Roesfiansjah Rasjidin Program Studi Teknik Industri Fakultas Teknik – Univ. Esa Unggul

Perkembangan konsep MRP MRP I : Material Requirement Planning Closed-Loop MRP MRP II : Manufacturing Resource Planning

MRP I Menghitung : Jumlah Waktu Dan Planned Order Release Untuk: Sub-assemblies Components Dan materials

Closed-Loop MRP Capacity Requirements Planning (CRP) Umpan balik yang menjelaskan kemajuan pelaksanaan order

Material Requirements Planning (MRP II) = Business Resource Planning (BRP) Sistem informasi yang mengintegrasikan kegiatan pemasaran, keuangan & operasi Mengkoordinasikan penjualan dan rencana produksi Mengkonversi kebutuhan sumber daya menjadi kebutuhan keuangan/financial

Tujuan Perencanaan Kebutuhan Material Menentukan apa yang akan dipesan Menentukan berapa yang akan dipesan Menentukan kapan akan dipesan Menentukan kapan menjadwalkan pengiriman Menentukan prioritas untuk perencanaan persediaan, perencanaan kebutuhan kapasitas (CRP) dan pengendalian lantai pabrik (SFC)

MRP Inputs 1. A master production schedule 2. A Bill of Materials 3. An inventory records file Product Structure Tree Lead Times

1. Master Schedule Master (production) schedule (MPS): Master (production) schedule (MPS): states which end items are to be produced, when these are needed, and in what quantities. Example: A master schedule for end item X: Come from: customer orders, forecasts and orders from warehouses to build up seasonal inventories

Master Schedule (Cont.) Cumulative lead time: Cumulative lead time: The sum of the lead times that sequential phases of a process require, from ordering of parts or raw materials to completion of final assembly. The master schedule should cover the cumulative lead time.

Planning Horizon The master schedule separates the planning horizon into a series of time periods and cover the cumulative lead time Procurement Fabrication Subassembly Assembly Time period (weeks)

2. Bill-of-Materials Bill of materials (BOM): Bill of materials (BOM): a listing of all of the raw materials, parts, subassemblies, and assemblies needed to produce one unit of a product. Each finished product has its own bill of materials. Product structure tree: Product structure tree: Visual depiction of the requirements in a bill of materials, where all components are listed by levels.

Assembly Diagram & Product Structure Tree

Example 1

Example 1 (Cont.) Using the information above to do the follows: a) Determine the quantities of B, C, D, E, and F needed to assemble one X.

Solution to Example 1 X Thus, one X will require B: 2 C: 1 D:6 F: 2 E: 28 (Note that E occurs in three places, with ) B(2)XC D(3)E E(4) E(2)F(2) a).

Example 1 (Cont.) Using the information above to do the follows: a) Determine the quantities of B, C, D, E, and F needed to assemble one X. b) Determine the quantities of B, C, D, E, and F needed to assemble ten X's, if you have the following in inventory: Component B C D E On hand

Component B C D E On hand Solution to Example 1 (Cont.) X Thus, given the amounts of on-hand inventory, 10 Xs will require B: 16 C: 0 D: 40 F: 0 E: 116 (=16+100) B(2)XC D(3)E E(4) E(2)F(2) b).

3. Inventory Records File Inventory records: Inventory records: includes information on the status of each item by time period: Gross requirements Scheduled receipts Expected amount on hand Lead time Lot size policy And more …

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