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E-raamat: Orlicky's Material Requirements Planning, Third Edition

  • Formaat: 352 pages
  • Ilmumisaeg: 05-Jun-2011
  • Kirjastus: McGraw-Hill Professional
  • Keel: eng
  • ISBN-13: 9780071755641
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  • Formaat: 352 pages
  • Ilmumisaeg: 05-Jun-2011
  • Kirjastus: McGraw-Hill Professional
  • Keel: eng
  • ISBN-13: 9780071755641

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A fully revised and updated edition of the landmark work on material requirements planning (MRP), Orlicky's Material Requirements Planning, Third Edition focuses on the new rules required to effectively support a manufacturing operation using MRP systems in the twenty-first century. This authoritative resource offers proven solutions that help you gain the competitive edge through strategic lead time reductions, substantial reductions in total inventory investment, and significant increases in service levels. This is an indispensable tool for manufacturing practitioners and anyone preparing for CPIM certification.

Coverage includes:





Inventory in a manufacturing environment Principles of MRP MRP system Processing logic Lot sizing System records and files Product definition Master production schedule Inventory planning and control system System effectiveness Industry effect on MRP Project manufacturing Remanufacturing Process industry application Repetitive manufacturing application Sales and operations planning Evolution of MRP and planning systems Demand driven MRP (DDMRP) logic Strategic inventory positioning Dynamic buffers Demand driven planning Highly visible and collaborative execution DDMRP performance reporting and analytics DDMRP future

Building on the pioneering work of Joseph Orlicky, this new edition of the classic text on material requirements planning (MRP) reveals the next evolutionary step for materials and supply chain synchronization in the modern manufacturing landscape.

Orlicky's Material Requirements Planning, Third Edition reviews the poor business results embedded in many of today's manufacturing systems, discusses the core problems causing these results, explains an alternative pull structure for planning and controlling materials flow, and presents results from actual implementations.

This thoroughly updated edition offers comprehensive coverage of MRP, describes the current state of the MRP application, and identifies the fundamental changes required to achieve sustainable success given the current global circumstances and technology options. This state-of-the art guide articulates the next generation of MRP logic--demand driven MRP (DDMRP)--and provides a roadmap for the near and distant future for this critical manufacturing management tool.

Carol Ptak is currently a partner with the Demand Driven Institute, and was most recently at Pacific Lutheran University as Visiting Professor and Distinguished Executive in Residence. Previously, she was vice president and global industry executive for manufacturing and distribution industries at PeopleSoft where she developed the concept of demand driven manufacturing (DDM). Ms. Ptak spent four years at IBM Corporation culminating in the position of global SMB segment executive.

