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Tables of Contents for Mrp and Beyond
Chapter/Section Title
Page #
Page Count
Foreword
xv
George Johnson
Preface
xvii
Acknowledgments
xxi
Introduction
xxiii
Inventory
1
20
Introduction
1
2
Inventory Types
3
7
Raw Materials
3
2
Work in Process (WIP)
5
1
Semifinished Goods
6
1
Finished Goods
7
1
Distribution Inventory
8
1
Maintenance, Repair, and Operational Supplies (MRO)
9
1
Inventory Functions
10
5
Anticipation
10
1
Fluctuation
10
1
Lot size
11
3
Transportation
14
1
Hedge
15
1
Managing Inventory
15
4
Maintaining Inventory Record Accuracy
16
1
Physical Inventory
17
1
Cycle Counting
18
1
Summary
19
2
The Production Plan
21
20
Introduction
21
1
The Production-Planning Process
22
12
Forecasting and the Production Plan
25
1
Representing the Production Plan
26
8
Developing the Production Plan---1,2,3
34
5
Identify Product Families
34
1
Select the Production Plan Unit of Measure
35
1
List Major Customers
36
1
Obtain Historical Sales Data
36
1
Project the Sales Data into the Future
36
1
Define Critical Resources and Calculate Requirements
37
1
Do a Validity Check
37
1
Have the Planning Meeting
37
2
Summary
39
2
Master Production Schedule (MPS)
41
24
Introduction
41
1
Independent and Dependent Demand
42
1
Understanding Lead Time
43
4
Developing the Forecast
47
7
Simple Moving Average
47
1
Weighted Moving Average
48
1
Trend Analysis
49
2
Seasonality
51
2
Selecting a Method
53
1
Evaluating and Using the Forecast
54
5
Error
54
1
Bias
55
1
Standard Error
56
1
Safety Stock
57
2
Developing the Master Schedule
59
5
Determine the Production Environment
59
3
Calculate Total Demand
62
1
Determine Critical Resources and Calculate Loads
62
1
Measure Results
63
1
Summary
64
1
Bills of Material and Resources
65
20
Introduction
65
2
Uses of Bills of Material and Resources
67
2
Defining Products and Resource Needs
67
1
Production Control
68
1
Marketing
69
1
Building the Bill of Material
69
4
Bills of Resource
73
2
Configuration Control
75
7
Making Configuration Changes
76
1
Planning Bills of Material
77
2
Pegging
79
1
Accuracy
80
2
Bill of Material Challenges
82
1
Summary
83
2
Inventory Record Accuracy
85
20
Introduction
85
1
Inventory Record Accuracy
86
4
Cycle Counting
90
2
Cycle Counting Requirements
90
2
Cycle Counting---1,2,3
92
4
Identify ABC groups
92
1
Select a Control Group
93
1
Count the Control Group Repeatedly
93
2
Identify Process Issues
95
1
Correct Process Issues
95
1
Expand to Other Part Numbers
95
1
Continue to Resolve Process Issues
96
1
Selecting Parts to Count
96
3
Calendar Frequency Using ABC Classification
96
1
Order Time
97
1
Receipt Time
97
1
Negative Inventory
97
1
Counting by Location
98
1
Defining Accuracy
99
2
Expected Results of Cycle Counting
101
1
Summary
102
3
Materials Requirements Planning (MRP)
105
16
Introduction
105
1
MRP System Development
106
1
Demand Patterns
107
4
Scheduling Alternatives
111
2
Backward Scheduling
111
1
Forward Scheduling
112
1
Planning the Unknown
113
1
MRP System Requirements
113
3
Master Production Schedule
113
1
Inventory Records
114
1
Unique Item Identification
114
2
Obtaining Quality Output
116
2
Accurate File Data
116
1
Realistic Lead Times
116
1
Inventory Transactions
117
1
Order Independence
117
1
MRP Output
118
1
Summary
118
3
MRP System Definition Refinements
121
20
Introduction
121
1
MRP---A Closer Look
122
8
Gross to Net Calculation
123
3
Low-Level Coding
126
2
Exception Messages
128
1
Pegging
129
1
Net Change/Regenerative MRP
130
1
Lot Sizing
131
7
Lot for Lot (LFL or Discrete)
132
1
Economic Order Quantity
132
4
Order Minimum/Multiple/ Maximum
136
1
Period of Supply (POS)
137
1
Summary
138
3
Working with the Tools
141
16
Introduction
141
1
Planned Orders
142
1
Firm Planned Orders
143
3
Resolving Planner Messages
146
3
Release Purchase Order
146
1
Release Manufacturing Order
147
2
Reschedule Orders
149
1
Planner Message Strategy
149
6
Prioritize Using Low-Level Codes
150
1
Bottom-up Replanning
151
2
Order Release Discipline
153
1
Trust Your Data
154
1
Address Underlying Issues
154
1
Summary
155
2
Capacity Requirements Planning
157
22
Introduction
157
1
Levels of Capacity Planning
158
1
Using Capacity Planning
159
2
Requirements for CRP
161
6
Units of Capacity
161
1
Routings
162
2
Schedule
164
2
Shop Calendar
166
1
Capacity Management Measures
167
3
Available Capacity
167
1
Utilization Factor
167
2
Efficiency
169
1
Rated Capacity
169
1
Scheduling Options
170
5
Backward Scheduling
170
1
Forward Scheduling
170
1
Infinite Loading
171
1
Input/Output Control
172
1
Finite Loading
173
2
Capacity Feedback and Control
175
2
Summary
177
2
The Right Tools for the Job
179
20
Essential Tools
179
6
MRP
181
1
MRP II
182
2
Just in Time (JIT)
184
1
Tools of the 1990s
185
4
Theory of Constraints
185
2
Computer-Integrated Manufacturing (CIM)
187
1
Total Quality Management (TQM)
188
1
ISO 9000
188
1
Combining the Tools
189
1
Tool Application
190
7
Remanufacturing
190
1
Continuous Process
191
1
Batch
192
1
Repetitive Shop
193
1
Project (Complex) Manufacturing
194
1
Job Shop
195
2
Summary
197
2
System Selection and Implementation
199
16
Introduction
199
1
Education
200
1
Training
201
1
Project Plan
202
4
Determine Needs
202
1
Select Software
203
2
Implement the System
205
1
Project Plan---Major Milestones
206
7
Select Project Team
206
1
Install and Test Hardware
207
1
Attend System Training
207
1
Complete Conference Room Pilot
207
2
Set-up Security and Permissions
209
1
Conduct Company-Specific Pilot
209
1
Identify Beginning Pilot
209
1
Enter Static Data
210
1
Enter Dynamic Data
211
1
Document Policies and Procedures
211
1
Cutover
211
2
Celebrate
213
1
Summary
213
2
Beginning the Journey
215
18
Opening the Toolbox
215
4
Developing the Vision
219
1
Creating the Mission Statement
220
2
Building the Strategy
222
4
Strengths
223
1
Weaknesses
223
2
Opportunities
225
1
Threats
226
1
Strategic Plan Focus
226
3
Order Winners
227
1
Order Qualifiers
227
1
Nonissues
228
1
Strategy Statement
229
1
Organizational Structure
229
1
Tactical Tools
230
1
Summary
231
2
References
233