Foreword |
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xiii | |
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Preface |
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xv | |
Part 1 Perspective |
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3 | (8) |
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3 | (3) |
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Focus and Organization of This Book |
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6 | (3) |
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9 | (2) |
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Chapter 2 MRP in the Modern World |
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11 | (14) |
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Key Questions for Planning and flexibility |
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15 | (1) |
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15 | (8) |
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Materials or Capacity: Where to Focus First? |
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23 | (2) |
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Chapter 3 The Four Critical Questions Answered |
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25 | (18) |
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Question 1: Relevance of MRP |
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25 | (2) |
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Question 2: MRP-Flawed Approach or Poorly Applied? |
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27 | (10) |
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Question 3: The MRP Conflict with Lean or Pull |
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37 | (3) |
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Question 4: MRP Progress in the Last 30 Years? |
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40 | (3) |
Part 2 Concepts |
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Chapter 4 Inventory in a Manufacturing Environment |
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43 | (40) |
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Manufacturing Inventories |
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43 | (2) |
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45 | (3) |
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The Logic of Manufacturing |
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48 | (1) |
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Order-Point Versus MRP Systems |
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49 | (10) |
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The Paradox of Inventory Management |
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59 | (19) |
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A Distribution Positioning Example |
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78 | (2) |
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80 | (1) |
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81 | (2) |
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Chapter 5 Principles of Materials Requirements Planning |
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83 | (12) |
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83 | (2) |
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Inventory System Categories |
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85 | (2) |
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Prerequisites and Assumptions of MRP |
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87 | (1) |
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88 | (1) |
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89 | (3) |
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Applicability of MRP Methods |
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92 | (2) |
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94 | (1) |
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Chapter 6 The Material Requirements Planning System |
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95 | (20) |
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95 | (2) |
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The Purpose of the System |
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97 | (2) |
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System Inputs and Outputs |
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99 | (3) |
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Factors Affecting the Computation of Requirements |
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102 | (13) |
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Chapter 7 Processing Logic |
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115 | (28) |
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115 | (3) |
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Techniques of Time Phasing |
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118 | (2) |
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Gross and Net Requirements |
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120 | (5) |
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Coverage of Net Requirements |
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125 | (3) |
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Explosion of Requirements |
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128 | (6) |
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134 | (3) |
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Entry of External-Item Demand |
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137 | (3) |
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140 | (2) |
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142 | (1) |
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143 | (20) |
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143 | (1) |
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144 | (12) |
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156 | (3) |
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Evaluating Lot-Sizing Techniques |
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159 | (2) |
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161 | (2) |
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Chapter 9 System Records and Files |
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163 | (18) |
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163 | (6) |
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Updating Inventory Records |
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169 | (5) |
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174 | (2) |
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176 | (2) |
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178 | (3) |
Part 3 Managing with the MRP System |
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Chapter 10 A New Way of Looking at Things |
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181 | (16) |
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Planned Versus Actual Manufacturing Lead Time |
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182 | (2) |
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Safety Stock in a New Light |
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184 | (3) |
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187 | (3) |
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Work-in-Process Revisited |
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190 | (4) |
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194 | (2) |
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196 | (1) |
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Chapter 11 Product Definition |
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197 | (24) |
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Assignment of Identities to Inventory Items |
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199 | (5) |
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Product Model Designations |
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204 | (3) |
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Modular Bills of Material |
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207 | (9) |
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216 | (1) |
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217 | (2) |
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219 | (2) |
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Chapter 12 Master Production Schedule |
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221 | (24) |
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Master Production Scheduling Concepts |
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221 | (2) |
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The Final Assembly Schedule |
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223 | (2) |
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Functions of Master Production Scheduling |
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225 | (1) |
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226 | (6) |
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232 | (7) |
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Management and Organizational Aspects |
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239 | (4) |
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243 | (2) |
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Chapter 13 More Than an Inventory Control System |
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245 | (14) |
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245 | (3) |
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An Inventory Planning and Control System |
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248 | (1) |
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A Priority Planning System |
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248 | (7) |
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Determining Capacity Requirements |
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255 | (4) |
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Chapter 14 System Effectiveness: A Function of Design and Use |
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259 | (14) |
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Critical System Design Features |
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259 | (6) |
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The System and the Inventory Planner |
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265 | (8) |
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Chapter 15 Industry Effect on MRP |
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273 | (13) |
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Project Manufacturing Company |
