Standard |
DMM 110 - Manufacturing Resources
Planning/Just-In-Time I
Provides introductory instruction and hands-on experience in utilizing Manufacturing Resources Planning (MRP II)/Just-In-Time, a fully integrated production and information management software system. Instruction moves step-by-step through system implementation and teaches how a state-of-the-art Manufacturing Resources Planning (MRP II) system works in today's zero inventory and Just-In-Time environment. Topics include: bills of material, MRP II logic, inventory planning, master production schedule, planning policies, statistical quality control (SQC), and quality at the source.
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Competency Areas |
Hours
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Bills of Material |
Class |
4 |
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MRP II Logic |
D. Lab |
6 |
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Inventory Planning |
P. Lab/O.B.I. |
0 |
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Master Production Schedule |
Credit |
7 |
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Planning Policies |
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Statistical Quality Control
(SQC) |
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Quality at the Source |
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Prerequisite: |
Provisional admission level math competency |
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Corequisite: |
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Course Guide |
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Competency |
After completing this
section, the student will: |
Hours |
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Class |
D.Lab |
P.Lab/ O.B.I. |
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BILLS OF MATERIAL |
5 |
10 |
0 |
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File |
Describe the contents of a bill
of material file. |
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Structure |
Define the term bill of
material structure. |
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Components |
Name the elements of a typical
bill of material. |
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Hierarchical structure |
Discuss how individual bills of
material are linked to illustrate a product. |
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Branches and levels |
Contrast levels and branches of
a hierarchy of bills of material. |
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Parent/component |
Explain the parent/component
relationship for bills of material. |
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Chained files |
Contrast explosion chain and
implosion chain as applied to bills of material. |
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Requirements |
Discuss the requirements a bill
of material must meet to satisfy MRP II systems. |
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Modular bill |
Explain the purpose of a
modular bill of material. |
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Pseudo bills |
Discuss the formation of a
super bill. |
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Use a super bill. |
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Development |
Create a bill of material for a
product having at least six components. |
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MRP II LOGIC |
5 |
5 |
0 |
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Fundamentals |
Describe the analysis of
materials procurement which MRP II logic involves. |
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Master production schedule |
Discuss the use of a master
production schedule as it applies to MRP II logic. |
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Bills of materials |
Describe the purpose of bills
of materials as they apply to MRP II logic. |
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Inventory data |
Discuss the role of inventory
data in reference to MRP II logic. |
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Data processing |
Explain why MRP II logic
requires processing data to determine quantity required. |
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Lead time |
Discuss the lead time as a
function of MRP II logic. |
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Flow of materials |
Give examples of materials
movement to and from customers and suppliers that apply to MRP II logic. |
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INVENTORY PLANNING |
5 |
10 |
0 |
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Objective |
Discuss the role of inventory
in accomplishing manufacturing objectives. |
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Inventory balancing |
State the major categories of
inventory balancing decisions. |
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Functional types |
Discuss the functional types of
inventories found in materials distribution centers. |
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Classes |
Explain the classification of
inventories according to condition during processing. |
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Costs |
Describe the classes of costs
which are reviewed in inventory planning. |
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Distribution by value |
Explain the ABC classification
system as it applies to inventory planning. |
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Discuss the use of ABC class
designators when applied to the concepts of degree of control, inventory
records, priority, and ordering procedures. |
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Management |
Explain the factors involved in
keeping the time interval between consumer level and production rates at a
minimum. |
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MASTER PRODUCTION SCHEDULE |
10 |
15 |
0 |
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Planning hierarchy |
Discuss the role of the master
production schedule in relationship with other plans in the planning
hierarchy. |
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Functions |
State the functions of the
master production schedule (MPS) within the context of manufacturing
resources planning. |
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Definition |
Define the term master
production schedule. |
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Inputs |
Describe the inputs needed to
develop an MPS. |
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Flexibility |
Give an example which
illustrates the technique called over planning the MPS. |
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Lead times |
Discuss the impact of lead
times on determining the minimum MPS horizon. |
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Format |
Develop an MPS for a product
family containing five or more end items. |
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Uses |
Give examples which illustrate
the uses of the MPS in manufacturing resources planning. |
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Management’s role |
Discuss the actions management
takes to assure that the MPS is an effective tool for manufacturing resources
planning. |
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PLANNING POLICIES |
5 |
5 |
0 |
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Objectives |
State the major objectives upon
which planning policies are developed. |
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Discuss the conflicts inherent
in planning policies designed to meet the objectives of most manufacturing
firms. |
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Forecasting |
Contrast planning policies
based upon long, intermediate, and short range forecasting. |
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Policy/control |
Contrast the roles of
management policy and production control in the planning process. |
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STATISTICAL QUALITY CONTROL
(SQC) |
5 |
5 |
0 |
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Concept |
Describe the concept of
statistical quality control as applied to a manufacturing operation. |
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Method |
Describe a typical sampling
action by a QC inspector. |
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Disadvantages |
Discuss the disadvantages of
placing responsibility for production quality with a separate QC unit. |
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QUALITY AT THE SOURCE |
5 |
10 |
0 |
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History |
Contrast the development of
manufacturing management expertise for Western Europe, U.S., and Japan from
1750 to 1955. |
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Compare Japanese, U.S., and
Eastern Europe manufacturing management expertise with Just-In-Time (JIT) and
Total Quality Control (TQC) between 1955 and 1980. |
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JIT/TQC key issues |
Discuss temperament, geography,
and education and training as issues of the JIT/TQC concept. |
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JIT concept |
Discuss the term stockless
production as it applies to the JIT concept. |
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Scrap/quality control |
Explain the effect on indirect
costs when JIT/TQC production methods are used in contrast to traditional
quality control methods. |
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TQC concept |
State the slogan which is
associated with the TQC concept. |
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Explain the difference in error
identification between the TQC method and the traditional inspector
statistical sampling method. |
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Responsibility |
Contrast the source of quality
control in the TQC method with that of the traditional inspector method. |
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Suggested Resources |
Suggested
Resources include textbooks shown below or most current edition.
Books
Aft, L. S.
(1987). Production and inventory control.
San Diego: Harcourt Brace Jovanovich.
Mecimore, C. D., & Weeks, J. K. (1987).
Techniques in inventory management
and control. Montrale, NJ: National
Association of Accounts.
Plossl, G. W., & Wright, O. W. (1985).
Production and inventory control:
Principles and techniques (2nd ed.).
Englewood Cliffs, NJ: Prentice Hall.
Schonberger, R. J. (1982). Japanese manufacturing techniques: Nine
hidden lessons in simplicity. New
York: Free Press.
Vollmann, T. E., et al. (1988).
Manufacturing planning and control
systems (2nd ed.). Homewood, IL:
Irwin.
Zenz, G. J.
(1987). Purchasing and the management of materials (6th ed.). New York: John Wiley & Sons.
Additional
Materials
For
additional materials and information on competencies in this course contact:
American Production & Inventory Control Society
500 W. Annandale Road
Falls Church, VA 22046-4274
Phone: 1-800-444-2742