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MRP II ve bir MRP II yazılım sistemi

Başlık çevirisi mevcut değil.

  1. Tez No: 46147
  2. Yazar: GÜNAL HAKAN ERDİK
  3. Danışmanlar: Y.DOÇ.DR. COŞKUN ÖZKAN
  4. Tez Türü: Yüksek Lisans
  5. Konular: Endüstri ve Endüstri Mühendisliği, Industrial and Industrial Engineering
  6. Anahtar Kelimeler: Belirtilmemiş.
  7. Yıl: 1995
  8. Dil: Türkçe
  9. Üniversite: İstanbul Teknik Üniversitesi
  10. Enstitü: Fen Bilimleri Enstitüsü
  11. Ana Bilim Dalı: Belirtilmemiş.
  12. Bilim Dalı: Belirtilmemiş.
  13. Sayfa Sayısı: 151

Özet

ÖZET Son yıllarda batı ülkelerinde yoğun ilgi gören bilgisayarlarla endüstriyel yönetim teknikleri uygulamalarının arasında en popüler olan ve uygulamada çok başarılı sonuçlar elde edilen aracın, MRP II (Üretim Kaynakları Planlaması) olduğu bilinmektedir. Sınai işletmelerde ve hatta hizmet kuruluşlarında, verimliliğin arttırılması karar vermede yönetime yardımcı olması, üretimde darboğazların giderilmesi ve stokları en azda tutularak kaynakların en iyi şekilde kullanılmasına olanak veren bu araçlar, Türkiye' de de hızla gelişmekte ve giderek bir çok sektörde aranılır olmaktadır. Yükselen ve kronikleşen enflasyonist ortam, stoklara (hammadde, yarı mamul ve mamul) bağlanan maddi kaynakları çok pahalı hale getirmiş, işletmeler bu yükleri en aza indirmeyi birincil hedefleri arasına koymuşlardır. Firmalarda üretim, finans, pazarlama gibi birimlerin arasında iç içe geçmiş, karşılıklı etkileşim ve anında bilgi akışının sağlanması gerekmektedir. Müşteri talepleri ve müşteri şikayetlerine dayalı geri besleme /düzenlemeye dayalı yönetimin ihtiyacı ortaya çıkmakta, yan sanayi ve ilişkiler bilgi akışı ve iş birliğine dayalı olması zorunluluğu doğmaktadır. Bu çalışmada yukarıda açıklanan faktörlerden dolayı işletmelerin temel üretim kaynakları olan malzeme, işçilik, makina ve paranın en etkin ve verimli kullanımı için geliştirilmiş olan Üretim Kaynakları Planlaması (Manufacturing Resources Planning - MRP II) çözümlerinin özellikleri araştırılmış, MRP II prensipleri çerçevesinde Micro-MRP, Inc. tarafından geliştirilmiş çok lisanlı (Multi Language) bir sistem olan Max ML-1.30 un türkçeleştirilmesi çalışmasında bulunulmuş ve sistemin ana özellikleri tanıtılmaya çalışılmıştır. Ayrıca Micro- MRP Inc. tarafından önerilen kılavuz niteliğindeki uygulama planı da çalışmaya eklenmiştir. IX

Özet (Çeviri)