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273 | (3) |
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276 | (4) |
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280 | (1) |
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281 | (1) |
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Make to Stock/Assemble to Order |
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282 | (4) |
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Chapter 16 Project Manufacturing |
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286 | (3) |
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289 | (1) |
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290 | (1) |
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291 | (1) |
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292 | (1) |
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Project Management Resources |
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293 | (2) |
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Chapter 17 Remanufacturing |
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295 | (10) |
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Remanufacturing Similarities and Differences |
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296 | (1) |
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Managing Remanufacturing Material |
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297 | (1) |
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Remanufacturing Bills of Materials |
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297 | (4) |
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301 | (1) |
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Remanufacturing Inventory Management |
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302 | (2) |
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Terms Related to the Remanufacturing Industry |
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304 | (1) |
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Chapter 18 Process Industry Application |
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305 | (10) |
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Process Industry Overview |
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305 | (3) |
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308 | (2) |
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310 | (2) |
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312 | (3) |
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Chapter 19 Repetitive Manufacturing Application |
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315 | (14) |
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General Repetitive Application |
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315 | (2) |
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317 | (2) |
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319 | (1) |
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Production-Sales-Inventory Analysis |
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320 | (3) |
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323 | (2) |
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325 | (1) |
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High-Volume Mixed-Model Manufacturing |
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325 | (1) |
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326 | (1) |
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327 | (2) |
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Chapter 20 Sales and Operations Planning |
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329 | (36) |
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330 | (1) |
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Traditional Sales and Operations Planning |
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331 | (2) |
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S&OP, the Unifier-Traditional S&OP Challenged |
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333 | (2) |
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S&OP, the Reconciler and Integrator |
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335 | (7) |
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Knowledge and Know-How Versus Drowning in Data |
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342 | (2) |
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Uncertainty Versus a Single Set of Numbers |
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344 | (1) |
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S&OP as the Aligner to Success and Future Sustainability |
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345 | (5) |
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Discoveries Leading to Breakthrough S&OP |
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350 | (2) |
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Application of S&OP to Various Environments |
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352 | (4) |
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356 | (4) |
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360 | (1) |
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361 | (4) |
Part 4 Looking Backward and Forward |
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Chapter 21 Historical Context |
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365 | (20) |
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Pre-MRP Inventory Control |
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365 | (7) |
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372 | (3) |
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375 | (3) |
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Evolution of MRP and Planning Systems |
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378 | (4) |
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Planning, Execution, and Control |
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382 | (3) |
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Chapter 22 Blueprint for the Future: Demand-Driven MRP Logic |
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385 | (6) |
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386 | (1) |
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Demand-Driven MRP Introduction |
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387 | (1) |
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The Five Primary Components of Demand-Driven MRP |
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388 | (3) |
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Chapter 23 Strategic Inventory Positioning |
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391 | (14) |
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ASR Lead Time: A New Type of Lead Time |
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391 | (5) |
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396 | (9) |
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Chapter 24 Buffer Profiles and Level Determination |
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405 | (18) |
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Inventory: Asset or Liability Revisited |
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405 | (1) |
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406 | (6) |
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412 | (2) |
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Calculating Buffer Levels |
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414 | (4) |
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418 | (4) |
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422 | (1) |
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Chapter 25 Dynamic Buffers |
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423 | (12) |
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423 | (2) |
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425 | (8) |
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433 | (2) |
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Chapter 26 Demand-Driven Planning |
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435 | (22) |
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Part Planning Designations |
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435 | (4) |
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439 | (1) |
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Supply Generation for Stocked Items |
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439 | (8) |
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Supply Generation for Nonstocked Items |
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447 | (7) |
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454 | (3) |
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Chapter 27 Highly Visible and Collaborative Execution |
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457 | (22) |
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Challenging Priority by Due Date |
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457 | (4) |
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461 | (10) |
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471 | (5) |
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476 | (3) |
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Chapter 28 Demand-Driven Material Requirements Planning (DDMRP) Performance Reporting and Analytics |
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479 | (6) |
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Oregon Freeze Dry Results |
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482 | (1) |
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LeTourneau Technologies Results |
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483 | (2) |
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485 | (8) |
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485 | (4) |
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489 | (1) |
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Success Leveraging Technology |
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489 | (4) |
Appendix A Joseph Orlicky's Contributions to Material Requirements Planning |
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493 | (2) |
Appendix B Definitions: APICS Terms and Their Place in DDMRP |
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495 | (6) |
Appendix C New Terms in Demand-Driven Material Requirements Planning |
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501 | (4) |
Appendix D To My Best Recollection: The Eras of Material Requirements Planning (MRP) with Packaged Software |
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505 | (10) |
Index |
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515 | |