Üretim kaynakları planlaması (MRP II)
Manufacturing resources planning
- Tez No: 46189
- Danışmanlar: Y.DOÇ.DR. ALPARSLAN FIĞLALI
- Tez Türü: Yüksek Lisans
- Konular: Endüstri ve Endüstri Mühendisliği, Industrial and Industrial Engineering
- Anahtar Kelimeler: Belirtilmemiş.
- Yıl: 1995
- Dil: Türkçe
- Üniversite: İstanbul Teknik Üniversitesi
- Enstitü: Fen Bilimleri Enstitüsü
- Ana Bilim Dalı: Belirtilmemiş.
- Bilim Dalı: Belirtilmemiş.
- Sayfa Sayısı: 148
Özet
ÖZET MRP II, yada Üretim Kaynakları Planlaması üretim şirketlerinin tüm kaynaklarını planlamada kullanılan bir teknikler grubudur. Organizasyondaki imalat, satış, satınalma, üretim planlama, envanter yönetimi, muhasebe, mali işler gibi tüm faaliyetlerin bir plan doğrultusunda birbirleri ile uyumlu bir şekilde gerçekleştirilmesini hedefler. Üretim kaynaklarının planlanması, malzeme ihtiyaç planlaması temeli üzerine geliştirilmiştir. Pek çok firma imalat proseslerini daha iyi kontrol edebilmek amacı ile malzeme ihtiyaç planlama (Material Requirements Planning - MRP) sistemleri kullanmaktadır. Bu sistemlerin kullanımı, bilgisayar sistemlerinin gelişmesi ile paralel olarak çeşitli MRP yazılımlarının piyasaya sunulması sonucunda yaygınlaşmıştır. Bilgisayarın kullanımı ile MRP sistemi daha kullanışlı hale gelmiş, bunun yanında bilgisayarla desteklenen MRP uygulamaları imalat yönetim sisteminin gelişmesinde önemli bir adım olmuştur. Sonuç olarak, MRP II sistemini başarılı uygulayan firmalar, atölyelerindeki kötü koşulları ortadan kaldırmışlardır. Bunun yanında göze çarpıcı kazançlar sağlamışlardır. Örnek vermek gerekirse; müşteri hizmetlerinde artış, daha iyi üretim planlama, stok seviyesinde düşüş, malzeme darboğazında düşüş, emniyet stoğunda düşüş, üretimdeki tedarik süresinde düşüş, fabrika veriminde artış, üretim maliyetlerinde düşüş vb. Bu çalışmada üretim sistemleri konusu, Üretim planlama ve kontrol fonksiyonunun bir işletme açısından önemi, Üretim kaynakları planlamasının temeli olan malzeme ihtiyaç planlaması, MRP II ile ilgili piyasada mevcut olan paketler modül modül incelenip, MRP II ile ilgili paket satın alırken hangi konulara dikkat edilmesi gerektiği ve tanıtımı yapılan AKKARDANSA A.Ş. için mevcut paketler değerlendirilmiştir. vı
Özet (Çeviri)
SUMMARY MANUFACTURING RESOURCES PLANNING MRP II or Production Sources Planning is a group of techniques used in planning all the sources of the production companies. Its aim is to certify all the activities like; production in organization, sales, purchases, production planning, inventory management, accounting, fiscal affairs according to a plan and with interrelation. MRP II is forming a new way of intelligence and comprehension in the company. A formal system should have been established for this intelligence in order to be valid in the company. Formal system is a system in which the responsibilities are defined and where both the lowest level and the highest level emplayees interact according to a plan and have a team spirit. It is developed on the base of production sources planning, material requirements planning. Lots of firms use material requirements planning in order to control their production processes in a better way the usage of these systems have become wide spread by the release of various MRP softwares which is parallel to development in computer systems. MRP became more convenient in usage by the help of computers, MRP applications which are supported by computers have become an important step in development of production management system. Material Requirements Planning (MRP) is an advanced technique that analyzes current and future manufacturing plans to project and optimum materials plan. Using the orderin policies, lead times, and product structure information established in the Bill of Material System, the inventories and orders maintained in the Material Control system, and the schedules coming from Master production Scheduling, MRP creates the time phased projection of your component part requirements in relation to available inventory, MRP determines when manufacturing, purchase, and vendor subcontract orders should be placed adjusted, rescheduled, or canceled and makes the necessary recommendotion to ensure that you have the right materials on hand when you need them. MRP system recommends when, how may and which main products should be produced, by the help of the main production schedules. With the information taken from the product tree, it examines the product structures, so it determines the components and the amount of these components which are necessary for a main product, it compares this information with inventory situation, also by using production achievement durations, IXspecifies the time that these components will be ordered. Consequently it programs machine and labor haves needed for production, amount of energy, material and parts by going earlier stages before transportation and delivery date including the control necessity of the main product. This application reduces the compulsory of stocking since it certiries the production or achievement of each product or its companents just before the time they are required. As reported in several publications, after the application of the MRP system, the firms had some advantages like lower inventory level, lower cost of inventory recording, shorter production achievement durations, on time delivery to customer, and better delivery performance. But in spite of these utilities, MRP system has some deficiencies, for example it doesn't exemine the capacity of the factory while giving the arders for material requirement, job and purchasing. MRP II is named as“firm administration system”and sometimes as“computer model of the firm”, to put it in another way, MRP II is a standart logical formal system which can simulate in order to test reel production administration and the effect of each activity. It's a way to specify the best one among the alternatives for upper level management. Most of the MRP II users usually use the MRP system which is combined to financial plans. The purpose is to certify the upper management by the help of the time oriented financial plans which include the time oriented operation plans. Another reason for that is, it gives the user the ability to determine realitic targets, overwork periods, profit and inventory investment. Another reason is that it