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Ops Man
Topic 3 & 4 - MRP Systems
| Question | Answer |
|---|---|
| what are benefits of MRP systems? | - Better response to customer orders - faster response to market changes - improved utilisation of facilities and labour - reduced inventory levels |
| what is a master production production schedule? | - what is to be made and when - in accordance with aggregate plan - result of production planning process - fixed/frozen in ST - rolling scheme |
| what are different process strategies? | 1. make to order = PROCESS FOCUS 2. assume to order or forecast = REPETITIVE FOCUS 3. stock to forecast = PRODUCT FOCUS |
| what is a bill of materials? | - list of components, ingredients, and materials needed to make the product - provides product structure (parents & children) |
| what is included in a products structure? | 1. components included in product 2. quantities of each component to get 1 unit of product 3. sequence which components are combined to get the final product |
| what is in an inventory records file? | 1. item masterfile 2. transaction file (level of inventory of each part) 3. secondary file (file on special orders, changes) |
| what is dependent demand? what are effective use needs of it? | = demand for one is related to the demand for another item = effective use needs: 1. MPS 2. Bill of materials 3. inventory available 4. purchase orders outstanding 5. lead times |
| what is MRP? | material requirement planning - objective of stocks management when the demand is irregular - assure availability of desired quantities on time in the right place |
| how does MRP work? | = hierarchical decision process = basic information/process/outputs = characteristics: 1. products 2. methodology 3. delay in time 4. capacity constraints not taken into account 5. integrated database |
| what are fundamental MRP inputs? | 1. timing 2. first part of MPS must be stable - rest can suffer variations (pegging) 3. MPS can be updated each week = ROLLPLAN 4. MPS aims to be realistic |
| what are principal reprogramming systems? | 1. Regenerative MRP = traditional method = complete recalculations = stable environments 2. Net change MRP = modern method = rapid updates/lower data processing = changing environments |
| what are safety (security) stocks? | to avoid stock break-up = maintain fixed quantities as safety stock = increase lead (supplying) times with security time margin = increase forecasted needs = hold a certain free production capacity in the factory |
| what are MRP outputs? | 1. primary outputs = materials planning 2. secondary outputs = exceptional individual messages, sources of needs report, ABC analysis report, materials in excess report, purchase agreement report, supplier analysis report |
| when would MRP be updated? | any changes to MRP changes the NET PRODUCTION REQUIREMENTS and the orders programming = results are reliable |
| state 4 functions of MRP in accounting | 1. standard cost calculations 2. sales budget development 3. procurement budget 4. budget of planned inventories |
| what is lot sizing in production planning? | calculates optimum lot size depending on balancing setup costs with holding costs |
| state the 6 types of lot sizing | 1. lot to lot = minimises storage costs, still setup costs 2. constant techniques 3. periodic order quantity = quantifies between opportunity cost & economies of scale 4. minimum unitary cost 5. minimum total cost 6. silver meal technique |
| what is manufacturing resource planning? | extension of MRP, closed feedback loop - strategic planning - production programming - stocks mangement outputs - cost calculations - financial information in monetary units |
Created by:
patriciam03
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