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Chapter 7
Push and Pull Production
Control Systems
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Basic Definitions
MRP. (Materials Requirements Planning). MRP is the basic
process of translating a production schedule for an end
product (MPS or Master Production Schedule) to a set of
requirements for all of the subassemblies and parts needed
to make that item.
JIT. Just-in-Time. Derived from the original Japanese
Kanban system developed at Toyota. JIT seeks to deliver the
right amount of product at the right time. The goal is to
reduce WIP (work-in-process) inventories to an absolute
minimum.
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Comparison
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MRP Basics
The MRP system starts with the MPS or Master
Production Schedule. This is the forecast for the
sales of the end item over the planning horizon.
The data sources for determining the MPS
include:
Firm customer orders
Forecasts of future demand by item
Safety stock requirements
Seasonal variations
Internal orders from other parts of the organization.
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Schematic of the
Productive System (Fig. 7.1)
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Explosion Calculus
Rules for translating gross requirements at one level to production
schedule at that level and requirements at lower levels.
Example
Basic Equation:
Net Req. = Gross req. - Scheduled Receipts - projected on hand
inventory
Basic Algorithm
1. Compute time-phased requirements
2. Determine Planned Order Release (LS)
3. Compute ending inventory
4. Proceed to next level (if any)
Asst. Prof. Dr. Mahmut Ali GKE, Izmir University of Economics
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Explosion Calculus
Schedule for end item A:
Week
8 9 10 11 12 13 14 15 16 17
Gross Req
77 42 38 21 26 112 45 14 76 34
Sch Rpt
12
6 9
Inv
23
Net Req
42 42 32 12 26 112 45 14 76 34
Schedule for item B (1 unit/2 weeks)
Week
6 7 8 9 10 11 12 13 14 15
Gross
42 42 32 12 26 112 45 14 76 34
Schedule for item C (2 units/4 weeks)
Week
4 5 6 7 8 9 10 11 12 13
Gross 84 84 64 24 52 224 90 28 152 68
Asst. Prof. Dr. Mahmut Ali GKE, Izmir University of Economics
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y r
i 1
i 1
for 1 j n.
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Methods
One could apply the EOQ formula by defining
but there are better methods.
1 n
ri
n
i 1
y1 r1 or y1 r1 r2 ,. . ., or y1 r1 r2 ... rn
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Methods (continued)
Another method that is popular in practice is part period
balancing. Here one chooses the order horizon to most closely
balance the total holding cost with the set-up cost.
Finally, a third heuristic is known as the least unit cost heuristic.
Here one minimizes the average cost per unit of demand (as
opposed to the average cost per period as is done in the Silver
Meal heuristic.) The average cost per unit of demand over j
periods is given by:
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Methods (concluded)
Experimental evidence seems to favor the
Silver Meal Heuristic among the four
discussed as the most cost efficient.
Optimal lot sizes can be found by using
backwards dynamic programming.
A heuristic method for lot sizing subject to
capacity constraints is discussed in this
section.
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Shortcomings of MRP
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Introduction to JIT
JIT (Just In Time) is an outgrowth of the Kanban system
developed by Toyota.
Kanban refers to the posting board where the evolution of the
manufacturing process would be recorded.
The Kanban system is a manual information system that
relies on various types of cards.
Its development is closely tied to the development of SMED:
Single Minute Exchange of Dies, that allowed model
changeovers to take place in minutes rather than hours.
(The mechanics of a typical Kanban system are pictured in
Figure 7-8.)
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River/Inventory Analogy
Illustrating the Advantages of Just-in-Time
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