MRP STABILIZATION & WORK-CENTER PLANNING ( Capacity requirement

Planning )

Rolex Rings Pvt. Ltd.

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Rolex Requirement
Material Requirement Planning

ROLLEX has requirement for detailed Material requirement planning to control inventory and to guarantee
material availability in time for each storage location. It will also control automatic creation of procurement
proposals for purchasing and planned order for production.

Work center planning:

 To plan production activity for different machines, like Forging, Annealing OR Normalizing, Shot
blasting, CNC, Heat treatment etc.
 Date wise CNC machine production plan based on it’s forging batch.
Master planning screen, where one can see daily planning for their work center and material
availability. We will discuss it on call.

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1. Material Requirement Planning
Prerequisites Production Planning Master data

 Material Master ( MRP views, Work scheduling view )

 Bill of Material
 Routing
 Work center

Assumptions

 Bill Of Material & Routing maintained accurately.

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 1. Material Requirement Planning

To guarantee material availability in time prerequisites is MRP with lead time scheduling.
In current system , MRP only calculates quantities to be planned.
In order to calculates accurate planned dates for in-house production activities and propose release dates for
purchase activities, prerequisites is MRP with lead time scheduling.

MRP with lead time scheduling is prerequisite for capacity/work centre planning.
Lead time scheduling is used to calculate accurate dates of production activities.

Information Needed form Rolex :

- Categories similar work center

- Individual capacities of each work center.
- Minimum production lot size for All Materials
- Average ‘Planned delivery time’ for externally procured materials.
- Shift timing

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Prerequisites : Lead time Scheduling with MRP

Assumption :

Rolex has continuous production flow between two work centre Machining activities.
BOM is maintained accurately.
Routing is maintained accurately.
MRP views & work scheduling data maintained accurately.

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Operation qty ‘Independent’ Work centers
 Work centers need to identify on which production process time is independent of Material quantity.
 Minimum and maximum production lot size as per capacity of work center.

Data required from Rolex :

- Maximum production lot size of Material depends on capacity constrain of work center.

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Planned Material with Production version

 In current scenario Rolex has some material with Alternative BOM.

 Currently Rolex Plan such material with Production version .
 With standard MRP system does not consider alternative BOM in planning.
 System consider Alternative BOM in Planning only after conversion of Planned order into production order, where user
manually select production version.

Solution :

 Execute MRP daily in background, to consider Alternative BOM components in planning.

 AIS will provide solution for Background JOB for MRP at Plant level.

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Assumption for MRP rollout

 BOM, Routing, work center is mainlined accurately.

 MRP views & Work scheduling views of Master data maintained accurately.
 Production version , alternative BOM maintained accurately.
 Continuous production flow between two work centers
 Master data for subcontracting materials ( eg SPK ) is maintained correctly

Data Required from Rolex

 Minimum Production lot size of material to be produce in house

 List of work centers with capacity in time.
 List of similar work center ( Categories/grouping of similar work center )
 List of work centers on which process time is independent of quantity.
maximum lot size of material depends on capacity constrain of such work centers.
 Test material on development server for which BOM, Routing, work centers has been maintained correctly.
 Shift timing for Materials
 Material wise document type of Purchase requisitions which relevant to MRP

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Solution : MRP Stabilization

1. Schedule background MRP

- To consider alternative BOM components with MRP
- To consider daily change in production activities ( eg split in operation activities )
2. MRP with Lead time scheduling
- To calculate exact dates of production activities of materials
- To calculate Planned release dates of Material to be procure externally
3. Tool to update setup time, processing time, Interoperation time ( work scheduling view )

With this tool system will update below details in background.

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2. Work Center Planning ( Capacity Requirement Planning )

 To plan production activity for different machines, like Forging, Annealing OR Normalizing, Shot
blasting, CNC, Heat treatment etc.
 Date wise CNC machine production plan based on it’s forging batch.
Master planning screen, where one can see daily planning for their work center and material
availability.

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 a. Work center Planning

Requirement :

Rolex plan Material Manually in excel sheet in below format to plan production activity for different machines, like
Forging, Annealing OR Normalizing, Shot blasting, CNC, Heat treatment etc
Date wise CNC machine production plan based on it’s forging batch

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 a. Work center Planning

Solution :

AIS will provide dynamic screen where user can display Work centre planning for Material as per MRP result.

User can display Work centre as per Planner name or work centre group.

At the planning stage system will not display reference batch of forging.

AIS will provide Option on dynamic screen to convert planned order to production reference to 1st operation of work
centre only . System will propose reference forging batch to while converting planned order into production order .

Reference forging batch would be displayed only after conversion of planned order to production order on dynamic
screen.

 As Rolex plans material with MTS strategy it is not possible to display customer name reference to work centre
from system
AIS will provide solution to mention customer for reference production order manually on dynamic screen.

 Split of Production order

( Note : Information needed whether production order is to be spited at order header level or Operation level )

( Note : detail discussion required for understanding of current report format )

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a. Work center Planning

Output report format will be as below

Dynamic report will have selection criteria as per production Planner , Date , work centre group Material

( Note : this is tentative format , output format finalized after detail discussion on business process )

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b. Master Planning Screen

Requirement

Master planning screen, where one can see daily planning for their work center and material availability

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b. Master Planning Screen

SOLUTION :

AIS will provide dynamic screen whether user can display daily plan as per work centre.

Report will display

Work centre ,
Header Material ,
Planned order or Production order,
Operation no ,
BOM components required and available quantity & withdrawn quantity depends on BOM assignment to routing.
Available operation quantity for production

Assumption :

No backlog of daily confirmation activity.

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b. Master Planning Screen

Output Format :

( Note : this is tentative format , output format finalized after detail discussion on business
process )

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Rolex Rollout Plan

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 Thank you

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