, while the business development, market share, and profitability pressures are high. The resultant deficiencies in quality (products/process) are brushed aside in the name of business pragmatism ahead of quality and the employee-first paradigm. FD Solutions can employ any MRP suitable for their needs upon deciding their future objectives. If not a sophisticated MRP, the factory can also use Microsoft Excel more heavily to manage their inventory and ensure that the full kitting solutions are deployed in the best way possible to result in maximum benefit.
Enterprise Systems
Published in Vivek Kale, Enterprise Process Management Systems, 2018
In the 1960s, MRP emerged with the rapid evolution of computers. The main emphasis of these systems was to manage inventory, and the use of MRP helped companies to control their inventory based on actual demand rather than reorder points. To do this, MRP used a set of techniques that took into account bills of material data, inventory data, and the master production schedule to predict future requirements for materials. A finished product was subdivided into its components and, for every component, a time schedule was developed. Based on this list, using computers, all necessary information required for the production of this specific product could be obtained in a very short time. The critical subcomponents could be tracked easily and, if necessary, could be obtained quickly to support on-time production. The critical path (time, resources, etc.) could be defined and orders could be organized in order to prevent time delays in the receipt of materials. However, even this simple procedure became tedious once the number of parts increased. Thus, a computer was essential to carry out these features of MRP. To sum up the benefits of MRP, it reduced the level of inventory a company needed to maintain, lowered production times by improving coordination and avoiding delays, and increased the company’s overall efficiency.
Design of intelligent manufacturing system based on digital twin for smart shop floors
Published in International Journal of Computer Integrated Manufacturing, 2023
Mengke Sun, Zongyan Cai, Ningning Zhao
Through the integration of PLM, WMS, CRM and SCM systems, the ERP system realizes the MRP operation driven by multi-source data such as parts information, material inventory, customers, suppliers and so on, so as to generate the shop floor production plan. However, MRP takes parts as the planning object and does not consider the limitation of load, so it is necessary to measure production capacity based on shop floor capacity information when planning and scheduling are formulated. On the premise that the production capacity of the shop floor can meet the requirements of planning capacity, MES combines the process sequence and resource constraints in the process route of parts to generate process-level job scheduling and determine the resources and time information occupied by each station. The job scheduling can be distributed to each section and the team to dispatch production tasks, such as receiving and distributing materials. In the process of job scheduling execution, SCADA system tracks the material, equipment and other resources of the shop floor and feedbacks the quality and cost data to the relevant departments.
Designing a dynamic model to evaluate lot-sizing policies in different scenarios of demand and lead times in order to reduce the nervousness of the MRP system.
Published in Journal of Industrial and Production Engineering, 2021
Alireza Pooya, Nadiye Fakhlaei, Ali Alizadeh-Zoeram
Production management deals with a series of factors shaping its base. Therefore, it is required to know the backgrounds affecting the performance and the accomplishment of the activities. Based on the role of production in the market, production companies find themselves in a changing environment which could be observed in various industries of consumer and capital goods such as automobile, electronics, and home appliances. Subsequently, the management has to adapt to the new strategies in order to cope with the competitive nature of this new environment. Inventory management is an important issue in the field of production. Two key questions should be replied to in inventory control fall the physical goods; when to prepare the inventory and how much inventory should be ordered [1]. The answers to these questions are different under various circumstances. In this regard, material requirement planning (MRP) can respond to the information required for planning, production, and inventory control. The main achievements of MRP are production planning and material supply in which the system would be able to produce in the scheduled time limit. In fact, MRP is a flow control system that orders materials’ requirement, it is also the base of production timing, material purchasing, and receiving procedures.
Using ant colony optimisation for improving the execution of material requirements planning for smart manufacturing
Published in Enterprise Information Systems, 2022
Gang Ke, Ruey-Shun Chen, Yeh-Cheng Chen, Shi Wang, Xin Zhang
According to the structure of material requirement planning system, MRP system must complete the following three main functions: parts demand calculation, inventory calculation, and purchase calculation. By using product structure (of raw material list, product material list) and the scheduled completion date of each component combination, MRP system could complete these three functions after getting the amount of product demand. To accomplish these three functions, the input items of MRP system are product structure, inventory status, lot sizing rule and master production schedule. Moreover, the output items are the quantity of components should be ordered, the capacity demands and the manufacturing demands.