DOC

06mfg60s-MPS

By Joanne Hunt,2014-04-29 02:59
19 views 0
06mfg60s-MPS

    2010-4-29 3:00:00

    Insert Tab Here Unit 6Master Production Scheduling

    Remove this page

null

    Unit 6Master Production Scheduling Unit Introduction ........................................................................................................ 1

    Objectives ............................................................................................................. 1 Terminology .......................................................................................................... 2 Master Production Scheduling ................................................................................... 3

    MRP II and Master Production Scheduling........................................................... 4

    Operations Management Planning ....................................................................... 5

    Priority Planning .............................................................................................. 6

    Resource Planning .......................................................................................... 7 Master Production Scheduling Integration ........................................................... 8

    Master Production Scheduling Process Flow ....................................................... 9

    Master Production Scheduling Master File Setup .............................................. 10

    Facility Planning Data Management ............................................................. 11

    MRP Time Frame Maintenance .................................................................... 11

    Forecast Maintenance .................................................................................. 11 Master Production Scheduling Functional Relationships ................................... 12

    Selecting Items to Master Schedule .............................................................. 13

    Master Scheduled Items ............................................................................... 14 Demand Management.............................................................................................. 15

    Good Scheduling Approach .......................................................................... 16

    Supply and Demand ...................................................................................... 17 Sources of MPS Demand ................................................................................... 18 Independent versus Dependent Demand ........................................................... 20

    Requirements Code ...................................................................................... 22

    Effects of Forecast on MPS .......................................................................... 23

    Forecast Proration ........................................................................................ 24 Customer Orders ................................................................................................ 25 MPS and MRP Planning and Controls ............................................................... 26

    Planning Start Date ....................................................................................... 26

    Global versus Facility-Specific ...................................................................... 26

     Table of Contents 6-i

    Net Change versus Regenerative ................................................................. 27

    Clear Planned Order File .............................................................................. 27 Cumulative Lead Time Analysis ......................................................................... 28

    Critical Path ................................................................................................... 28

    Manufacturing Lead Time .............................................................................. 29

    Planning Horizon ................................................................................................ 30

    Master Production Scheduling Horizon ......................................................... 31

    MPS Horizon Date ......................................................................................... 31 Demand Control .................................................................................................. 35

    Demand Codes .............................................................................................. 35

    Demand Time Fence ..................................................................................... 37 Minimum BalanceSafety Stock ........................................................................ 39

    Minimum Balance Guidelines ........................................................................ 41

    Dynamic Minimum Balance ........................................................................... 42

    Order Policy Codes............................................................................................. 43

    ADiscrete ................................................................................................... 44

    FLeast Cost ............................................................................................... 45

    GPeriod Order Quantity ............................................................................. 47

    HDiscrete Above the Standard Lot Size .................................................... 48

    IIncremental above the standard lot size ................................................... 48

    JMultiple of the Standard Lot Size ............................................................. 49

    KPeriod Order Quantity for Fixed Defined Period...................................... 50

    BlankReorder Point .................................................................................... 50

    Order Policy Fields ........................................................................................ 51

    MPS/MRP Planning Controls ........................................................................ 52

    Order Types ........................................................................................................ 53

    Planned Orders ............................................................................................. 54

    Firm Planned Orders ..................................................................................... 54

    Order Dates ................................................................................................... 55 Master Production Schedule Generation ............................................................ 56

    6-ii Manufacturing WorkshopStudent Guide

    Elements of the Master Production Schedule .................................................... 57

    MPS Calculation ................................................................................................. 61

    Master Production Acceptance Cycle................................................................. 62

    Within the MPS Horizon ................................................................................ 63

    Capacity Time Frame .................................................................................... 64

    Material Time Frame ..................................................................................... 64

    Action Exception Messages ............................................................................... 65 MPS Reports and Inquiries ...................................................................................... 67

    Planning and Pegging Inquiry ....................................................................... 67

    Master Schedule Detail Inquiry ..................................................................... 67

    MPS Planning Report Master Schedule Items .............................................. 67

    Rescheduling FPO Listing ............................................................................ 67

    Shop Order Rescheduling ............................................................................. 68

    Rescheduling...................................................................................................... 69

    Schedule Adjustment .......................................................................................... 71 Customer Order Promising ...................................................................................... 72

    Available-to-Promise .......................................................................................... 73

    ATP Calculation ............................................................................................ 74

    Available-To-Promise Inquiry ........................................................................ 76 ATP Reports and Inquiries....................................................................................... 77

    ATP Inquiry ................................................................................................... 77

    MPS Planning Report.................................................................................... 77 Planners Assistant ................................................................................................... 78

    Master Production Scheduling Review .................................................................... 80

