What is a master production schedule MPS and what are the da

What is a master production schedule (MPS), and what are the data inputs and outputs to a MPS? What are bill of materials (BOMs)? Also, what is the material requirements planning (MRP) process and when should it be used? Reference

Solution

Master Production Schedule (MPS) :-

The master production schedule is effectively the plan that the company has developed for production, staffing, inventory, etc.

It sets the quantity of each end item to be completed in each week of a short-range planning horizon. A Master Production Schedule is the master of all schedules. It is a plan for future production of end items.

MPS Inputs :-

MPS Outputs :-

Bill Of MAterials (BOM) :-

It is a list of the raw materials, sub-assemblies, intermediate assemblies, sub-components, parts and the quantities of each needed to manufacture an end product.

Types of BOMs :-

Modular BOM :-

BOMs are of hierarchical nature, with the top level representing the finished product which may be a sub-assembly or a completed item. BOMs that describe the sub-assemblies are referred to as modular BOMs.

Configurable BOM :-

A configurable bill of materials (CBOM) is a form of BOM used by industries that have multiple options and highly configurable products (e.g. telecom systems, data-center hardware (SANS, servers, etc.), PCs, autos).

Multi-level BOM :-

A Multi-Level Bill of Materials (BOM), or referred as an indented BOM, is a bill of materials that lists the components, assemblies, and parts required to make a product.

Material Requirements Planning (MRP) :-

Material Requirements Planning (MRP) is a computer-based production planning and inventory control system. MRP is concerned with both production scheduling and inventory control.

It is a material control system that attempts to keep adequate inventory levels to assure that required materials are available when needed.

MRP is applicable in situations of multiple items with complex bills of materials. MRP is not useful for job shops or for continuous processes that are tightly linked.

The major objectives of an MRP system are to simultaneously:

1. Ensure the availability of materials, components, and products for planned production and for customer delivery,

2. Maintain the lowest possible level of inventory,

3. Plan manufacturing activities, delivery schedules, and purchasing activities

The MRP Process :-

Starting with end items the MRP process goes through the following steps :-

1. Establish gross requirements.

2. Determine net requirements by subtracting scheduled receipts and on hand inventory from the gross requirements

3. Time phase the net requirements.

4. Determined the planned order releases.

MRP applications in services may involve material goods that form a part of the product-service package, or they may involve mainly service components.

An example of a product-service package is a food catering service. To estimate quantities and costs of an order, the food manager would have to determine the quantities of the ingredients for each recipe on the menu (i.e., a bill of material), which would then be combined with the number of each meal to be prepared to obtain a material requirement plan for the event.

In order to implement and operate an effective MRP system, it is necessary to have:

References :-

\"Super BOM\". SAP ERP 6.0. SAP. 2012. Archived from the original on 2012-07-17. Retrieved 2012-07-17.

Volman, T, E, Berry, W.L., and Whybark, D.C. (1992) Manufacturing Planning and Control Systems, Third Edition, IRWIN, Burr Ridge, IL.