permits the financial and operational plans become daily more frequently than some changes in production conditions become. The effect of these changes is simulated to system output reports, and so department managers come across with possible changes in operation, capacity and material requirement, so the whole MRP II system ensures a developed level of management control. The total establishment of MRP II system is the first step in establishment of MRP II project. Each firm that will use MRP II system, should obtain an operational MRP system to use in MRP simulations once in a week in order to evaluate the possible changes in main production schedule. The ability of MRP simulations will help answering the“if, so”questions as well as developing a main production schedule for management. MRP II simulations are generally used to answer these ratine questions:“What happens if we change our product mix?”or“How much of a specific product should a firm manufacture?”,“Can we Increase the level of production of one or more products?”. These questions are generally asked by the marketing departman in order to meet the changes in customer's demand or customer specifications. Changing a product mix includin produced and purchased components needs a great change in number of other components. After using the MRP simulations, the production department will have the information to determine the things that should be done quickly without having a loss in production effeciency. I had previously told that the usage of MRP II which is considered as the nucleus of CIM (Computer Integrated Manufacturing was becoming wide spread in Turkey. Nevertheless some problems may occur, these problems are mostly about the indefinite situations in sotware selection and usage.According to the results of a research which was performed in the United States, it's seen that efficiency isn't ensured in eight of each ten firms which use MRP II software. MRP II system's not being efficient has the meaning of no reduction in invertory levels and inner process stocks, a confusion in transmitting information between levels and no delivery on time. In coming out of this negative situation, beside the other factors, the wrong behaviours in selection of the MRP II software are most important factors. In a firm, while buying an MRP 11 software, two kinds of mistakes occur. The first one is, the firm purchases MRP II software although it has no need for an MRP II software, or the firm buys it when the priority of purchase shouid be given to another requirement of the firm. The second mistake is, althaugh the decision of buying MRP II software is right, the selection of software is wrang. In other words, the MRP II software purchased isn't fit for the firm. Today, there are around 130 different MRP II labeled saftwares in the world and almost 20 of then are existing in our country. The prices vary from $15,000 to $ 1.000.000. This price difference comes out as detail functions crowd not as the basic functions. But just like the reality of quality existing in details, here the total effect of the functions speecif ies the success. After assuring that the purchase of MRP II software has a priority, we can consider that the industrial purchase process has four main levels. They are; 1- Formation of selection team 2- Analysing the utility/cost 3- Determination of softwares that will be evaluated 4- Analysis of the determined softwares. The purchase team consists of a top manager, the managers of the departments where MRP II modules will be used and a person who has enough knowledge and experience about computer softwares. The team should discuss what the MRP II philosophy is, why the firm requires MRP II software. These topics should be disoussed in the first meeting. The team should be busy with the possible utilities in buying MRP II softwares which will create extra time and the determination of monetary sum of these softwares but in order to do these operations, an economical life should be estimated for the software. At the level of determination of softwares that will be evaluated, the first thing to do is to reach as many softwares as possilde, MRP II software should support effectively the work style that timefirm desires. Some properties that are required in an MRP II software are, * The system must be ready mode * The system must be effective * It must be fit to firm's operations XI* It must be elastic and universal * It must have facility in settlement * The system should be in a way that can be learnt easily and in a short time * It should be converient for easy and fast usage. * The screens and reports should reveal time Information required * There must be RE-DE (research - development) activitres which beldng to MRP II system At the level of analysis and eveluation of determined softwares; * The service capability of the supplier. Whether they have enough qualifications for education and consulting or not * The existence of a substitute company which* keeps the source codes of the software in case of the closure of the company * The possibility of making several changes on the software in a short time After determination of softwares and the short list is formed, a meeting should be performed with producer firms, demonstrations should be watehed carefully and there shouldn't be any question which isn't asked till the minds get clear. Generally, all of the MRP II manufacturing management systems contain, * Bill of Material system * Material Control system * Material Requirement Planning system * Purchasing Control system * Process and Routing system * Shop Floor Control System * Cost Development system * Cost Management system * Multiproduct Management system XII* Lot Traceability system * Schedule -Managed Proction * Master Production Scheduling * Order Processing Consequently, the firms that can manage to apply MRP II system successfully, abolishes the bad conditions in their workshops, beside that they make profits which aren't negligible. If we're to give example, some of them are, an increase in customer services, better production planing, a decrease in stock level, decrease in material deficiency, decrease in safety stock, reduction in the achievement duration, an increase in factory productivity, a decrease in production costs, ete. XIII
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