Orlicky's Material Requirements Planning
Not much about MRP appeared in print until 1975, when its principles and precepts were set down by Joseph Orlicky in the first edition of this book. It soon became the "bible" of MRP, and played a major role in MRP's wide acceptance and success in the field.
Now in this second edition, another MRP pioneer, George Plossl, brings Orlicky's seminal work up to date to meet the needs of today's manufacturing companies while retaining all of the outstanding features that made the original a best-selling classic.
Orlicky's Material Requirements Planning forgoes much of the conventional wisdom about production and inventory control, and rejects such piecemeal measures as transplanting manufacturing practices from one company to another. With specific step-by-step implementation procedures it shows how the logic of MRP achieves a better balance between inventory input and output.
It explains why inventory management is inseparable from production planning. It examines the effects of both independent and dependent demand on inventory control, and points out the weaknesses of such commonly accepted approaches as stock replenishment and order points (OP) while providing preferred MRP alternatives.
Plossl also discusses driving present-day MRP programs effectively using time-phased master production schedules, structuring various types of bills of material (BoM), assigning a numbering system, setting up efficient files of inventory data, using shop calendars, and establishing realistic lead times for every purchased and manufactured item.
Orlicky's Material Requirements Planning thoroughly covers all the important post-MRP developments such as the many uses of MRP output data, MRPII, Just-in-Time (JIT), and Total Quality Management (TQM). And it contains a full array of MRP applications, implementation problems to anticipate, and their most effective solutions.
Expanded coverage of master production scheduling . . . capacity requirements planning and control . . . structuring of bills of materials . . . generously illustrated with over 100 charts, diagrams, and drawings . . . this landmark book is an indispensable tool for any P&IC practitioner or anyone preparing for CPIM certification.
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Dependent and Independent Demand
Mixed Independent and Dependent Demand
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actions allocated bills of material bucket capacity requirements planning change MRP coverage customer orders economic order quantities effects end items engineering changes errors example execution Figure final assembly schedules forecast function gross requirements handle hond independent demand input inventory control inventory item inventory management inventory planners inventory records inventory status item's Leod load load profiles logic lot sizes lot-sizing techniques master production schedule master scheduling material requirements planning ments modular BoM MRP programs net requirements open order operations option order due dates order quantity order release output parent items part-periods period planned lead Planned-order releases planning and control planning horizon plant priority control problems processing purchase queue raw material released orders replanning replenishment order rescheduling safety stock Scheduled receipts service-part setup shortages shown in Fig specific subassemblies suppliers time-bucket tion TPOP transactions units updating valid week work-in-process