Geri Dön

MRP II ve bir uygulama

Başlık çevirisi mevcut değil.

  1. Tez No: 46190
  2. Yazar: CENK BAŞKARACA
  3. Danışmanlar: Y.DOÇ.DR. COŞKUN ÖZCAN
  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: 69

Özet

ÖZET Günümüzün endüstri kuruluşlarında çok sık tartışılan bir konu olan“Üretim Kaynakları Planlaması”projesinin tanıtımı, uygulanması ve uygulamaya alınmasından sonra elde edilen yararlar bu çalışmada sunulmaktadır. Firma otomotiv yan sanayi olarak sipariş üzerine termoplastik parça üretmektedir. Amaç giderek artan rekabet ortamında pazar payını arttırmak ve uluslararası kalite standartlarında üretim yapmaktır. Bu nedenle firmada otomasyona geçilmesi yönünde kararlar alınmış ve bunun ilk adımı da MRP II projesini uygulamaya konulması olmuştur. Proje uygulamaya alındıktan sonra temel bazı kriterlere göre fayda analizi çalışması yapılmış ve ilk aşamada 1 milyon doların üzerinde bir fayda getirdiği hesaplanmıştır.

Özet (Çeviri)

SUMMARY Quality and productivity. Those themes are central issues for companies in every manufacturing industry. When we look into the production history of well developed countries, we can easily see that they have been growing step by step. The first movements started out in 18th century; - Experience in manufacturing 1776 - Scientific management 1900 - Time and motions studies 1 900 - Scheduling with chart scheduling 1901 - Human resources and relations 1927 - Mass production 1930 - Operations research in World War II 1940 - First digital computer applications 1946 - Linear programming 1947 - Computer applications in manufacturing 1970 -CAD/CAM 1980 MRP II TQM FMS CIM New technics were began to use in manufacturing system since consumer demands have changed. Although Fordist production theory provides huge number of products at the same quality level, the customers need product diversification. So this approach was not good enough to solve the problem. Those new concepts are introduced as follows; JIT : The mean of just in time is to produce at the right time and at the right number. The main characteristic is this is a demand pull system and does not contains buffer inventory. Just in time manufacturing work best when they are a common basis for synchronizing activity throughout the production sequence. This is an egaliterian arrangement in which each process in the production flow becomes the customer for the preceding process and each process becomes a supermarket to the following process. vinThe Origin of JIT: The conveyor system that Henry Ford established in the United States inaugurated the era of mass production. After that, no company could expect to survive long in modern industry without taking an advantage of the new production technologies. The Japanese manufacturers were quick to build their own conveyor based assembly lines. But Japanese demand for automobiles in the 1930s, when Toyota started making cars, was hardly enough to support the scale economies of mass production. Management at Toyota recognized that they would have to find ways to achieve those economies with small volumes of production. When the Toyota Group set up an automobile manufacturing operation in the 1930s, Kiichiro Toyoda inherited the challenge of adapting Henry Ford's conveyor system to the modest realities of the Japanese market. Mass production required manufacturers to keep the steps in the production sequence supplied with a diversity of parts. An entire line would grid to a halt if a employees ran out of needed parts at any step in the sequence. To prevent shortages and avoid work stoppages, automakers maintained surplus inventories along their production lines. But that was a luxury that manufacturers in Japan could hardly afford, given their tiny volumes of production. So, Kiichiro conceived an 'dea for providing the different processes in the assembly sequence with only the kinds and quantities of items that they needed and only when they needed them. In this system, each process produced only the kinds and quantities of items that the next process in the sequence needed and oi'y when it needed them. Total Quality Management : Total Quality management (TQM) has become the management style of the 1990s. It is a continuos improving approach the whole company contributes. Quality improvement encompasses both improving fitness for use and reducing the level of defects or errors. Both of these activities apply to all customers internal and externa'. Improving fitness for use can have some important benefits: - Better quality for the users, - Higher market share for the manufacturer, - Premium price for the manufacturer, - Status in the marketplace for the manufacturer, Reducing the level of defects and errors also provides multiple benefits : - Lower costs and fewer rritations for users, - Dramatically lower costs for the manufacturer, - Improved productivity: more usable product is produced with the same resources, - Reduction in inventories to assist the Just-In-Time concept. IXDespite these obvious benefits, most organizations have traditionally conducted their affairs with limited priority on improvement. During periods of economic growth, products are saleable if they are generally competitive as to quality. The costs due to poor quality are passed on the customers in the form of higher prices. The companies establish the own system that satisfy their customers in the bases of quality, cost and shipment time. The customer relations are not only the relation with the outside of the company but also every department in the organization is a customer to the next. The basic principal is not a final control, the control must be in every step of the whole process. Only solving a problem is not enough in this approach, system requires the preventive actions. CIM : (Computer Integrated Manufacturing) This is a integration of all kind of manufacturing functions by using the computerized environment. It covers many improved technology such as computer aided design and manufacturing, the robotics and JIT. It allows all the functions of a business to act as a single coherent system. The research council of the United States study into the quantifiable gains which CIM can generate, produced the following results: - Design cost reductions of 15%-30% - Lead time reductions or' 30%-60% - Quality improvements up by 200%-500% - Productivity imp'oved by 40%-70% - Asset utilization up by :?.00%-300 MRP : Material Requirement Planning is a system that balances time-phased supply and demand to create accurate material plans. The master production schedule defines which product when will be produced and bill of material defines which raw materials or work-in-process goods and how many of them will be used per each product. The calculations can be done by using MPS and BOM in order to find how many material and which material will use. Some technical explanations that will be given as follows were copied from APICS (American Production & Inventory Control Society) Dictionary 1987. According to APICS: MRP: A set of techniques which uses bills of material, inventory data, and the master production schedule to calculate requirements for materials. It makes recommendations tc reiease replenishment orders for material. Further, since it is time phased, it makes recommendations to reschedule open orders when due dates and need dates are not in phase. Originally seen as merely a better way to order inventory, today it is thought of as primarily scheduling technique, i.e..., a method for establishing and maintaining valid due dates (priorities) on orders.MRP II: A method for the effective planning of all resources of a manufacturing company. Ideally, it addresses operational 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 requirements planning and the execution support systems for capacity and material. MPS (Master Production Schedule): The anticipated build schedule for those items assigned to the master scheduler. The master scheduler maintains this schedule and. in turn, it becomes a set of planning numbers which“drives”material requirements planning. It represents what the company plans to produce expressed in specific configurations, quantities and dates. The master production schedule is not a sale forecast that represents a statement of demand. MRP II in Turkey With the need for n'n^ges and improvements in the Turkish Manufacturing sector, because of increasing cost of material and labor, the need for factory automation is becoming an increasing requirement. In America, during ihe iate 60's and early 70's, many projects regarding manufacturing 'improvements were undertaken. This was caused by the grcwing co?t of laoor and raw material. During this period, many computerized solutions Dwcaive available. Buying a computer and designing a software does not solve the problem actually it is a point that real problems began. Turkey is moving raciaiy into a changing economic situation. As a result of this, manufacturers must move quickly into factory automation. The process used in determining manufacturing problems in a Turkish Manufacture is no different: than experienced in America. That is quality problems, excess invent': ?ry! If.te shipments, customer complaints, increased labor cost, increased material cost and the list goes on. I will attempt to explain :r.e selection process of obtaining an MRP solution in Turkey and ganerai steps on how to install it. The first step in »Vis orocess is admitting to the fact that having a problem. When yen mirr\i :iis problem the improvement process has started, it will be very Mice to ootam all the necessary information of the company:.. Sales volume - Inventory value - Inventory turns XI- Monthly shipment Amount - Backlog of orders - Bills of material engineering and manufacturing - Secured stockrooms - Number of purchase orders per month - Process sheets for manufacturing - Number of vendors - Number of manufacturing orders per month The reason for this information is to establish some common needs and data that will be required to match your requirements to a software solution. A'ter beginning the implementation system offers the benefits. In this thesis company has this benefits item: 1. Inventory management 2. Purchasing 3. Marketing 4. Quality 5. Capacity and resources 6. Productivity 7. Production 8. Cash flow management Total gain of the company is the sum of the benefits the beneath $1,200,000. xn

