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Psycho Sports Ltd Nadia Febianita Shinta Dwi Wahyuni Yohanes Febryanto.

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Presentasi berjudul: "Psycho Sports Ltd Nadia Febianita Shinta Dwi Wahyuni Yohanes Febryanto."— Transcript presentasi:

1 Psycho Sports Ltd Nadia Febianita Shinta Dwi Wahyuni Yohanes Febryanto

2 Background Key Person : Peter Townsend Psycho Sports  Sports Goods Manufacturing Over the last two years  had grown rapidly Product Customers Table Tennis Bats Including : Tennis Balls, Darts, Protective Equipment for various games Specialist Sport Shops Included some of major sports retail chain

3 Take as examples  ‘High-Resolution Bat‘ (5654) Peter set six exercise too understand fully basics of MRP Problem “Manufacturing Control“ Would soon to install some systematic procedures and routines to manage the business Background

4 Sales Forecasts WeeksQuantity per week per week per week Given Data

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7 1.Why did Peter have such problems getting to the relevant information? 2.Perform all the exercises which Peter set for himself. Do you think he should now fully understand MRP? Questions

8 Exercise 1 Draw up: (a)the single-level bill of materials for each level of assembly, (b)a complete indented bill of materials for all levels of assembly Exercise 2 (a)Create the materials requirements planning records for each part and sub-assembly in the bat (b)List any problems that the completed MRP records identify (c)What alternatives are there that the company could take to solve any problems? What are their relative merits? Exercises

9 Exercise 3 Based on the first two exercises, create another set of MRP records, this time allowing one week‘s safety lead time for each time: that is, ensuring the items are in stock the week prior to when they are required Exercise 4 Over the time period of the exercise, what effect would the imposition of a safety lead time have on average inventory value? Exercises

10 Exercise 5 If we decided that our first task was to reduce inventory cost by 15 per cent, what action would be recommend? What are the implications of our action? Exercise 6 How might production in our business be smoothed? Exercises

11 Question 1 Data mengenai Inventori tidak tersimpan secara centralized dan tidak ada komunikasi antar departemen Beberapa informasi tidak tercatat dengan baik

12 Exercise 1 a. The single-level bill of materials for each level Part No5654 DescriptionBat Level0 Part NumberDescriptionQuantity 10499Handle Assy Shaft Connector Nail Rivet Face Assy1

13 Part No0772 DescriptionFace Assy Level1 Part NumberDescriptionQuantity 26511Rubber Face Wooden inner Foam Panel2 Part No0499 DescriptionHandle Assy Level1 Part NumberDescriptionQuantity 21821Handle Nail2 Exercise 1

14 b. Complete idented bill of materials for all levels of assembly LevelPart NumberDesriptionQuantity 05654Bat Handle Assy Handle Nail Shaft Connector Nail Rivet Face Assy Rubber Face Wooden inner Foam Panel2 Exercise 1

15 Exercise 2 a. Material Requirement Planning (MRP) Record Part Number5654 EQ500 LT2 Week Number Avrg level Unit Cost Avrg Value Gross Requirement Schedule Receipts On Hand Inventory Planned Order Release 500 Part Number0499 EQ400 LT3 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory Planned Order Release Part Number7754 EQ1000 LT5 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory Planned Order Release 1000 Part Number0955 EQ5000 LT4 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory Planned Order Release 5000

16 Part Number9110 EQ5000 LT4 Week Number Avrg level Unit Cost Avrg Value Gross Requirement Schedule Receipts On Hand Inventory Planned Order Release 5000 Part Number8744 EQ5000 LT4 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 2000 Schedule Receipts On Hand Inventory Planned Order Release 5000 Part Number0772 EQ250 LT4 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory Planned Order Release 500 Part Number1821 EQ500 LT4 Week Number Avrg level Unit Cost Avrg Value Gross Requirement Schedule Receipts On Hand Inventory Planned Order Release Exercise 2 a. Material Requirement Planning (MRP) Record

