İmalat kaynakları planlaması
Manufacturing resource planning (MRP II)
- Tez No: 39856
- Danışmanlar: PROF.DR. ATAÇ SOYSAL
- Tez Türü: Yüksek Lisans
- Konular: Endüstri ve Endüstri Mühendisliği, Industrial and Industrial Engineering
- Anahtar Kelimeler: Belirtilmemiş.
- Yıl: 1993
- Dil: Türkçe
- Üniversite: İstanbul Teknik Üniversitesi
- Enstitü: Fen Bilimleri Enstitüsü
- Ana Bilim Dalı: Belirtilmemiş.
- Bilim Dalı: Belirtilmemiş.
- Sayfa Sayısı: 180
Özet
İşletmelerin uluslararası rekabet ortamında yaşamlarını sürdürebilmeleri için tüm kaynaklarını etkin ve hassas bir şekilde planlamaları ve yönetmeleri gerekmektedir. Dolayısı ile is hayatında gerçek sorunları ortaya çıkaran, çözüm yolları öneren ve kullanımı kolay sistemlere ihtiyaç vardır Sürekli desisen bir ortamda fiziksel gerçeği an be an yansıtan ve yeni duruma göre olası sonuçları önceden göstere bilen bilgi sistemleri,, başarılı bir yönetimin en önemli rekabet silahı olmaktadır. Günümüzde bilgisayar donanım ve yazılım teknolojilerinin gelişmesi ile firmalar, problemlerini bu olanaklardan faydalanarak çözmeye çalışmaktadırlar. Bu çalışmaların sonucu olarak, imalat Kaynakları Planlaması (Manufacturing Resource Planning - MRPII), bilgisayar gücünün üretim planlama ve kontrol için ise yarar hale getirilmesi olarak tanıtılmıştır. İmalat Kaynakları Plan laması, özel olarak envanter seviyesini yeterli miktarda tutmak için sipariş teknikleri içeren Malzeme İhtiyaç Plan laması (Material Requirements Planning - MRP) 'nın geliştirilmiş sekli olup, isletmenin üretim, finans, pazarlama, muhasebe ve satın alma fonksiyonlarını bütünleştirerek etkin bir şekilde yönetilmesini bilgisayar desteği ile sağlayan bir yöntemdir. Sonuç, firmanın işlemlerinin daha iyi kontrolü ve daha iyi rekabet performansıdır. Bir üretim firmasının tüm kaynaklarını yöneten bir sis tem olarak, İmalat Kaynakları Planlaması sisteminin ana yapısı, faydaları ve eksik yönlerini anlatmayı amaçlayan bu çalışmada, öncelikle Malzeme İhtiyaç Planlaması sistemi incelenmiş ve ardından İmalat Kaynakları Planlaması yaklaşımının gelişimi, ana yapısı, faydaları, eksik yönleri ve geleceği anlatıldıktan sonra İmalat Kaynakları Planlamasının Türkiye 'deki uygulamaları hakkında bilgi verilmiştir. Sonraki bölümde ise, NETAS şirketinde yapılan gerçek bir İmalat Kaynakları Planlaması uygulama çalışmaları anlatılmış ve alınan paket programın yapısı ile işletim sistemi hak kında bilgiler verilmiştir. Çalışmanın sonunda, yapılan inceleme ve araştırmalardan elde edilen sonuçlara yer verilmiştir. -ıx-
Özet (Çeviri)
The one of the most important function of business management is planning. In general mean, planning is to be organized the every kinds operations are neccesary for manufacturing which business will make before hand. The basic aim of the businesses is to make manufacturing. Therefore, production planning in the view point of produc tion inputs, are material, workmanship, financing etc., is the first of operations necessary to be done. The most important point in view of planning and management opera tions is information that managers will use to make a decision. In planning or management, information forms the base of everything. In this information, characteristics which are truth, nature, exact and timely are be wanted. It is not possible to advantage from information which is not to be known at the right time. Every operations is to be carried out against to time in production. Computers obtain possibilities which are recording, storing, quickly penetrating of every kind information connected with planning and management operations and the most important is which these operations can be done true and cheap to business. Computers also deeply affect manu facturing 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 way to profit maximum advantage from computers. Its best example is the Manufacturing Resource Planning C MRP II ) 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 MRP II system, its aims, basic structure is described and it is tried to transfer the studies about faultinesses and future of MRP II, describing application steps and subjects which will be careful in application. Therefore, firstly the definition of MRP II system is highlighted by application samples in Turkey and the real application, describing MRP II system and development of its approach after introduction of the Material Requirements Planning system which had been used before MRP II system and form a base for development of MRP II system. In the direction of the purpose determined above, in the second part, it is described Material Requirements Planning system which is a kind of order technics for inventory keeping at convergent level which MRP II has been developed. -x-Material requirements planning is the element of production planning and control system which computer i zed ly find out manufacturing resources in sufficient quantities and converient time to realize the manufacturing after the determination the kinds of production which will be produced in planning phase according to result of master production planning, production quantities and production time. Material requirements planning system can be described as a computer software system which explodes end products by receiving master production schedule as data, and so, develops general raw material order schedule comparing inventory level separately for each one after fixing necessary raw material quantities for planned phase. The aim of MRP system approach is to provide the right item at the right time and enough quantity. MRP system needs a lot of data to do its function. Only, if the data is entered rightly, system can produce outputs at the direction of user desires. All MRP software packets own a system structure which prepares order schedules functioning information in the three kinds data files. These data? i) Master Production Schedule ii> Bill of Material / Product Tree Files iii) Inventory Status File The main outputs of the MRP system can be summarized as follows} 1) Planned Order Schedule 25 Changes in Planned Orders 3) Exception Reports 4) Performance Reports 5) Planning Reports The joint aim of MRP systems is to determine gross and net needs on all inventory units base for periods, and so way, to produce information for a realistic inventory management. The aims of MRP can be summarized as follow: * To provide arrivals of all materials and raw materials to business in the planned period * To keep inventory at a level as minumum as possible not to enhance manufacturing * To develop a system to provide all materials and raw materials * To form an order technique determining requirements densities for all materials and raw materials -xi-MRP system uses working steps as follows. 