     Table of Contents 6-iii

List of Figures

    Figure 6 - 1. MRP II and Master Production Scheduling Integration ......................... 4 Figure 6 - 2. Operations Management Planning Overview ....................................... 5 Figure 6 - 3. Priority Planning Overview ................................................................... 7 Figure 6 - 4. Master Production Scheduling Integration with BPCS.......................... 8 Figure 6 - 5. Master Production Scheduling Process Flow ....................................... 9 Figure 6 - 6. Master Production Scheduling Master File Setup .............................. 10 Figure 6 - 7. Master Production Scheduling Functional Relationships ................... 12 Figure 6 - 8. Selecting Items to Master Schedule ................................................... 13 Figure 6 - 9. Master Production Schedule Cardinal Rules ...................................... 16 Figure 6 - 10. Supply and Demand ......................................................................... 17 Figure 6 - 11. Sources of MPS Demand ................................................................. 18 Figure 6 - 12. Master Production Scheduling Elements .......................................... 19 Figure 6 - 13. Independent versus Dependent Demand ......................................... 21 Figure 6 - 14. Proration Example ............................................................................ 24 Figure 6 - 15. Customer Order Request Date ......................................................... 25 Figure 6 - 16. Cumulative Lead Time ...................................................................... 28 Figure 6 - 17. Planning Horizon .............................................................................. 30 Figure 6 - 18. MPS Horizon Date ............................................................................ 31 Figure 6 - 19. Manufacturing Demand Policy .......................................................... 32 Figure 6 - 20. Who Can Change the MPS .............................................................. 34 Figure 6 - 21. Demand Control................................................................................ 36 Figure 6 - 22. Demand Type Control Example ........................................................ 37 Figure 6 - 23. Demand Strategies ........................................................................... 38 Figure 6 - 24. Safety Stock...................................................................................... 40 Figure 6 - 25. Dynamic Minimum Balance .............................................................. 42 Figure 6 - 26. Order Policy Codes .......................................................................... 43 Figure 6 - 27. Least Cost Formula .......................................................................... 45 Figure 6 - 28. Least Cost Example .......................................................................... 46 Figure 6 - 29. Planned versus Firm Planned Orders .............................................. 54 6-iv Manufacturing WorkshopStudent Guide

    Figure 6 - 30. Order Dates ...................................................................................... 55 Figure 6 - 31. MPS Acceptance Cycle .................................................................... 62 Figure 6 - 32. Within the MPS Horizon ................................................................... 63 Figure 6 - 33. Capacity Time Frame ....................................................................... 64 Figure 6 - 34. Material Time Frame ........................................................................ 64 Figure 6 - 35. Available-to-Promise ........................................................................ 73 Figure 6 - 36. ATP Calculation ............................................................................... 74 Figure 6 - 37. Planners Assistant ........................................................................... 78

     Table of Contents 6-v

List of Tables

    Table 6 - 1. MPS Problems ..................................................................................... 15

    Table 6 - 2. Forecast Demand Example .................................................................. 23

    Table 6 - 3. MPS Horizon Date ............................................................................... 33

    Table 6 - 4. Demand Codes .................................................................................... 35

    Table 6 - 5. Where to Maintain Safety Stock .......................................................... 41

    Table 6 - 6. Discrete Order Policy with No MPS Horizon ........................................ 44

    Table 6 - 7. Discrete Order Policy with MPS Horizon ............................................. 44

    Table 6 - 8. G Period Order Quantity ................................................................... 47 Table 6 - 9. H Discrete Above the Standard Lot Size .......................................... 48 Table 6 - 10. I Incremental above the standard lot size ....................................... 48 Table 6 - 11. J Multiple of the Standard Lot Size ................................................. 49 Table 6 - 12. Periods ............................................................................................... 50

    Table 6 - 13. Planned Orders .................................................................................. 50

    Table 6 - 14. Order Policy Required Fields ............................................................. 51

    Table 6 - 15. Planning Parameter Control Summary .............................................. 52

    Table 6 - 16. MPS Elements ................................................................................... 60

    Table 6 - 17. MPS Calculation ................................................................................ 61

    Table 6 - 18. Rescheduling ..................................................................................... 70

    Table 6 - 19. Available-To-Promise ........................................................................ 75

    Table 6 - 20. Available-To-Promise Inquiry............................................................. 76

    6-vi Manufacturing WorkshopStudent Guide

Unit Introduction

    This unit covers the Master Production Scheduling (MPS) process, which is part of Operations Management Planning. This material is used in conjunction with the next unit to formulate the production plan.

    Objectives

    At the end of this unit you will be able to:

    ? Produce a manual Master Production Schedule.

    ? Calculate an item’s cumulative lead time.

    ? Maintain a manual forecast.

    ? Generate exception reports and reschedule as needed. ? Commit customer order ship dates based on the Master Production Schedule.

     Master Production Scheduling 6-1

    Terminology

    Uncommitted portion of inventory or scheduled receipts. Available-to-Promise

    Amount of time needed to produce an item, from purchase Cumulative Lead Time

    of raw material to point of ship.

    Demand derived from higher level demand. Dependent Demand

    Planned orders no longer controlled by the system because Firm Planned Order

    they have been accepted, and/or changed.

    System adjustment made to forecast when unconsumed Forecast Proration

    forecast quantities and time periods overlap with the

    planning start date.

    Total independent and dependent demand for a part or Gross Requirements

    assembly in a time period. Demand which cannot be calculated from another item’s Independent Demand

    demand and must be forecast. Statement of production plans in terms of what, how much, Master Production

    and when. Scheduling (MPS)

    Set of techniques using bill of material, inventory data, and Material Requirements

    master production schedule, to calculate material Planning (MRP)

    requirements.

    Waiting or moving time at the end of an operation. Move Time

    System suggested replenishment orders not yet accepted by Planned Order

    the planner.

    Amount of time the master schedule extends into the future. Planning Horizon

    Calculated inventory amount at end of time period. Projected On-hand

    Time spent waiting prior to an operation. Queue Time

    Open purchase orders or shop orders that have been issued. Released Orders

    Standard production rate. Run Time

    Additional inventory planned as a safeguard. Safety Stock

    Manufacturing, purchase, and firm planned orders with an Scheduled Receipts

    open balance, scheduled to be received in a time period.

    Work required to change a specific machine, resource, work Setup Time

    center, or production line from one product to another.

    6-2 Manufacturing WorkshopStudent Guide

Report this document

For any questions or suggestions please email
cust-service@docsford.com