Ch. 6 Master Production Scheduling SCM 461 Dr. Ron Tibben-Lembke Pages: 168-181, 183-188.
7 - Manufacturing Resource Planning Dr. Ron Tibben-Lembke pp. 222-234, 236-7, 240.
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Transcript of 7 - Manufacturing Resource Planning Dr. Ron Tibben-Lembke pp. 222-234, 236-7, 240.
7 - Manufacturing Resource Planning
Dr. Ron Tibben-Lembke
pp. 222-234, 236-7, 240
How do we account for LT?
System for organizing WIP releases Consider LT for each item Look at BOM to see what parts needed Release so they will arrive just as needed
Example Figure 7.2 Order quantity is 50 units LT is one week I’ve added “Net requirements” and “scheduled
releases” rows to Figure for clarity
Fig 7.2
1 2 3 4 5
Gross Requirements 10 40 10
Scheduled receipts (begin) 50
Projected Available Balance (ending) 4
54
44
44
4
Net Requirements 6
Planned Order Receipts
Planned Order Releases
6 units short
Fig 7.2
1 2 3 4 5
Gross Requirements 10 40 10
Scheduled receipts (begin) 50
Projected Available Balance (ending) 4
54
44
44
4
Net Requirements 6
Planned Order Receipts 50
Planned Order Releases 50
Order 50 units week earlier
Fig 7.2
1 2 3 4 5
Gross Requirements 10 40 10
Scheduled receipts (begin) 50
Projected Available Balance (ending) 4
54
44
44
4
44
Net Requirements 6
Planned Order Receipts 50
Planned Order Releases 50
Ending inventory
Terminology
Projected Available balance Not on-hand (that may be greater) Tells how many will be available (in ATP sense)
Planned order releases ≠ scheduled receipts Only when material has been committed to their
production Move to scheduled receipts as late as possible Preserves flexibility
Figure 7.3 1605 Snow Shovel
1605 Snow Shovel
048Scoop-shaftconnector
13122 Top Handle Assy314 scoop assembly
118 Shaft (wood)
062 Nail (4)
14127 Rivet (4)
314 scoop assembly
314 scoop assembly
14127 Rivet (6)019 Blade (steel)
2142 Scoop (aluminum)
13122 Top Handle Assembly
1118Top handle
Coupling (steel)
11495 WeldedTop handle bracket
Assembly
13122 Top Handle Assembly
457 Top handle(wood)
129 Top HandleBracket (steel)
082 Nail (2)
BOM Explosion
Process of translating net requirements into components part requirementsTake into account existing inventoriesConsider also scheduled receipts
BOM Explosion Example
Need to make 100 shovelsWe are responsible for handle
assemblies.
13122 Top Handle Assembly
1118Top handle
Coupling (steel)
11495 WeldedTop handle bracket
Assembly
13122 Top Handle Assembly
457 Top handle(wood)
129 Top HandleBracket (steel)
082 Nail (2)
Net Requirements
Sch Gross NetPart Description Inv Rec Req ReqTop handle assy 25 -- 100 75
Top handle 22 25Nail (2 required) 4 50Bracket Assy 27 --
Top bracket 15 --Top coupling 39 15
Figure 7.5
Sch Gross NetPart Description Inv Rec Req ReqTop handle assy 25 -- 100 75
Top handle 22 25 75 28Nail (2 required) 4 50 150 96Bracket Assy 27 -- 75 48
Top bracket 15 --Top coupling 39 15
13122 Top Handle Assembly
1118Top handle
Coupling (steel)
11495 WeldedTop handle bracket
Assembly
13122 Top Handle Assembly
457 Top handle(wood)
129 Top HandleBracket (steel)
082 Nail (2)
Figure 7.5
Sch Gross NetPart Description Inv Rec Req ReqTop handle assy 25 -- 100 75
Top handle 22 25 75 28Nail (2 required) 4 50 150 96Bracket Assy 27 -- 75 48
Top bracket 15 -- 48 33Top coupling 39 15 48 --
Timing of Production
This tells us how many of each we needDoesn’t tell when to startStart as soon as possible?Dependent events (oh no, not that!)