1> Firstly, end product quantity which will produce for every production periods is determined by master production schedule 2) An addition this, change items, which are not to be in the master production schedule but customers demand or known that they will need, are recorded 3) As third step, gross material requirement is deter mined for interested production period exploding products in the master production schedule through product trees 4> After that, gross material requirement is trans formed to net material requirement taking into consideration information in inventory status file, inventory level and materials which its orders was given before hand 5) Finally, order dates are determined taking into consideration lead times for every phase To realize these aimsj MRP is supposed to fulfill activities such as determining gross and net requirements, lead time, safety stock, calculating gross item and material requirement, determining order quantities, producing orders. There are a lot of methods to determine order quantities. These are as follows? 1) Fixed Order Quantity 2) Economic Order Quantity 3) Modified Economic Order.Quantity 4) Periodical Order Quantity 5> Order Quantity as much as Requirement 6) Fixed Period Requirement 7) Minumum Unit Cost 8) Minumum Total Cost Part III, is the part which is described MRP I I forming and also which is transfered its definition, aims, basic structure, application steps and application experiments. In addition, it is provoked the studies about fault inesses and future of MRPII. Developments in which manufacturing managements problems are solved by computer can be studied under the three basic titles; 1) Material Requirements Planning ( MRP ') 2) Closed - Loop MRP 3) Manufacturing Resource Planning < MRPII ) -xii-Financial and manufacturing plans which are developed using MRP input and output datas are named as Manufacturing Resource Planning. MRP II is a well-known methodology for production planning and control in discrete parts manufac turing and assembly. Sometimes called Closed-Loop MRP, this methodology represents an entension of the material requirements planning concepts that were developed in the early sixties. From the beginning, MRP II was associated with computerization, because the massive data handling capabilities of modern computers were needed to make its implement t at ion feasible. MRP II was touted as the way of harnessing the power of the computer for manufacturing planning and control. An MRP II software packet basically embodies two frameworks: one to describe the manufacturing operations (products, inventory items, bill of materials, production centers and part routings), and one for planning and controlling the process. These two frameworks will generally differ from the ones previously used by the organisation buying the packet. Consequently, procedural and organisational changes will be required. The planning functions include master production scheduling and material reguirements planning. The main output of these functions, which feeds in to the execution modules, is a series of time-phased manufactured and purchase orders. The execu tion modules include inventory control, production control and purchasing. The main function of these modules is to keep track of inventory levels and of the progress of manufacturing and purchase orders. The contributions and benefits of MRP II have been described in many ways and in many publications. For this study, the one outstanding merit of MRP II as a production planning and control methodology that it provides an intergrated database. In day-to-day manufacturing opera tions, simple questions can not be answered unless all the departments in the manufacturing organization are sharing informations. Examples these questions are s * What is this product made of ? * What operations are needed to make this product ??. * What is our inventory position for this product ? * How much do we have on hand ? * How much has been ordered by our customer ? * How much are we going to produce, When ? Through the integrated database, MRP II assures smooth communications between the execution and planning modules. 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 -xiii-and holds together designing, 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 informa tions as base. So, it should be possible to organise a coherent and result given system. In inquiries which was be done on different companies use MRP II for 2-3 years, the results was be found as follow; * Increase at market share ( V. Ö-2Ö ) * Decrease at purchase costs C % 2-10 ) * Increase at workingpower productivity < 7. 5-15 ) * Increase at inventory transformation rate C2-3 times!» Output reports of MRP II system are as follow 1) Reports which are produced by MRP 2) Loading plans 3) Master production schedule 4) Material requirements plan 5) Purchase report 6) Workshop capacity report 7) Customer order situation 8) Product cost reports 9) Cost budget reports 10) Capacity requirement plans In this part, furthermore, it is tried to transfer the some fault inesses of MRP II describing steps which follow at MRP II applications in companies, and subjects which will be careful in applications. Reduced lead time... faster responses to constantly changing customer demands... flexibil ity to quickly adapt to dynamic market conditions... instantaneous, accurate communication with customer and suppl ievs...these competi tive advantages have become increasingly vital to manufac turing enterprises with the onset of aggressive global competition and decreased customer loyalties. To gain such strategic advantages, many manufacturers for a long time turned to MRP II and have fully exploited the poten tial of that technology. But, manufacturers must continue to improve on the competitive gains MRP II has provided to survive and thrive in today's markets. For this reason, manufacturers must go beyond MRP II with an integrated solution that includes MRP II, Computer-Integrated Manufacturing
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