materials requirements planning
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Materials Requirements Planning. MRP. Suatu perusahaan dengan beberapa produk, menerima pesanan dalam beberapa perioda. Perusahaan perlu untuk mengatur bahan baku apa saja, berapa, dan kapan setiap bahan itu diperlukan agar biaya produksi bisa diminimalkan. - PowerPoint PPT PresentationTRANSCRIPT
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Materials Requirements Planning
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MRPSuatu perusahaan dengan beberapa produk, menerima pesanan dalam beberapa perioda.Perusahaan perlu untuk mengatur bahan baku apa saja, berapa, dan kapan setiap bahan itu diperlukan agar biaya produksi bisa diminimalkan.Perlu juga dipertimbangkan kuantitas pesanan agar dimungkinkan menekan biaya inventory.
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MRPUntuk mengetahui kebutuhan bahan baku, perlu diketahui Bill of Material ( BoM) dari setiap produk.BOM = Resep = Formula BOM adalah material, bagian, komponen, unit atau proses yang diperlukan untuk menghasilkan suatu produk.
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Bill of Materials (BOM) FileA Complete Product DescriptionMaterialsPartsComponentsProduction sequence
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Deskripsi BOM
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Table100Base 200Top023Legs (4)203Boards (3)030Leg Bolts (4)220Frame (1)300Sides (2)622Ends (2)411Leg Supports (4)533Glue 066Glue 066Multilevel Bill
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Table100Base 200Top023Legs (4)203Boards (3)030Leg Bolts (4)220Frame (1)300Sides (2)622Ends (2)411Leg Supports (4)533Glue 066Glue 066Single-level BillBase 200Top023Frame (1)300
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XYL M N(2) OP GJ K(2)B(2) C DF G(2) M(2) NJ K(2)Using the following product tree, construct the appropriate single level trees. How many Ks are needed to make 100 Xs and 50 Ys?Example Problem
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ADCBCPegged requirementsPegged requirements
Source of requirementsPegging identify each parent item that created demand
Item NumberWeek12345C501252550150
A5025255050B100100
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Example of MRP Logic and Product Structure TreeProduct Structure Tree for Assembly ALead TimesA1 dayB 2 daysC1 dayD 3 daysE4 daysF1 dayTotal Unit DemandDay 10 50 ADay 8 20 B (Spares)Day 6 15 D (Spares)Given the product structure tree for A and the lead time and demand information below, provide a materials requirements plan that defines the number of units of each component and when they will be needed
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First, the number of units of A are scheduled backwards to allow for their lead time. So, in the materials requirement plan below, we have to place an order for 50 units of A on the 9th day to receive them on day 10.
Sheet: Sheet1
Sheet: Sheet2
Sheet: Sheet3
Sheet: Sheet4
Sheet: Sheet5
Sheet: Sheet6
Sheet: Sheet7
Sheet: Sheet8
Sheet: Sheet9
Sheet: Sheet10
Sheet: Sheet11
Sheet: Sheet12
Sheet: Sheet13
Sheet: Sheet14
Sheet: Sheet15
Sheet: Sheet16
Day:
A
Required
50.0
Order Placement
50.0
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Next, we need to start scheduling the components that make up A. In the case of component B we need 4 Bs for each A. Since we need 50 As, that means 200 Bs. And again, we back the schedule up for the necessary 2 days of lead time.