17 Part Number6511 EQ2000 LT10 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 1000 Schedule Receipts On Hand Inventory neg Planned Order Release 2000 Part Number2547 EQ300 LT7 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory 10 neg Planned Order Release Part Number8561 EQ1000 LT8 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 1000 Schedule Receipts On Hand Inventory neg Planned Order Release 1000 Total Exercise 2 a. Material Requirement Planning (MRP) Record

18 b. Problems from MRP Records Terdapat masalah pada inventory yaitu pada item Rubber Face (6511), Wooden Inner (2547) dan Foam Panel (8561). Perusahaan tidak dapat memenuhi demand tepat waktu dikarenakan 3 item tsb tidak tersedia pada saat dibutuhkan (delay). a. Menekan supplier untuk memproduksi lebih cepat. Dengan resiko: membayar lebih mahal dan kualitas menurun. b. Mencari supplier lain yang bersedia untuk memproduksi material yang sama lebih cepat Dengan resiko: belum mengetahui kualitas dari supplier baru c. Alternative Solutions Exercise 2

19 Part Number5654 EQ500 LT2+1 Week Number Avrg level Unit Cost Avrg Value Gross Requirement Schedule Receipts On Hand Inventory Planned Order Release 500 Part Number0499 EQ400 LT3+1 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory Planned Order Release Part Number7754 EQ1000 LT5+1 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory Planned Order Release 1000 Part Number0955 EQ5000 LT4+1 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory Planned Order Release 5000 Exercise 3 a.Material Requirement Planning (MRP) Record + 1 safety week

20 Part Number9110 EQ5000 LT4+1 Week Number Avrg level Unit Cost Avrg Value Gross Requirement Schedule Receipts On Hand Inventory Planned Order Release 5000 Part Number8744 EQ5000 LT4+1 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 2000 Schedule Receipts On Hand Inventory Planned Order Release 5000 Part Number0772 EQ250 LT4+1 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory Planned Order Release 500 Part Number1821 EQ500 LT4+1 Week Number Avrg level Unit Cost Avrg Value Gross Requirement Schedule Receipts On Hand Inventory Planned Order Release Exercise 3 a.Material Requirement Planning (MRP) Record + 1 safety week

21 Part Number6511 EQ2000 LT10+1 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 1000 Schedule Receipts On Hand Inventory 0000neg Planned Order Release 2000 Part Number2547 EQ300 LT7+1 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory10 neg Planned Order Release Part Number8561 EQ1000 LT8+1 Week Number Avrg level Unit Cost Avrg Value Gross Requirement 1000 Schedule Receipts On Hand Inventory 0000neg Planned Order Release Total Exercise 3 a.Material Requirement Planning (MRP) Record + 1 safety week

22 Inventory ValueSource Exercise Exercise 3 Increase: 86,92% Exercise 4

23 a.Raw Materials – Mengurangi inventory level dengan prinsip Just-In- Time (JIT) – Exercise 2 dan 3 menunjukkan dengan one-week safety lead time, cost of inventory meningkat 86.92% Implikasi: – Order cost meningkat karena sedikitnya order – Resiko stock-outs Exercise 5

24 b. Finished Goods – Fleksibilitas dalam jumlah produksi dengan menyesuaikan kuantitas permintaan sehingga mengurangi inventory Implikasi: – Mengurangi produktivitas mesin dan pekerja – Resiko stock-outs Exercise 5

25 c. Work in Process – Untuk mengurangi unnecessary delays, perusahaan harus meningkatkan kontrol pada sistem produksi – Memaksimalkan kapasitas mesin dan penggunaan JIT Implikasi: – Butuh tambahan pekerja untuk melakukan kontrol Exercise 5

26 Dalam realita, ada beberapa hambatan: – Fleksibilitas Beberapa variabel MRP (lead time, batch size) bersifat fixed  kurang reliable – Unexpected events (mesin rusak) Perusahaan perlu memiliki kontrol terhadap keseluruhan sistem dan perencanaan yang matang Exercise 6

27 Simulasi yang dilakukan dapat membantu Peter memahami cara kerja MRP dan mengerti keterkaitan antar department dalam Pscycho Sports Ltd. Question 2

28 Q & A session


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