Üretim planlama ve kontrolu MRP II ve bir MRP II uygulama çalışması
Manifacture planning and control munifacture resouce planning (MRPII) and an application study of MRPII
- Tez No: 22053
- Danışmanlar: PROF. DR. ATAÇ SOYSAL
- Tez Türü: Yüksek Lisans
- Konular: Endüstri ve Endüstri Mühendisliği, Industrial and Industrial Engineering
- Anahtar Kelimeler: Belirtilmemiş.
- Yıl: 1992
- Dil: Türkçe
- Üniversite: İstanbul Teknik Üniversitesi
- Enstitü: Fen Bilimleri Enstitüsü
- Ana Bilim Dalı: Belirtilmemiş.
- Bilim Dalı: Belirtilmemiş.
- Sayfa Sayısı: 202
Özet
ÖZET 1980'li yıllara kadar üretim sektöründeki işletme lerde üretim planlaması ve kontrolü, malzeme giriş ve çıkışları temel alınalarak yürütülmekte, malzeme akışı üretim sistemine göre üretimin her safhasında izlenme- mekteydi. Stok kontrolü malzemelerin üretim safhasına girişine ve çıkışına göre belirlenmekte, üretime giren her malzeme yarı mamul olarak tanımlanmaktaydı. Ayrıca finansman bölümü ve üretim bölümü birbirlerinden ayrı olarak çalışmalarını sürdürmekte, bilgi alışverişlerini üretimin başında ve sonunda yapmaktaydı. Son yıllarda ülkemizde de kullanımı yaygınlaşan İmalat Kaynak Planlaması (MRPII)-(Manif acturing Resouce Planning) sisteminde ise imalat bilgisayar destekli ola rak, tüm safhalarında ve tüm operasyonlarda izlenmekte dir. İmalat için gerekli tüm operasyonlar ürün ağacı sırasına göre bilgisayarda tanımlanmakta, ve imalat bil gisayar tarafından operasyonlar düzeyinde izlenmektedir. Böylece her malzemenin durumu operasyon, operasyon kont rol edilmekte, stoklar her operasyon sonunda değiştiri lerek, işletmenin gerçek malzeme takibi yapılabilmekte dir. Bunun yanında bilgisayarda izlenen tüm üretim sis temi bilgilerinden üretim bölümü dışındaki bölümlerde- özellikle finansman bölümü, satınalma bölümü satış bölü mü gibi-bölümlerde yararlanabilmekte, böylece tüm işlet me koordinasyonlu bir şekilde çalışabilmektedir. Üretim Planlama ve Kontrolü etkinliğinin artmasını sağlayan MRPII sisteminin kullanın^ faydalarını anlatmayı amaçlayan bu çalışmada, öncelikle Üretim Yönetimi Temel kavramları, Üretim Sistemleri, Üretim Planlama ve Kont rolü konuları ile bugün hala bir çok işletmede kullanı lan malzeme yönetimi ve malzeme ihtiyaç planlaması tek nikleri anlatıldıktan sonra, MRP ve MRPII ilişkisi, MRPII Türkiye'deki uygulamaları, en sonunda ise gerçek bir MRPII uygulamasının, Standar Pompa ve Makina Tic. A.Ş.1 de gerçekleştirme çalışmaları anlatılmıştır. Eski ve yeni yöntemlerin aynı çalışma içinde gösterilme sinin amacı, yeni tekniklere temel oluşturan eski sis temleri ile yeni sistemler arasındaki farkın, avantaj ve dezavantajların kolaylık ve zorlukların kavranabilme- sini sağlayabilmektir. ıx
Özet (Çeviri)
MANIFACTURE PLANNING AND CONTROL, MUNIFACTURE RESOUCE PLANNINE(MRPII) AND AN APPLICATION 5TUDY OF MRPII SUMMARY Computers also deeply affect manufacturing systems and manufacturing methods such as they affect our all life by their super development speeds. Therefore, manufacturing systems and methods developed in recent years are being developed in the wayto profit maximum advantage from computers. Its best example is the MRP II (Manf ucturing Resource Planning) system which keeps under control the manufacturing at every phase and every operation level by the intervention of computers and can make planning inclined to this purpose. In this study; the definition of MRPII system, its purpose and application is described and it is tried to show the difference of MRP system, describing the knowledge on manufacturing and also various systems related to manu facturing. Therefore, in the study, the definition of MRPII system is highlighted by a real application, decribing MRPII system after the introduction of mater ial management and material requirement planning systems which had been used before MRP II system and form a base for the development of MRP II system following the definitions such as manufacturing management, manufacturing systems, manufacturing planning and control fallowing the definition of manufacturing at the beginning. In the direction of the purpose determined above, in the second part, it is described the basic concepts of manufacturing managemenet and it is explained the definition of manuf actiring management, it aims, func tions and duties following a summarization on the definition of manufacturing and its factors. So, manufacturing means tD make a modification on a physical matter to increase its value on to transfer a raw material or semi manufactured material into a finished manufacture ready to be used in the view pointof engineers though it means to create a profit according to economist. Manufacturing is the synthesis of land, Labor and capital factors. In recent years, management had also been included in these factors. On the other hand, manufacturing management means to put together the material, machine and man power resources at hand of a business in a way