Chad Smith is cofounder and managing partner of Constraints Management Group, a services and technology company specializing in pull-based manufacturing, materials, and project management s
Foreword xiii
David Turbide
Preface xv
Part 1 Perspective
Chapter 1 Overview
3(8)
Orlicky's Vision
3(3)
Focus and Organization of This Book
6(3)
Bibliography
9(2)
Chapter 2 MRP in the Modern World
11(14)
Key Questions for Planning and flexibility
15(1)
Dealing with Variability
15(8)
Materials or Capacity: Where to Focus First?
23(2)
Chapter 3 The Four Critical Questions Answered
25(18)
Question 1: Relevance of MRP
25(2)
Question 2: MRP-Flawed Approach or Poorly Applied?
27(10)
Question 3: The MRP Conflict with Lean or Pull
37(3)
Question 4: MRP Progress in the Last 30 Years?
40(3)
Part 2 Concepts
Chapter 4 Inventory in a Manufacturing Environment
43(40)
Manufacturing Inventories
43(2)
Distribution Inventory
45(3)
The Logic of Manufacturing
48(1)
Order-Point Versus MRP Systems
49(10)
The Paradox of Inventory Management
59(19)
A Distribution Positioning Example
78(2)
Summary
80(1)
Bibliography
81(2)
Chapter 5 Principles of Materials Requirements Planning
83(12)
Time Phasing
83(2)
Inventory System Categories
85(2)
Prerequisites and Assumptions of MRP
87(1)
Part Numbers
88(1)
Bills of Material (BOMs)
89(3)
Applicability of MRP Methods
92(2)
Bibliography
94(1)
Chapter 6 The Material Requirements Planning System
95(20)
Objectives of the System
95(2)
The Purpose of the System
97(2)
System Inputs and Outputs
99(3)
Factors Affecting the Computation of Requirements
102(13)
Chapter 7 Processing Logic
115(28)
Inventory Status
115(3)
Techniques of Time Phasing
118(2)
Gross and Net Requirements
120(5)
Coverage of Net Requirements
125(3)
Explosion of Requirements
128(6)
Time-Phased Order Point
134(3)
Entry of External-Item Demand
137(3)
System Nervousness
140(2)
Bibliography
142(1)
Chapter 8 Lot Sizing
143(20)
Costs in Lot Sizing
143(1)
Lot-Sizing Techniques
144(12)
Lot-Size Adjustments
156(3)
Evaluating Lot-Sizing Techniques
159(2)
Bibliography
161(2)
Chapter 9 System Records and Files
163(18)
The Time-Phased Record
163(6)
Updating Inventory Records
169(5)
The Database
174(2)
Input-Data Integrity
176(2)
Bibliography
178(3)
Part 3 Managing with the MRP System
Chapter 10 A New Way of Looking at Things
181(16)
Planned Versus Actual Manufacturing Lead Time
182(2)
Safety Stock in a New Light
184(3)
A Fresh Look at Queues
187(3)
Work-in-Process Revisited
190(4)
Total Planning Hierarchy
194(2)
Bibliography
196(1)
Chapter 11 Product Definition
197(24)
Assignment of Identities to Inventory Items
199(5)
Product Model Designations
204(3)
Modular Bills of Material
207(9)
Pseudo-BOMs
216(1)
Interface to Order Entry
217(2)
Bibliography
219(2)
Chapter 12 Master Production Schedule
221(24)
Master Production Scheduling Concepts
221(2)
The Final Assembly Schedule
223(2)
Functions of Master Production Scheduling
225(1)
MPS Development
226(6)
Closing the Loop
232(7)
Management and Organizational Aspects
239(4)
Bibliography
243(2)
Chapter 13 More Than an Inventory Control System
245(14)
Use of System Outputs
245(3)
An Inventory Planning and Control System
248(1)
A Priority Planning System
248(7)
Determining Capacity Requirements
255(4)
Chapter 14 System Effectiveness: A Function of Design and Use
259(14)
Critical System Design Features
259(6)
The System and the Inventory Planner
265(8)
Chapter 15 Industry Effect on MRP
273(13)
Project Manufacturing Company
273(3)
Make to Stock
276(4)
Make to Order
280(1)
Assemble to Order
281(1)
Make to Stock/Assemble to Order
282(4)
Chapter 16 Project Manufacturing
Project Life Cycles
286(3)
Projects in MRP
289(1)
Capacity Deployment
290(1)
Material Allocation
291(1)
Summary
292(1)
Project Management Resources
293(2)
Chapter 17 Remanufacturing
295(10)
Remanufacturing Similarities and Differences
296(1)
Managing Remanufacturing Material
297(1)
Remanufacturing Bills of Materials
297(4)
Remanufacturing Routings
301(1)
Remanufacturing Inventory Management
302(2)
Terms Related to the Remanufacturing Industry
304(1)
Chapter 18 Process Industry Application
305(10)
Process Industry Overview
305(3)
Process-Flow Scheduling
308(2)
MRP System Requirements
310(2)
Summary
312(3)
Chapter 19 Repetitive Manufacturing Application
315(14)
General Repetitive Application
315(2)
Kanban
317(2)
Rate-Based Scheduling
319(1)
Production-Sales-Inventory Analysis
320(3)
Backflush
323(2)
Period Costing
325(1)
High-Volume Mixed-Model Manufacturing
325(1)
Configurators
326(1)
Summary
327(2)
Chapter 20 Sales and Operations Planning
329(36)
What's in a Name?
330(1)
Traditional Sales and Operations Planning
331(2)
S&OP, the Unifier-Traditional S&OP Challenged
333(2)
S&OP, the Reconciler and Integrator
335(7)
Knowledge and Know-How Versus Drowning in Data
342(2)
Uncertainty Versus a Single Set of Numbers
344(1)
S&OP as the Aligner to Success and Future Sustainability
345(5)
Discoveries Leading to Breakthrough S&OP
350(2)
Application of S&OP to Various Environments
352(4)
Summary
356(4)
About the Authors
360(1)
Bibliography
361(4)
Part 4 Looking Backward and Forward
Chapter 21 Historical Context
365(20)
Pre-MRP Inventory Control
365(7)
The Story of MRP
372(3)
Evolution of the Art
375(3)
Evolution of MRP and Planning Systems
378(4)
Planning, Execution, and Control
382(3)
Chapter 22 Blueprint for the Future: Demand-Driven MRP Logic
385(6)
The MRP Conflict
386(1)
Demand-Driven MRP Introduction
387(1)
The Five Primary Components of Demand-Driven MRP
388(3)
Chapter 23 Strategic Inventory Positioning
391(14)
ASR Lead Time: A New Type of Lead Time
391(5)
ASRLT and Matrix BOMs
396(9)
Chapter 24 Buffer Profiles and Level Determination
405(18)
Inventory: Asset or Liability Revisited
405(1)
Buffer Profiles
406(6)
Buffer Zones
412(2)
Calculating Buffer Levels
414(4)
Buffer Level Summary
418(4)
Summary
422(1)
Chapter 25 Dynamic Buffers
423(12)
Recalculated Adjustments
423(2)
Planned Adjustments
425(8)
Manual Adjustments
433(2)
Chapter 26 Demand-Driven Planning
435(22)
Part Planning Designations
435(4)
The DDMRP Process
439(1)
Supply Generation for Stocked Items
439(8)
Supply Generation for Nonstocked Items
447(7)
Decoupled Explosion
454(3)
Chapter 27 Highly Visible and Collaborative Execution
457(22)
Challenging Priority by Due Date
457(4)
Buffer Status Alerts
461(10)
Synchronization Alerts
471(5)
Execution Collaboration
476(3)
Chapter 28 Demand-Driven Material Requirements Planning (DDMRP) Performance Reporting and Analytics
479(6)
Oregon Freeze Dry Results
482(1)
LeTourneau Technologies Results
483(2)
Chapter 29 DDMRP Future
485(8)
Research Opportunities
485(4)
Prediction of the Future
489(1)
Success Leveraging Technology
489(4)
Appendix A Joseph Orlicky's Contributions to Material Requirements Planning 493(2)
Appendix B Definitions: APICS Terms and Their Place in DDMRP 495(6)
Appendix C New Terms in Demand-Driven Material Requirements Planning 501(4)
Appendix D To My Best Recollection: The Eras of Material Requirements Planning (MRP) with Packaged Software 505(10)
Index 515
Chad Smith (McKinney, TX) has been programming in [ incr Tcl/Tk] since 1995 and is the lead GUI designer/developer on his current project at ADC Telecommunications. Chad received his BS in Computer Science from the University of Texas at Dallas in 1996 and is currently working towards an MSEE in Telecommunications at Southern Methodist University. Chad was a high school/junior high school teacher for 4 years and is an excellent teacher and communicator.