Benzer Tezler

  1. Tez No

    126534

    İmalat kaynakları planlaması (MRP II) ve bir uygulama

    Manufacturing resources planning (MRP II) and an application

    MEHMET SİNAN

    Yüksek Lisans

    Türkçe

    Türkçe

    2002

    Makine MühendisliğiMarmara Üniversitesi

    Makine Eğitimi Ana Bilim Dalı

    PROF. DR. İ. METE DOĞRUER

  2. Tez No

    66443

    Üretim kaynakları planlaması (MRP II) ve yan sanayi maliyet analizi ve kontrolü sistemi

    Manufacturing resources planning (MRPII) and vendor firms cost analysis and control system

    SERKAN SANCAN

    Yüksek Lisans

    Türkçe

    Türkçe

    1997

    Endüstri ve Endüstri Mühendisliğiİstanbul Teknik Üniversitesi

    Endüstri Mühendisliği Ana Bilim Dalı

    DOÇ. DR. TUFAN VEHBİ KOÇ

  3. Tez No

    66709

    Üretim kaynakları planlaması ve optimize üretim sistemlerinin analizi

    Analysis of manufacturing resources planning and optimized production technologd2s

    YEŞİM EMANET

    Yüksek Lisans

    Türkçe

    Türkçe

    1997

    Endüstri ve Endüstri Mühendisliğiİstanbul Teknik Üniversitesi

    Endüstri Mühendisliği Ana Bilim Dalı

    DOÇ. DR. MEHMET TANYAŞ

  4. Tez No

    22053

    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

    OSMAN EGE

    Yüksek Lisans

    Türkçe

    Türkçe

    1992

    Endüstri ve Endüstri Mühendisliğiİstanbul Teknik Üniversitesi

    PROF. DR. ATAÇ SOYSAL

  5. Tez No

    46147

    MRP II ve bir MRP II yazılım sistemi

    Başlık çevirisi yok

    GÜNAL HAKAN ERDİK

    Yüksek Lisans

    Türkçe

    Türkçe

    1995

    Endüstri ve Endüstri Mühendisliğiİstanbul Teknik Üniversitesi

    Y.DOÇ.DR. COŞKUN ÖZKAN

Geri Dön