Sheet: Sheet1
Sheet: Sheet2
Sheet: Sheet3
Sheet: Sheet4
Sheet: Sheet5
Sheet: Sheet6
Sheet: Sheet7
Sheet: Sheet8
Sheet: Sheet9
Sheet: Sheet10
Sheet: Sheet11
Sheet: Sheet12
Sheet: Sheet13
Sheet: Sheet14
Sheet: Sheet15
Sheet: Sheet16
Day:
A
Required
50.0
Order Placement
50.0
B
Required
20.0
200.0
Order Placement
0.0
0.0
0.0
0.0
0.0
20.0
200.0
0.0
0.0
0.0
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Finally, repeating the process for all components, we have the final materials requirements plan:The McGraw-Hill Companies, Inc., 2001*
Sheet: Sheet1
Sheet: Sheet2
Sheet: Sheet3
Sheet: Sheet4
Sheet: Sheet5
Sheet: Sheet6
Sheet: Sheet7
Sheet: Sheet8
Sheet: Sheet9
Sheet: Sheet10
Sheet: Sheet11
Sheet: Sheet12
Sheet: Sheet13
Sheet: Sheet14
Sheet: Sheet15
Sheet: Sheet16
Day:
A
Required
50.0
LT=1
Order Placement
50.0
B
Required
0.0
0.0
0.0
0.0
0.0
0.0
0.0
20.0
200.0
0.0
LT=2
Order Placement
0.0
0.0
0.0
0.0
0.0
20.0
200.0
0.0
0.0
0.0
C
Required
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
100.0
0.0
LT=1
Order Placement
0.0
0.0
0.0
0.0
0.0
0.0
0.0
100.0
0.0
D
Required
0.0
0.0
0.0
0.0
0.0
55.0
400.0
300.0
0.0
0.0
LT=3
Order Placement
0.0
0.0
55.0
400.0
300.0
0.0
0.0
0.0
E
Required
0.0
0.0
0.0
0.0
0.0
20.0
200.0
0.0
0.0
0.0
LT=4
Order Placement
0.0
20.0
200.0
0.0
0.0
0.0
0.0
F
Required
0.0
0.0
0.0
0.0
0.0
0.0
0.0
200.0
0.0
0.0
LT=1
Order Placement
0.0
0.0
0.0
0.0
0.0
0.0
200.0
0.0
0.0
Spares
B
20.0
C
D
15.0
E
F
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Additional MRP Scheduling TerminologyGross RequirementsScheduled receiptsProjected available balanceNet requirementsPlanned order receiptPlanned order release
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MRP ExampleRequirements include 95 units (80 firm orders and 15 forecast) of X in week 10
Sheet: Sheet1
Item
On-Hand
Lead Time (Weeks)
X
A
B
C
D
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A(2)XIt takes 2 As for each X
Sheet1
Day:12345678910
XGross requirements95
LT=2Scheduled receipts
Proj. avail. balance50505050505050505050
On-Net requirements45
handPlanned order receipt45
50Planner order release45
AGross requirements90
LT=3Scheduled receipts
Proj. avail. balance7575757575757575
On-Net requirements15
handPlanned order receipt15
75Planner order release15
BGross requirements45
LT=1Scheduled receipts
Proj. avail. balance2525252525252525
On-Net requirements20
handPlanned order receipt20
25Planner order release20
CGross requirements4540
LT=2Scheduled receipts
Proj. avail. balance1010101010
On-Net requirements3540
handPlanned order receipt3540
10Planner order release3540
DGross requirements100
LT=2Scheduled receipts
Proj. avail. balance20202020202020
On-Net requirements80
handPlanned order receipt80
20Planner order release80
Sheet2
Sheet3
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B(1)A(2)XIt takes 1 B for each X
Sheet1
Day:12345678910
XGross requirements95
LT=2Scheduled receipts
Proj. avail. balance50505050505050505050
On-Net requirements45
handPlanned order receipt45
50Planner order release45
AGross requirements90
LT=3Scheduled receipts
Proj. avail. balance7575757575757575
On-Net requirements15
handPlanned order receipt15
75Planner order release15
BGross requirements45
LT=1Scheduled receipts
Proj. avail. balance2525252525252525
On-Net requirements20
handPlanned order receipt20
25Planner order release20
CGross requirements4540
LT=2Scheduled receipts
Proj. avail. balance1010101010
On-Net requirements3540
handPlanned order receipt3540
10Planner order release3540
DGross requirements100
LT=2Scheduled receipts
Proj. avail. balance20202020202020
On-Net requirements80
handPlanned order receipt80
20Planner order release80
Sheet2
Sheet3
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A(2)B(1)XC(3)It takes 3 Cs for each A
Sheet1
Day:12345678910
XGross requirements95
LT=2Scheduled receipts
Proj. avail. balance50505050505050505050
On-Net requirements45
handPlanned order receipt45
50Planner order release45
AGross requirements90
LT=3Scheduled receipts
Proj. avail. balance7575757575757575
On-Net requirements15
handPlanned order receipt15
75Planner order release15
BGross requirements45
LT=1Scheduled receipts
Proj. avail. balance2525252525252525
On-Net requirements20
handPlanned order receipt20
25Planner order release20
CGross requirements4540
LT=2Scheduled receipts
Proj. avail. balance1010101010
On-Net requirements3540
handPlanned order receipt3540
10Planner order release3540
DGross requirements100
LT=2Scheduled receipts
Proj. avail. balance20202020202020
On-Net requirements80
handPlanned order receipt80
20Planner order release80
Sheet2
Sheet3
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A(2)B(1)C(2)XC(3)It takes 2 Cs for each B
Sheet1
Day:12345678910
XGross requirements95
LT=2Scheduled receipts
Proj. avail. balance50505050505050505050
On-Net requirements45
handPlanned order receipt45
50Planner order release45
AGross requirements90
LT=3Scheduled receipts
Proj. avail. balance7575757575757575
On-Net requirements15
handPlanned order receipt15
75Planner order release15
BGross requirements45
LT=1Scheduled receipts
Proj. avail. balance2525252525252525
On-Net requirements20
handPlanned order receipt20
25Planner order release20
CGross requirements4540
LT=2Scheduled receipts
Proj. avail. balance1010101010
On-Net requirements3540
handPlanned order receipt3540
