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MRP(manufacturing requirements planning) is a process that involves the planning and scheduling of jobs and purchase orders and the management of inventory to fulfill customer orders.
Scheduling not only occurs when planned jobs are created, but also when jobs need to be rescheduled to meet changing dates and conditions. At the work center and machine level, scheduling occurs daily when determining job assignments.
You can use any combination of push and pull planning styles to manage your inventory.
For push style planning where inventory levels are set to anticipate demand, you can establish reorder levels, minimum order quantities, and enter forecasts.
For pull style planning where you only manufacture or purchase in response to actual demand, you can set reorder levels to zero and designate selected items to be made or ordered only in response to actual requirements.
You can freely mix the two styles and use push planning for some items and pull planning for others.
Variable Planning Period by Item During MRP generation, each item is assigned its own planning period based on the sum of its Lead Days plus Job Days plus the interval days between MRP runs. Variable planning periods significantly reduce the number of items to be planned for and focuses attention on just those items that need it.
With the efficient supply chains of today, many items can be replenished quickly and are therefore excluded from the MRP generation until shortly before they are actually needed.
Dynamic Job Scheduling within MRP The multi-level MRP generation of planned jobs pauses at each level so that jobs can be dynamically scheduled backward from required dates. This combines MRP and scheduling into one process and produces accurate job schedules down through all levels of your product structures.
Transparency of Numbers Within each item’s Drill-Down and Job Days Calculator screens, all the numbers that were used to generate the planned job and PO details are fully transparent and traceable.
Work Center Job Prioritization Daily Work Center Dispatch Lists are created and sent to the shop floor for work assignments. Jobs are prioritized using a Critical Ratio, which assures that jobs running behind schedule are given priority over jobs that are running ahead of schedule. When you schedule the entire factory in this manner, more jobs will get completed on time with fewer bottlenecks and less expediting.
MRP Settings This screen is used to maintain MRP-related settings for your stock items, including reorder level, minimum order, lead days, and job days.
Forecasts Forecasts are used to plan for demand that is expected to materialize in the future for orders that have not yet been received. Forecasts (outside an exclusion window) are included in the total demand within each item’s planning period.
MRP This screen is used to generate planned jobs and PO’s and to schedule and convert them into actual jobs and purchase orders.
Buy-for-Job This screen is used to generate PO’s directly from jobs for ‘to-order’ items and for non-stock items such as subcontract services (painting, plating, heat-treating, etc.).
Work Center Scheduling This screen is used to prioritize jobs within work centers and machines and to generate a daily dispatch list that is used out on the shop floor for work assignments. You can also use this screen to maintain scheduling-related settings such as daily capacity, queue time, and safety buffer.
Job Scheduling This screen is used to reschedule jobs and sales orders when required dates change or jobs are running early or late.
Delivery Date Estimator Use this screen to calculate a projected delivery date for any stock item and quantity.
Planning Worksheets Planning worksheets provide a listing of items that need planned orders and enable you to do your planning on paper as an alternative to doing so on the screen. Each item’s MRP settings and existing and projected demand and supply are listed on the reports so that all the planning information you need is at your fingertips.
Scheduling Reports A set of scheduling reports are available, including a master job schedule, work center schedule, machine schedule, and subcontract service schedule.
"MRP & Scheduling" is part of the DBA Manufacturing Next-Generation line of products, developed by DBA Software.