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Mrp ii
- 1. MANUFACTURING RESOURCE PLANNING (MRP II)
- 2. • Manufacturing resource planning (MRP II) is defined as a method for the effective planning of all resources of a manufacturing company. Ideally, it addresses operational planning in units, financial planning, and has a simulation capability to answer "what-if" questions and extension of closed-loop MRP.
- 3. Key functions and features: > MRP II is not a proprietary software system and can thus take many forms. It is almost impossible to visualize an MRP II system that does not use a computer, but an MRP II system can be based on either purchased–licensed or in-house software. Almost every MRP II system is modular in construction. Characteristic basic modules in an MRP II system are: - Master Production Schedule (MPS) - Item master data (technical data) - Bill of Materials (BOM) (technical data) - Production resources data (manufacturing technical data) - Inventories and orders (inventory control)
- 4. Together with auxiliary systems such as: - Business planning - Lot traceability - Contract management - Tool management - Engineering change control - Shop floor data collection - Sales analysis and forecasting - Configuration management - Finite capacity scheduling (FCS) and related systems such as: -Accounts Payable (purchase ledger) - General Ledger - Accounts receivable (sales ledger) - Estimating - Sales order management - Project management - Distribution requirements planning (DRP) - Automated warehouse management - Technical records - Computer-aided design/computer-aided manufacturing (CAD/CAM)
- 5. Benefits: MRP II systems can provide: - Better control of inventories - Improved scheduling - Productive relationships with For design / engineering: - Improved design control - Better quality and quality control - For financial and costing: - Reduced working capital for inventory - Improved cash flow through quicker deliveries - Accurate inventory records
- 6. Industry specifics: •manufacturing industries. implemented in most MRP II systems have been •pharmaceuticals or food •required by otherscan afford to disregard facilities Other industries •many industries is the key to success in this as in Capacity planning •MRP II is less appropriate
- 7. MRP and MRP II: History and Evolution •Material requirements planning (MRP) •manufacturing resource planning (MRPII) •enterprise resource planning (ERP) •Both MRP and MRPII are still widely used. •original vision of integrated information systems
- 8. The vision for MRP and MRP II : •Centralize •integrate business information •increase the efficiency of the production line overall. In the 1980s: •manufacturers developed systems that they would need to use computer •and softwaremanagers recognized production technology
- 9. KEY ELEMENTS • Sales and Operations Planning (SO&P) • Sales Forecasting • Master Production Schedule (MPS) • Material Requirements Planning (MRP) • Capacity Requirements Planning (CRP)
- 10. KANBAN • It is a scheduling system that tells you what to produce, when to produce it, and how much to produce.
- 11. MRP II vs KANBAN • Computerized system • Manual system • More concerned in • Involve in very small lot projecting requirement sizes, short lead times, • Planning and leveling high-quality output capacity via computer • Simple • Complex
- 12. MRP and MRPII: General concepts • > Material requirements planning (MRP) and manufacturing resource planning (MRPII) are both incremental information integration business process strategies that are implemented using hardware and modular software applications linked to a central database that stores and delivers business data and information.
- 13. • > MRP is concerned primarily with manufacturing materials while MRPII is concerned with the coordination of the entire manufacturing production, including materials, finance, and human relations. The goal of MRPII is to provide consistent data to all players in the manufacturing process as the product moves through the production line. • > Paper-based information systems and non-integrated computer systems that provide paper or disk outputs result in many information errors, including missing data, redundant data, numerical errors that result from being incorrectly keyed into the system, incorrect calculations based on numerical errors, and bad decisions based on incorrect or old data. In addition, some data is unreliable in non- integrated systems because the same data is categorized differently in the individual databases used by different functional areas.
- 14. • > MRPII systems begin with MRP, material requirements planning. MRP allows for the input of sales forecasts from sales and marketing. These forecasts determine the raw materials demand. MRP and MRPII systems draw on a master production schedule, the breakdown of specific plans for each product on a line. While MRP allows for the coordination of raw materials purchasing, MRPII facilitates the development of a detailed production schedule that accounts for machine and labor capacity, scheduling the production runs according to the arrival of materials. • > An MRPII output is a final labor and machine schedule. Data about the cost of production, including machine time, labor time and materials used, as well as final production numbers, is provided from the MRPII system to accounting and finance (Monk and Wagner).
- 15. Finance MARKET DEMAND Manufacturing Marketing PRODUCTION PLAN Rough Out Capacity Planning Problems? Master Production Schedule MRP Capacity requirement planning Problems? Requirements Schedules