to provide the manufacturing of certain amount of manufacture in requested qualities, in requested period and if passible in low cost. The functions of manufacturing management are material, machine, method and labor force providing at planning phase but are routing, time estimation, programming later on and are distribution, pursue and control, inspection and evaluation at latest phase. In Part-Ill, it is made classification of manufac turing systems moving from the definstion of manufacturing inside the definition of manufacturing systems deseribed in this part. Actording to this classification, manu facturing systems are being classified according to general methods, kind of manufature and manufacturing quantity or manufacturing flowing, firstly. Later on, these categories are being divided into subcategories according to various factors. But, out of this classi fication, manufacturing system can be divided into two main categovies under the names of transient and contiuous manufacturing systems. The differences between these two main categories are deseribed at the end of this part. In Part IV, it is deseribed the definatian of manufacturing planning and control purposes and later on, it is summarized its all functions, separetely. Most of firms have three main aims when they profit. These are as follows: 1 - To provide maximum service for customer 2- To keep the inventory investment all minimum level 3- To provide productive business operation. In modern businesses, the main aim of production planning and control is to find out the optimum soluiton to provide the consensus among these three request which contradict eachother. XIIn the direction af the aim above, the functions of production planning and control are as follows: 1 - Sales estimation 2- Planning a- For inventory levels b- For ^capacity 3- Control a- For manufacturing quantity b- For input programming and loading c- For output distribution and processing Manufacturing planning can be dsseribed as the whole of necessary activities to be fulfilled to meet the demand in the future. Therefore, in this part, it is deceribed by samples in detail the sales estimation and sales methods which are the most important phase of manufacturing planning and control. In this part; it is included in analysis of time serials, simple time serial model, simple up hand correction method, double up hand correction method, the up hand correction method which takes into account seasonal correction and adaptive estimation method, too. In this part, later on, the preparation of manufac turing planning, the preparation of manufacturing program and at last, the topics of manufacturing control and the evaluation of its result altogether with their definitions and functions are described. All businesses in manufacturing sector, the most important responsible division of business productivity is the division of manufacturing planning and control. Because if there is not a good planning and coordination among these factors though a business is powerfull enough in the view of capital, labor force, machine park and marketing, it is impossible to work productively for this business. The greatest advantage in a business is possible by a good manufacturing planning and control. Therefore, in this part, it is tried to deseribe in detail the duties and functions of manufacturing plann ing and control division. In Part V, it is deseribed the definition and functions of material management necessary to be xnorganized at a business in manufacturing s rial management means methods and principl organize and examine the material flowing since raw material purchasement until its customer. Material management shoulde be best if not only before the manufacturing phases of manufacturing it is applied for semi finished manufacture material and fin ture procurement. On the other hand, mate should be adjusted according to recent ve avvargement of the, business, cherking tim doing necessary regulations and revisions sophisticated knowledges and situations sh evaluated. ector. Mate- es which plan, in the period deliver to profitable but at every raw material ished manufac- rial management quirements and e by time and and also ould be The aims of materials management can be summarized as follows: 1 - To procure materials continuously and in sufficient quantities. 2- To procure materials in a way simpler and cheaper than ever. 3- Modern transportation and storage of materials 4- To keep manufacture quality at requested level 5- To provide realization of manufacturing planning 6- To increase the productivity. The functions of material management could be coonted as classic can be put in order as follows: 1- Manufacturing control 2- Stock control 3- Procurement k- Transportation 5- Material transfer 6- Receiving 7- Storing There are some cost factors taken into account during the organizing of material management system. These activities have criterial qualities during system development. These are as follows: xm1 - Order Cost: All charges in the period since the purchase decision of any material on raw material until its stacking in depot. 