(We ignore statistical fluctuations)Front schedule Cutting approach (Fig. 7.6)
p. 231Back schedule Fig. 7.7 p.232
Fig 7.8 – 13122 Top Handle Assy
13122 Top handle LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req 20 10 20 5 35 10
Sch receipts
Proj. Avail Bal (ending)
25
25
5
5
Net Req 5
Pl Order Rec 5
Pl Order Rel 5
p. 233
Fig 7.8 – 13122 Top Handle Assy -2
13122 Top handle LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req 20 10 20 5 35 10
Sch receipts
Proj. Avail Bal (ending)
25
25
5
5
0
0
0
0
0
0
0
Net Req 5 20 5 35 10
Pl Order Rec 5 20 5 35 10
Pl Order Rel 5 20 5 35 10
13122 Top Handle Assembly
1118Top handle
Coupling (steel)
11495 WeldedTop handle bracket
Assembly
13122 Top Handle Assembly
457 Top handle(wood)
129 Top HandleBracket (steel)
082 Nail (2)
X
457 Top Handle
13122 Top handle LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req 20 10 20 5 35 10
Sch receipts
Proj. Avail Bal (ending)
25
25
5
5
0
0
0
0
0
0
0
Net Req 5 20 5 35 10
Pl Order Rec 5 20 5 35 10
Pl Order Rel 5 20 5 35 10
LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req 5 20 5 35 10
Sch receipts 25
Proj. Avail Bal (ending)
22
22
Net Req
Pl Order Rec
Pl Order Rel
One handle forEach assembly
457 Top Handle
LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req 5 20 5 35 10
Sch receipts 25
Proj. Avail Bal (ending)
22
22
17
Net Req
Pl Order Rec
Pl Order Rel
457 Top Handle
LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req 5 20 5 35 10
Sch receipts 25
Proj. Avail Bal (ending)
22
22
17
42
22
17
17
Net Req 18 10
Pl Order Rec 18 10
Pl Order Rel 18 10
13122 Top Handle Assembly
1118Top handle
Coupling (steel)
11495 WeldedTop handle bracket
Assembly
13122 Top Handle Assembly
457 Top handle(wood)
129 Top HandleBracket (steel)
082 Nail (2)
X
13122 Top Handle Assembly
1118Top handle
Coupling (steel)
11495 WeldedTop handle bracket
Assembly
13122 Top Handle Assembly
457 Top handle(wood)
129 Top HandleBracket (steel)
082 Nail (2)
X
X
082 Nail (2 required)
LT = 1 Lot Size = 50
1
2
3
4
5
6
7
8
9
10
Gross Req 10 40 10 70 20
Sch receipts 50
Proj. Avail Bal (ending)
4
54
Net Req
Pl Order Rec
Pl Order Rel
13122 Top handle LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req 20 10 20 5 35 10
Sch receipts
Proj. Avail Bal (ending)
25
25
5
5
0
0
0
0
0
0
0
Net Req 5 20 5 35 10
Pl Order Rec 5 20 5 35 10
Pl Order Rel 5 20 5 35 10
Two nails forEach assembly
082 Nail (2 required)
LT = 1 Lot Size = 50
1
2
3
4
5
6
7
8
9
10
Gross Req 10 40 10 70 20
Sch receipts 50
Proj. Avail Bal (ending)
4
54
44
44
4
Net Req 6
Pl Order Rec 50
Pl Order Rel 50
082 Nail (2 required)
LT = 1 Lot Size = 50
1
2
3
4
5
6
7
8
9
10
Gross Req 10 40 10 70 20
Sch receipts 50
Proj. Avail Bal (ending)
4
54
44
44
4
44
Net Req 6 26 20
Pl Order Rec 50
Pl Order Rel 50
082 Nail (2 required)
LT = 1 Lot Size = 50
1
2
3
4
5
6
7
8
9
10
Gross Req 10 40 10 70 20
Sch receipts 50
Proj. Avail Bal (ending)
4
54
44
44
4
44
44
24
4
4
4
Net Req 6 26
Pl Order Rec 50 50
Pl Order Rel 50
13122 Top Handle Assembly
1118Top handle
Coupling (steel)
11495 WeldedTop handle bracket
Assembly
13122 Top Handle Assembly
457 Top handle(wood)
129 Top HandleBracket (steel)
082 Nail (2)
X
XX
11495 Bracket Assembly
13122 Top handle LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req 20 10 20 5 35 10