SUMMARY SUBJECT: MRP II AND AN MRP II SOFTWARE SYSTEM In this century manufacturing has changed in a variety of vays and the goal has become to automate and integrate the activities at all levels of a production system. This brings strategic advantages such as reduced lead time, faster responces to constantly changing customer demands, instantaneous and accurate communication with customers and suppliers. As the international competition increases, finding global markets has gained importance. Today, many characteristics and features such as low cost, customer oriented design are expected along with high quality. To compete and indeed to survive, companies need bussiness technologies that enable them to discover, define, and meet the expectations of the customer. The most common ones among these technologies can be listed as follows: 1. Just in time (JIT); 2. Total quality control (TQC) ; 3. Computer integrated manufacturing (CIM) ; 4. Group technology (GT) ; 5. Manufacturing resource planning (MRP II); All of these manufacturing management techniques should work together in harmony for the benefit of the company. The essence of manufacturing is flow of materials from suppliers through to customers, and of information to all parties about what was planned, what has happened, and what should happen next. All benefits will be directly proportional to the speed of flow of materials and information. From that reason JIT, which has arisen as an attempt to achieve zero inventories has now evolved to be a total manufacturingphilosophy. Its goal is to eliminate all waste in the entire cycle, starting from the product design up to its delivery to customer. This approach was first developed by Toyota Motors in Japan. Ever since, JIT has been applied successfully in all types of manufacturing firms all over the world. TQC is generally considered as a prerequisite to implementing JIT. Because, in JIT application, inventories are reduced to a minimum so that quality problems are not buffered by inventories. JIT in purchasing seeks to extens the concepts of JIT in production to the network of suppliers. The aim is to obtain frequent, small shipments of high-quality materials just as they are needed. TQC on the other hand, is an integrated approach to quality control. The underlying philosophy to TQC is that any defects are unacceptable and that effort must be directed at continuous improvement to achieve zero defects. Therefore the major responsibility for quality control is placed directly at the department level and primarily at the point of production. Achieving total quality management requires the involvement of senior management, and a major part of that leadership involves providing a clear mission statement and a set of objectives. GT is a manufacturing philosophy and strategy that assist a company in understanding what it manufactures and how those parts are then manufactured. It groups items and processes according to their similarities, and it takes the advantages of this grouping to design and manufacture. Once defined, standardization and simplification of closely related and repetitive activities avoid unnecessary dublication of effort. In general, GT provides a means to organize and structure data about manufacturing parts and process and subsequently to store and retrieve that information using compters. GT is therefore an important step towards CAD/CAM integration and CIM. As it is well-known, in all the above mentioned methods, data integration is an indispensable pre-requisite to ensure quick response and MRP II is an information XItechnology integrating distinct functions of company over a common data-base. It is an operational and financial system concerned with all business activities. MRP II approach was first emerged in the sixties with Bill of Material (BOM) and Material Requirements Planning (MRP) concepts. MRP II began in the 1960 as Material Requirements Planning. Its inventors were looking for a better method for ordering material and parts, and they found it in this technique. The logic of Material Requirements Planning asks the following questions: * What are we going to make? * What does it take to make it? * What do we have? * What do we have to get? Ollie Wight called this the Universal Manufacturing Equation. Material Requirements Planning simulates the universal Manufacturing Equation. It uses the master production schedule (What are we going to make? ), the bill bill of material (What does it take to make it? ) and inventory records (What do we have? ) to determine future requirements (What do we have to get? ). Manufacturing resource planning is a concept that extends MRP to include financial functions. In brief, the evolution of MRP is as follows. First, MRP (Material Requirements Planning) was used only to perform materials netting and lead-time offsetting. MRP thus indicated the quantity and timing of production orders and purchase orders. This first system is often called a w launch and forget“ system, since there was initialy no mechanism for updating MRP orders information on orders already released. Because the environment in which MRP is used is very dynamic, i.e., because order quantity and due date changes are not infrequent, there exist a need to update order due date and order status after the order has been launched. Adding this feedback capability to MRP resulted in closed-loop MRP. MRP II is defined in the APICS Dictionary as: WA method for the effective planning of all the resources of the manufacturing company. Ideally, it addresses XIIoperational planning in units, financial planning in dollars, and has a simulation capability to answer ”what if“ questions. It is made up of variety of functions, each linked together: business planning, sales and operations (production planning), master production scheduling, material requirements planning, capacity planning, and the execution system for the capacity and material. Outputs from these systems wouls be integrated with financial reports such as the business plan, purchase commitment report, shipping budget, inventory projection in dollars, etc. Manufacturing resource planning is a direct outgrowth and extension of closed- loop MRP.”Meanwhile, Distribution Requirements Planning (DRP) concept has also arisen as a new approach that is characterized by planning of shipments out through a planning horizon, the syncronization of shipments to distribution warehouses with the Master Production Schedule (MPS) and the use of the same logic as is used in MRP. DRP has also been extended to include the planning of warehouse space, personel and transportation equipment, and this new concept has become a part of the overall MRP II system. As manufacturing companies begin to cope with a rapidly changing, they realize that the current business systems no longer meet their needs. Companies in 1990' s will be located at geographically dispersed sites, manufacturing by using JIT supply philosophy and processing a distributed supply chain. Integration within such an environment requires an information technology above MRPII. Indeed the rise of the networked manufacturing company where the connection /differences among supplier, distributor and manufacturer becomes vague now redefines business relationships. Thus a new concept Enterprice Resource Planning (ERP) has arisen. Turkish industry is also faced with the challenge of increasing global competition, and the organizations are getting aware of the fact that they should implement the above mentioned technologies and developments in order to survive in the market. In fact, many companies have already undertaken projects to implement these. XIIIPlanning can be done by computer-based systems with minimum human involvement, but successful execution depends on people taking the proper actions promptly. Effective planning systems are necesssary but not sufficient; they make tight control possible, but people make it happen. The aim of this study is to provide principles of Manufacturing Resources Planning (MRP II) and an overwiev of Max ML-1.30, a software designed to serve as manufacturing planning and control system. In this study guidelines to implementation plan proposed by Micro-MRP Inc. has also been included. XIV

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