10Planner order release3540
DGross requirements100
LT=2Scheduled receipts
Proj. avail. balance20202020202020
On-Net requirements80
handPlanned order receipt80
20Planner order release80
Sheet2
Sheet3
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A(2)B(1)D(5)C(2)XC(3)It takes 5 Ds for each B
Sheet1
Day:12345678910
XGross requirements95
LT=2Scheduled receipts
Proj. avail. balance50505050505050505050
On-Net requirements45
handPlanned order receipt45
50Planner order release45
AGross requirements90
LT=3Scheduled receipts
Proj. avail. balance7575757575757575
On-Net requirements15
handPlanned order receipt15
75Planner order release15
BGross requirements45
LT=1Scheduled receipts
Proj. avail. balance2525252525252525
On-Net requirements20
handPlanned order receipt20
25Planner order release20
CGross requirements4540
LT=2Scheduled receipts
Proj. avail. balance1010101010
On-Net requirements3540
handPlanned order receipt3540
10Planner order release3540
DGross requirements100
LT=2Scheduled receipts
Proj. avail. balance20202020202020
On-Net requirements80
handPlanned order receipt80
20Planner order release80
Sheet2
Sheet3
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Schedule ReceiptKerjakan kembali bila pada perioda 6 ada schedule receipt material D sebanyak 50 unit.Kerjakan kembali bila lot size C adalah 100.
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ADCBCLow Level CodePart Low Level
A 0 B 1 C 1 2 D 2
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AB(2)D(1)E(1)C(1)D(2)F(1)Given the following product tree, explode, offset, and determine the gross and net requirements. All lead time are one week, and the quantities required are show in parentheses.The master production schedule call for 100 As to be availableIn week 5,. There are 20 Bs available.
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AB(2)D(1)E(1)C(1)D(2)F(1)Given the following product tree, explode, offset, and determine the gross and net requirements. All lead time are one week, and the quantities required are show in parentheses.The master production schedule call for 100 As to be availablein week 5, there is a schedule receipt of 100 Bs in week 1.There are 200 Fs available. All order quantities are lot-for-lot.
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HI(2)J(2)K(3)Given the following partial product tree, explode, offset, and determine the gross and net requirements for components H, I, J, and K. Lead time are 1, 2, 1, and 1 week, and the quantities required are show in parentheses.The master production schedule call for production of 50 Hs in week 3, and 80 in week5. There is a scheduled receipt of 100 Is in week 2,. There are 400 Js, and 400 Ks available.
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Suatu produk mempunyai Bill of Material seperti di bawah ini :Buatlah product tree dari produk A dan B.MPS menentukan agar produk A tersedia 50 unit pada perioda 4, dan produk BTersedia 100 unit pada perioda 5.Produk A telah tersedia 10 pada awal perioda serta komponen C dijadwalkan akan diterima pada perioda 2 sebesar 100. Buatlah MRP untuk semua komponen.
ProdukKomponenJumlahLead TimesizeAC21L4LD3BE11L4LC1CE11L4LF2DE21L4LC1E--1100F--1500
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Lot Sizing in MRP ProgramsLot-for-lot (L4L)Economic Order Quantity (EOQ)Period Order Quantity (POQ)Part Period Balancing (PBB)Least Unit Cost (LUC)Least average Total Cost (LTC) Silver MealWhich one to use? -> The one that is least costly!
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Lead Time = 1 mingguHolding cost = $2/unit/mingguSetups cost =$200; Lot size = 1Lot for LotBiaya setup = 7*$200 = $1400Biaya Hold = 0 ( tidak ada inv)Total biaya = $1400
Week012345678910GR353040010403003055OHI350000000000NR30401040303055POR30401040303055PORel30401040303055
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D=(35+30+ .. + 55) = 270Q= ((2*200*270)/20) = 74EOQBiaya order = 4*$200 = $800Biaya Hold = (44+4+4+..+61)*$2 = $790Total biaya = $800+$790 = $1590
Week012345678910GR353040010403003055OHI3504444682872724261NR306213POR74747474PORel74747474
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EOI =EOQ/d = 74/27 = 3 periode; pemesanan setiap 3 periodePeriodic Order Quantity (POQ)Biaya order = 3*$200 = $600Biaya Hold = (50+10+10+..+30)*$2 = $380Total biaya = $600+$380 = $980
Week012345678910GR353040010403003055OHI350501010060303000NR304055POR8010055PORel8010055
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Part Period Balancing (PPB)Menyeimbangkan biaya setup dan biaya holding dengan menggunakan Economic Part Period (EPP). EPP di definisikan sebagai rasio dari biaya setup terhadap biaya holding.Teknik PPB mengkombinasikan periode kebutuhan sehingga jumlah part period mendekati nilai EPP
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Part Period BalancingEPP = 200/2 = 100Mencari pesanan yang mendekati EPP, dg dasar pemikiran Menyimpan 100 unit selama 1 periode sama dengan menyimpan50 unit selama 2 periode ( biaya penyimpanan sama )Kombinasi Lot size Part Period ( inventory)periode 30 02,3 30+40=70 40*1p=402,3,4 30+40+0=70 402,3,4,5 30+40+0+10=80 40*1p+10*3p=702,3,4,5,6 30+40+0+10+40=120 230Part period yg paling dekat dg EPP adalah 70, maka pesanan awal pada periode 2 sejumlah 80 unit untuk memenuhi demand pada periode 2-5.