Sch receipts
Proj. Avail Bal (ending)
25
25
5
5
0
0
0
0
0
0
0
Net Req 5 20 5 35 10
Pl Order Rec 5 20 5 35 10
Pl Order Rel 5 20 5 35 10
LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req
Sch receipts
Proj. Avail Bal (ending)
27
Net Req
Pl Order Rec
Pl Order Rel
One bracket forEach assembly
11495 Bracket Assembly
13122 Top handle LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req 20 10 20 5 35 10
Sch receipts
Proj. Avail Bal (ending)
25
25
5
5
0
0
0
0
0
0
0
Net Req 5 20 5 35 10
Pl Order Rec 5 20 5 35 10
Pl Order Rel 5 20 5 35 10
LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req 5
Sch receipts
Proj. Avail Bal (ending)
27
Net Req
Pl Order Rec
Pl Order Rel
One bracket forEach assembly
11495 Bracket Assembly
13122 Top handle LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req 20 10 20 5 35 10
Sch receipts
Proj. Avail Bal (ending)
25
25
5
5
0
0
0
0
0
0
0
Net Req 5 20 5 35 10
Pl Order Rec 5 20 5 35 10
Pl Order Rel 5 20 5 35 10
LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req 5 20 5 35 10
Sch receipts
Proj. Avail Bal (ending)
27
Net Req
Pl Order Rec
Pl Order Rel
One bracket forEach assembly
11495 Bracket Assembly
LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req 5 20 5 35 10
Sch receipts
Proj. Avail Bal (ending)
27
22
22
2
Net Req 3 35 10
Pl Order Rec 3 35 10
Pl Order Rel 3 35 10
13122 Top Handle Assembly
1118Top handle
Coupling (steel)
11495 WeldedTop handle bracket
Assembly
13122 Top Handle Assembly
457 Top handle(wood)
129 Top HandleBracket (steel)
082 Nail (2)
X
XXX
129 Top Bracket
LT = 1
1
2
3
4
5
6
7
8
9
10
Gross Req 3 35 10
Sch receipts
Proj. Avail Bal (ending)
15
Net Req
Pl Order Rec
Pl Order Rel
LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req 5 20 5 35 10
Sch receipts
Proj. Avail Bal (ending)
27
22
22
2
Net Req 3 35 10
Pl Order Rec 3 35 10
Pl Order Rel 3 35 10
129 Top handle bracket
LT = 1
1
2
3
4
5
6
7
8
9
10
Gross Req 3 35 10
Sch receipts
Proj. Avail Bal (ending)
15
15
15
12
12
Net Req 23 10
Pl Order Rec 23 10
Pl Order Rel 23 10
13122 Top Handle Assembly
1118Top handle
Coupling (steel)
11495 WeldedTop handle bracket
Assembly
13122 Top Handle Assembly
457 Top handle(wood)
129 Top HandleBracket (steel)
082 Nail (2)
X
XXX
X
1118 Top handle coupling
LT = 3 Safety Stock = 20
1
2
3
4
5
6
7
8
9
10
Gross Req 3 35 10
Sch receipts
Proj. Avail Bal (ending)
39
Net Req
Pl Order Rec
Pl Order Rel
LT = 2
1
2
3
4
5
6
7
8
9
10
Gross Req 5 20 5 35 10
Sch receipts
Proj. Avail Bal (ending)
27
22
22
2
Net Req 3 35 10
Pl Order Rec 3 35 10
Pl Order Rel 3 35 10
1118 Top handle coupling
LT = 3 Safety Stock = 20
1
2
3
4
5
6
7
8
9
10
Gross Req 3 35 10
Sch receipts 15
Proj. Avail Bal (ending)
39
39
54
51
51
16
Net Req 4
Pl Order Rec 4
Pl Order Rel 4
1118 Top handle coupling
LT = 3 Safety Stock = 20
1
2
3
4
5
6
7
8
9
10
Gross Req 3 35 10
Sch receipts 15
Proj. Avail Bal (ending)
39
39
54
51
51
20
20
20
20
20
20
Net Req 4 10
Pl Order Rec 4 10
Pl Order Rel 4 10
Other considerations
Safety stock if uncertainty in demand or supply quantity Don’t let available go down to 0
Safety LT if uncertainty in arrival time of supplyPlace order earlier than necessary
Order quantitiesEOQ, Lot-For-Lot, Periodic Order quantity,
more to come in ch. 14
Homework
DQ: 3, 7Problems: 3,5,6,7