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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 13-21100 per week 22-29150 per week 30-35200 per week Given Data

5

6

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 Assy1 17754Shaft1 10955Connector1 19110Nail4 18744Rivet4 10772Face Assy1

13 Part No0772 DescriptionFace Assy Level1 Part NumberDescriptionQuantity 26511Rubber Face2 22547Wooden inner1 28561Foam Panel2 Part No0499 DescriptionHandle Assy Level1 Part NumberDescriptionQuantity 21821Handle1 29110Nail2 Exercise 1

14 b. Complete idented bill of materials for all levels of assembly LevelPart NumberDesriptionQuantity 05654Bat1 10499Handle Assy1 21821Handle1 29110Nail2 17754Shaft1 10955Connector1 19110Nail4 18744Rivet4 10772Face Assy1 26511Rubber Face2 22547Wooden inner1 28561Foam Panel2 Exercise 1

15 Exercise 2 a. Material Requirement Planning (MRP) Record Part Number5654 EQ500 LT2 Week Number1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 100 150 200 Schedule Receipts On Hand Inventory00000000000040030020010004003002001004503001500350200504002000300100400200 145.7121748.6 Planned Order Release 500 Part Number0499 EQ400 LT3 Week Number1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory0000000000300 200 100 000300 200 100 125.74502.8 Planned Order Release 800 400 800 400 Part Number7754 EQ1000 LT5 Week Number1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory15 515 15 515 15 515 15 515 243.61 Planned Order Release 1000 Part Number0955 EQ5000 LT4 Week Number1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory350 4850 4350 3850 3350 2850 2350 1850 2607.10.0252.1 Planned Order Release 5000

16 Part Number9110 EQ5000 LT4 Week Number 1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 1600 2000 800 2000800 2000800 3600 2800 8002000 Schedule Receipts On Hand Inventory 120 3520 1520 720 37202920 920120 1520 3720 2920920 3920 1794.30.0117.9 Planned Order Release 5000 Part Number8744 EQ5000 LT4 Week Number 1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 2000 Schedule Receipts On Hand Inventory 3540 1540 4540 2540 540 3540 1540 4540 2997.10.0129.9 Planned Order Release 5000 Part Number0772 EQ250 LT4 Week Number1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory00000000000000000000000000000000000050 Planned Order Release 500 Part Number1821 EQ500 LT4 Week Number 1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 800 400 800 400 Schedule Receipts On Hand Inventory 0000000200 300 400 000200 300 400 222.92445.7 Planned Order Release 1000 500 1000 500 Exercise 2 a. Material Requirement Planning (MRP) Record

17 Part Number6511 EQ2000 LT10 Week Number 1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 1000 Schedule Receipts On Hand Inventory 000000neg 10000000 000 00 516.10.5258.1 Planned Order Release 2000 Part Number2547 EQ300 LT7 Week Number 1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory 10 neg110 210 10 110 210 10 110 95.31.5142.9 Planned Order Release 600 300 600 300 600 Part Number8561 EQ1000 LT8 Week Number1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 1000 Schedule Receipts On Hand Inventory 000000neg 00000000000000000000000000000.50 Planned Order Release 1000 Total3441.8 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 1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 100 150 200 Schedule Receipts On Hand Inventory 00000000000500400300200100500400300200600450300150500350200550400200500300600400200245.7122948.6 Planned Order Release 500 Part Number0499 EQ400 LT3+1 Week Number1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory00000000800300 700200 600100 50000800300 700200600100 231.44925.7 Planned Order Release 800 400 800 400 Part Number7754 EQ1000 LT5+1 Week Number1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory 15 1015515 15 1015515 15 1015515 151015515 372.11 Planned Order Release 1000 Part Number0955 EQ5000 LT4+1 Week Number1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory 350 53504850 4350 3850 3350 2850 2350 1850 2792.90.0255.9 Planned Order Release 5000 Exercise 3 a.Material Requirement Planning (MRP) Record + 1 safety week

20 Part Number9110 EQ5000 LT4+1 Week Number 1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 1600 2000800 2800 16002000 8002000800 2000 Schedule Receipts On Hand Inventory 120 51203520 1520720 57202920 120 512035201520 572037202920 92059203920 2697.10.0127.0 Planned Order Release 5000 Part Number8744 EQ5000 LT4+1 Week Number1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 2000 Schedule Receipts On Hand Inventory 3540 1540 65404540 2540 540 55403540 154065404540 3454.30.0134.5 Planned Order Release 5000 Part Number0772 EQ250 LT4+1 Week Number1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory000000005000000 000 000 00 00 0 00000100.05500.0 Planned Order Release 500 Part Number1821 EQ500 LT4+1 Week Number1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 800 400 800 400 Schedule Receipts On Hand Inventory 00001000200 700300 800400 001000200 700300800400 360.02720.0 Planned Order Release 1000 500 1000 500 Exercise 3 a.Material Requirement Planning (MRP) Record + 1 safety week

21 Part Number6511 EQ2000 LT10+1 Week Number 1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 1000 Schedule Receipts On Hand Inventory 0000neg 0020001000 0020001000 020001000 793.10.5396.5 Planned Order Release 2000 Part Number2547 EQ300 LT7+1 Week Number1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 500 Schedule Receipts On Hand Inventory10 neg 110710210 51010 610110 710210 51010610110 194.41.5291.6 Planned Order Release600 300 600 300 600 Part Number8561 EQ1000 LT8+1 Week Number1234567891011121314151617181920212223242526272829303132333435 Avrg level Unit Cost Avrg Value Gross Requirement 1000 Schedule Receipts On Hand Inventory 0000neg 100000020001000 00 00 0 0000000000 322.60.5161.3 Planned Order Release 2000 1000 Total6433.2 Exercise 3 a.Material Requirement Planning (MRP) Record + 1 safety week

22 Inventory ValueSource 3441.78Exercise 2 6433.20Exercise 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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