طرق وعمليات المخزون - الجزء الثاني.pdf

‫طرق ومعليات اخملزون‬ ‫‪APSC 211‬‬ ‫‪2nd Term‬‬ ‫‪2023 – 2024‬‬ Material Requirement Planning (MRP) Definition System used in manufacturing and production management to efficiently plan and control the materials and components needed for the production process. Steps involved in Material Requirement...

‫طرق ومعليات اخملزون‬ ‫‪APSC 211‬‬ ‫‪2nd Term‬‬ ‫‪2023 – 2024‬‬ Material Requirement Planning (MRP) Definition System used in manufacturing and production management to efficiently plan and control the materials and components needed for the production process. Steps involved in Material Requirement Planning (MRP) Bill of Materials (BOM): Create or update a detailed list of all the components, sub-assemblies, and materials required to manufacture the final product. Master Production Schedule (MPS): Develop a production schedule that specifies what and how much of the final product needs to be manufactured over a specific time period. Inventory Status: Assess the current inventory levels of raw materials, components, and finished goods. Steps involved in Material Requirement Planning (MRP) Net Requirements Calculation: Calculate the net requirements for each component by considering the demand from the MPS, subtracting the available inventory, and factoring in lead times. Planned Orders: Generate planned orders for materials that need to be replenished or produced, taking into account safety stock levels and order quantities. Purchase Orders and Work Orders: Create purchase orders for external suppliers to procure raw materials and components, and work orders for in-house production of items as needed. Release Orders: Release purchase and work orders to the respective departments and suppliers according to the schedule. Steps involved in Material Requirement Planning (MRP) Tracking and Monitoring: Continuously track and monitor the progress of orders, inventory levels, and production to ensure that everything aligns with the plan. Adjustments and Revisions: Regularly review and adjust the MRP plan as changes occur, such as revised customer orders, supplier delays, or production issues. Performance Evaluation: Evaluate the MRP system's performance in meeting production goals and reducing inventory costs, making necessary improvements as needed. Material Requirement Planning (MRP) benefits Improved Efficiency MRP helps optimize production schedules and inventory management, reducing wasted time and resources. Cost Reduction By ensuring the right materials are available when needed, MRP helps minimize excess inventory and associated carrying costs. Enhanced Customer Service Meeting production schedules reliably ensures timely delivery to customers, improving customer satisfaction. Material Requirement Planning (MRP) benefits Better Resource Utilization MRP allows for efficient allocation of resources, reducing overproduction and underutilization of capacity. Accurate Inventory Control MRP helps maintain accurate inventory levels, reducing the risk of stockouts and overstock situations. Reduced Lead Times MRP can help shorten lead times for production, which can be a competitive advantage. Material Requirements Planning (MRP) Challenges 1. ACCURATE DATA REQUIREMENTS 2. SOFTWARE IMPLEMENTATION 3. FORECASTING ACCURACY MRP HEAVILY RELIES ON ACCURATE AND UP-TO-DATE DATA, INCLUDING BILLS OF MATERIALS, INVENTORY LEVELS, AND LEAD TIMES. MAINTAINING DATA ACCURACY CAN BE A SUBSTANTIAL CHALLENGE, AND ERRORS CAN LEAD TO INACCURATE PLANNING. SELECTING, IMPLEMENTING, AND INTEGRATING MRP SOFTWARE CAN BE A COMPLEX AND COSTLY PROCESS. IT REQUIRES A WELL-DEFINED STRATEGY AND OFTEN THE ASSISTANCE OF EXPERTS. MRP DEPENDS ON DEMAND FORECASTS, AND INACCURATE FORECASTS CAN LEAD TO OVERPRODUCTION OR SHORTAGES. ACHIEVING PRECISE DEMAND FORECASTING IS A CONTINUAL CHALLENGE. Material Requirements Planning (MRP) Challenges 4. LEAD TIME VARIABILITY 5. WORKLOAD BALANCING 6. COST OF IMPLEMENTATION SUPPLIER LEAD TIMES CAN VARY, WHICH CAN LEAD TO UNCERTAINTY IN THE ARRIVAL OF MATERIALS. THIS REQUIRES EFFECTIVE MANAGEMENT AND CONTINGENCY PLANNING. EFFICIENTLY MANAGING PRODUCTION AND RESOURCE CAPACITY TO MATCH DEMAND CAN BE CHALLENGING, ESPECIALLY IN INDUSTRIES WITH FLUCTUATING DEMAND PATTERNS. IMPLEMENTING MRP SYSTEMS CAN BE EXPENSIVE, AND SMALLER ORGANIZATIONS MAY FACE FINANCIAL CONSTRAINTS IN ADOPTING SUCH TECHNOLOGY. Material Requirements Planning (MRP) Challenges 7. CHANGE MANAGEMENT 8. TRAINING AND SKILL GAPS 9. CUSTOMIZATION EMPLOYEES MAY RESIST CHANGES IN THEIR WORKFLOW, AND MANAGING THIS TRANSITION EFFECTIVELY IS CRUCIAL FOR A SUCCESSFUL MRP IMPLEMENTATION. STAFF MAY REQUIRE TRAINING TO USE MRP SOFTWARE EFFECTIVELY, AND THERE MAY BE A LEARNING CURVE ASSOCIATED WITH ITS ADOPTION. TAILORING THE MRP SYSTEM TO MEET THE SPECIFIC NEEDS OF AN ORGANIZATION CAN BE TIMECONSUMING AND COMPLEX, PARTICULARLY IN INDUSTRIES WITH UNIQUE REQUIREMENTS. Examples of companies in Saudi Arabia that use Material Requirements Planning (MRP) 1. Saudi Aramco Saudi Aramco, the world's largest oil and gas company, utilizes MRP to manage the extensive materials and components required for its operations. MRP helps Saudi Aramco plan the procurement of critical equipment and spare parts for their oil and gas facilities, ensuring that maintenance and production activities run smoothly and efficiently. 2. SABIC (Saudi Basic Industries Corporation) SABIC, one of the largest petrochemical companies in the world, relies on MRP to optimize its supply chain and production processes. MRP assists SABIC in forecasting demand for various petrochemical products and planning the procurement of raw materials and intermediates. This enables SABIC to maintain consistent production and meet market demand. 3. Saudi Arabian Airlines (Saudia) Saudi Arabian Airlines, the national carrier of Saudi Arabia, uses MRP for managing aircraft maintenance and spare parts. MRP helps Saudia plan the availability of critical components, reducing aircraft downtime and ensuring the safe and efficient operation of their fleet. ‫وفقكم هللا واعانكم‬