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Part Period BalancingKombinasi Lot size Part Period ( inventory)periode6 40 06,7 70 306,7,8 70 306,7,8,9 100 120Part period yg paling dekat dg EPP adalah 120, maka pesanan awal pada periode 6 sejumlah 100 unit untuk memenuhi demand pada periode 6-9.Kombinasi Lot size Part Period ( inventory)periode
10 55 0
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Tabel MRPPart Period Balancing (PPB) Biaya order = 3*$200 = $600Biaya Hold = (50+10+10+..+30)*$2 = $380Total biaya = $600+$380 = $980
Week012345678910GR353040010403003055OHI350501010060303000NR304055POR8010055PORel8010055
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Least Unit Cost (LUC)Metode Lot Sizing heuristik LUC menetapkan lot size yang memperhitungkan sejumlah periode demand sedemikain sehingga total biaya per unit minimum
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Least Unit CostKombinasi Lot size Kumulatif Total Cost periode kumulatif Cost per unit 30 200 200/30=6.672,3 30+40=70 200+40*2=280 280/70=42,3,4 30+40+0=70 280 280/70=42,3,4,5 30+40+0+10=80 200+70*2=340 340/80=4.25Replenishment pada awal periode 2, lot size = 70 untuk memenuhi kebutuhan periode 2-4.5 10 200 200/10=205,6 50 280 280/50=5.65,6,7 80 400 55.6.7.8 80 400 55,6,7,8,9 110 600 5.82Replenishment pada awal periode 5, lot size = 80 untuk memenuhi kebutuhan periode 5-8
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Tabel MRPLeast Unit CostBiaya order = 3*$200 = $600Biaya Hold = (40+70+30+55)*$2 = $390Total biaya = $600+$390 = $990
Week012345678910GR353040010403003055OHI35040703000550NR30104030POR708085PORel708085
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Minimum Cost per PeriodeSilver MealTeknik ini mencoba mengkombinasikan beberapa periode perencanaan (trial error) untuk mendapatkan rata-rata total biaya yang minimumRata-rata biaya adalah jumlah order cost dan holding cost dari n periode dibagi dengan n.
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Silver MealKombinasi Lot size Kumulatif Rata-rata periode kumulatif Cost Total cost 30 200 200/1=2002,3 30+40=70 200+40*2=280 280/2=1402,3,4 30+40+0=70 280 280/3=93.332,3,4,5 30+40+0+10=80 200+70*2=340 340/4=852,3,4,5,6 120 660 660/5=132 Replenishment pada awal periode 2, lot size = 80 untuk memenuhi kebutuhan periode 2-5.6 40 200 200/1=2006,7 70 200+30*2=260 260/2=130 6,7,8 70 260 260/3=86.676.7.8,9 100 440 440/4=110Replenishment pada awal periode 6, lot size = 70 untuk memenuhi kebutuhan periode 6-9 30 200 200/1=20010 85 310 310/2=155
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Tabel MRPSilver MealBiaya order = 3*$200 = $600Biaya Hold = (50+10+10+30+55)*$2 = $310Total biaya = $600+$310 = $910
Week012345678910GR353040010403003055OHI35050703000550NR30104030POR807085PORel807085
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Tabel PerbandinganDipilih yang terkecil
MetodeTotal BiayaLot for Lot1400EOQ1500POQ980PPB980LUC990Silver Meal 910*
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Diketahui biaya pesan untuk item A adalah $20 /order, biaya simpan$2/unit/periode. Tentukan jumlah order yang harus dipesan dan biaya minimal yang harus dikeluarkan, dan tentukan dengan metodeapa yang sebaiknya digunakan bila diketahui lead time 2 minggu, dan persediaan minggu lalu masih tersisa 35 unit.
Periode12345678TotPermintaan51510151011131089
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*1313*44*55*66*77*1919*1818*2121*2121*2121*2121*2121*2323