2- Possessing Cast: The costs came from stacking of materials and raw materials or manufactures. 3- Dispossesing Cost: The cost form because of any material, rau material, semi finished manufacture material or finished manufactur not in stack. Classic material management described in this part form a base and support for the development and function of MRP-II system. Material management in MRP-II system is thoroughly computerized. Every material, semi finished manufacture material, finished manufacture and raw material are continously planned and controlled at every phase and operation of manufacturing by a developed coding system. In part VI, it is described MRP(Material Requirements Planning) system which is a kind of order technics for inventory keeping at converient level which MRP has been developed. Material Requirements planning is the element of manufacturing planning and control system which compu- terizedly find out manufacturing resources in sufficient quantities and converient time to realize the manufacturing after the determination the kinds of manufacture which will be manufactured in planning phase according to result of main manufacturing planning, manufacturing quantities and manufacturing time. If we express in other way, MRP is a computerpackage which prepares order reports using the informations of inventory and manufac ture in main manufacturing planning. The aims of MRP can be summarized as follows: * To provide arrivals of all materials and raw mate rials to business in the planned period. * To keep inventory at a level as minimum as possible not to enhance manufacturing. XIV* To develop a system to procure all materials and raw materials. * To from an order technics determining requirements densities for all materials and raui materials. To realize these aims; material requirements plann ing is supposed to ful fill activities such as determin ing gross and net requirements, forming manufacture trees preparing material lists, determining stock lists, order points, procurement period and safety (buffer) stock. Fixed order method described in this part after these studies, is responsible of determining and applying one of order methods of economic order quantity, modified economic order quantity, periodical order quantity, order quantity as much as requirements, fixed period requive- ments, minimum (lowest) unit cost method or more than one of them for various material groups. Part VII, is the part which is described in Manufac turing Resource Planning (MRP II) farming and also which is tranfered in application experiments. Financial and manufacturing plans which are developed using MRP input and output datas are named as Manufactur ing Resource Planning (MRP II). MRP II put together developed MRP elements to create financial profit. Generally, MRP II provides working of all those by the same numerical values though there are different numerical values of operation division and different numerical values of financial division MRP II is a manufacturing simulation and holds together design ing, marketing, accounting and manufacturing divisions. MRP II system which composing financial informations and manufacturing informations of the business in MRP system, provides by this way that financial and operational plans receive the same informations as base. So, it should be passible to organize a coherent and result given system. In this part, a the other hand, the experiments of various managers and withorized offirers who apply MRP II system are transfered, too. In our day, there are package programs inclined to MRP II system application. xvBut, the important one is to apply this package program and MRP II system to business. Package programs are very little flexible tough they are converient do all manufacturing systems ve they are inclined to be used in every business. Therefore it is necessary to try to approach business to system. Various experiements on this subject are transferred here. Part VIII consists of describing a MRP II applica tion in details. The study on application of PRODSTAR MRP II package program to STANDART PGMP8 MAKİNA VE TİCARET A.Ş. is transferred in this part. The study sequence used in this application is as f allows : 1- Study of hardware and softwar providing. 2- Forming of organization scheme 3- MRP II application a- Study of demand estimating b- Preperation of part manufacture lists and entering to computer, c- Determining of part monufacture stocks and entering to computer, d- Entering manufacture trees to computer. e- Forming main manufacture plan, f- Operation of MRP g- Preparation of information forms, h- Developing ofphysical form flowing order. XVI
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