PRODUCTION MANAGEMENT MRPII GAME TURBIX David CHEN IMS-LAPS, Université Bordeaux 1
TURBIX - Turbix manufactures ‘Réducteurs’ referenced from R1 to R8;
TURBIX ASSEMBLE REDUCTEUR R3
- The “Réducteurs” are composed of two types of parts: E1-E8 manufactured in the TURBIX company, and P1-P5 MACHINING purchased externally. - The parts E1-E8 are manufactured using two types of raw materials: M1 and M2
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Bill of Materials (BOM) Finished products: Manufactured parts: Purchased parts: Raw materials:
R1, R2, R3, R4, R5, R6, R7, R8 E1, E2, E3, E4, E5, E6, E7, E8 P1, P2, P3, P4, P5 M1, M2
R2
R1
R4
R3
1
1
2
1
1
1
1
2
3
1
1
1
E1
E5
P1
P5
E1
E6
E1
E7
P2
P3
E2
E5
1
1
1
1
1
1
1
1
M1
M2
M1
M2
M1
M2
M1
M2
R6
R5
R7
R8
1
2
1
1
1
3
1
1
2
1
1
1
1
E2
E3
E8
P4
E3
E4
E1
E5
P2
E6
P1
P2
P5
1
1
1
1
1
1
1
1
M1
M1
M2
M1
M1
M1
M2
M2
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PHYSICAL FLOW
Turbix
P1 to P5
M1 and M2
TURBIX MACHINING
E1 to E8
TURBIX ASSEMBLE
STOCK P
LINE 1
STOCK E
LINE 2
LINE 3
LINE TEST
STOCK FINISHED PRODUCTS
CUSTOMERS
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STORE OF ITEMS E
STORE OF ITEMS P
STORE EXIT
STORE EXIT
Assembly Shop Rules
LINE 1 Waiting Area
LINE 2 Waiting Area
LINE 3 Waiting Area
PREPARATION
PREPARATION
PREPARATION
- The boxes Store ‘Entry’ and ‘Exit’ represent a delay of one day - The boxes with number represent the path to follow for the lot to be assembled. Each box represents one day of production. - The lot to be manufactured will be placed in the box with the number corresponding to the lot size. A lot progresses one box per day - It is not possible to put two lots in the same boxes - It is not possible to put two lots in the same line simultaneously
LINE TEST Waiting Area
STORE ENTRY
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Determine order point for parts E (January) Items
Cost (euro)
Demand Maxi (per month)
Constraints (Multiple quantity)
Number of delivery (Maxi = 16)
Order quantity
Order point
E1
3
48
12
4
12
24
E2
6
6
6
1
6
3
E3
9
9
6
1
6
5
E4
5
8
6
1
6
4
E5
6
40
4
4
8
20
E6
6
16
4
2
8
8
E7
9
16
4
2
8
8
E8
9
7
4
1
8
4
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Determine order point for parts P (January) Items
Cost (euro)
Demand Maxi (per month)
Constraints (Multiple quantity)
Number of delivery
Order quantity
Order point
P1
2
70
8
3
24
35
P2
1
24
4
2
12
12
P3
1
6
4
1
8
3
P4
3
6
4
1
8
3
P5
0,3
40
4
2
20
20
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INFORMATION FEBRUARY On hand stock
Customer Orders
R1: 11 R2: 5 E1: 14 E2: 5 E3: 0 E4: 12 E5: 15 E6: 4 E8: 4 P1: 22 P2: 16 P3: 2 P4: 4 P5: 20
562 583 560 572 547 548 553 566 546 577
WIP (Work In Progress)
R3: 4, for 06/02 R3: 2, for 06/03 R4: 2, for 16/02 R4: 2, for 20/02 R5: 4, for 16/02 R6: 4, for 04/02 R6: 4, for 11/02 R6: 4, for 01/03 R7: 2, for 09/02 R8: 4, for 11/02
R2: 4 OF16 waited on 06/02 in the box Preparation L1 R3: 4 OF99 waited on 06/02 in Test line Waiting area R6: 4 OF98 waited on 04/02 last day for test
Sale forecasts Week
01/02
06/02
11/02
16/02
01/03
06/03
R1
4
4
4
4
5
5
R2
2
2
2
2
2
2
P5
1
1
1
1
1
1
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Information for parts (E & P) planning (February) On hand inventory at Feb. 1st:
E
E1
E2
E3
E4
E5
E6
E7
E8
Stock
14
5
0
12
15
4
0
4
Constraint
12
6
6
6
4
4
4
4
Work In Progress on Feb. 1st:
Rules for parts E:
- 6 E2 - 12 E3 - 4 E6
- No safety stock - Rule : Coverage (10 working days) - Lead time: 10 working days
order 298 waited for Feb. 6 order 299 waited for Feb. 1 order 300 waited for Feb. 6
On hand inventory at Feb. 1st:
P
P1
P2
P3
P4
P5
Stock
22
16
2
4
20
Constraint
8
4
4
4
4
Work In Progress on Feb. 1st:
Rules for parts E:
No WIP
- Safety stock: P5 = 3 - Rule : Coverage (10 working days) - Lead time: 10 working days MRPII GAME
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Simulation
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FIN Merci pour votre attention MRPII GAME
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INFORMATION (JANUARY) Customer orders at January 1st Order
Quantity
Ref
For
557
2
R2
JAN. 1st
515
1
R6
JAN. 8th
532
4
R8
JAN. 13th
Note: The customers ask immediate delivery for orders of R1 & R2. For R3 to R8, the customer orders received at TURBIX have a lead time of approximately 10 days Information January N°1 MRPII GAME
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INFORMATION (JANUARY) Sale records (last six months)
R1:
between 18 and 21 products per month
R2:
between 6 and 9 products per month
R3 to R8:
Totally for the six references (between 16 and 25 products per month)
Information January N°2 MRPII GAME
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INFORMATION (JANUARY) - Q: the Quantity in stock (S) after a delivery - T: the time of use of Q - DL: the lead time of delivery - D: the average demand
time
Order point Pt = D x DL
Method of Reorder Point Define the inventory level which triggers a purchasing order (or production) This inventory level (recorder point) must satisfy the needs during the lead time Information January N°3 MRPII GAME
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INFORMATION (JANUARY) Monthly demand of Item E (record of the last 6 months)
E1
E2
E3
E4
E5
E6
E7
E8
MINI
40
2
4
4
28
10
10
3
MAXI
48
6
9
8
40
16
16
7
Information January N°5 MRPII GAME
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INFORMATION (JANUARY) Monthly demand of Item P (record of the last 6 months)
P1
P2
P3
P4
P5
MINI
50
16
4
4
20
MAXI
70
24
6
6
40
Information January N°6 MRPII GAME
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INFORMATION (JANUARY) Technical constraints for item E supplying (Manufactured items) The machining shop can provided multiple quantity of: 12 for E1 (one full container) 6 for E2, E3, E4 (one half container) 4 for E5, E6, E7, E8. On the other hand, the machining workshop can not plan more than 16 orders per month (Lead time = 10 days) Information January N°7 MRPII GAME
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INFORMATION (JANUARY) Technical constraints for item P purchasing (Purchased items) The supplier of parts P can deliver the multiple quantity of: 8 for P1 (one full container) 4 for P2, P3, P4, P5 (one half container) Lead time = 10 days Information January N°8 MRPII GAME
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Manage Finished Products (R1 to R8) 1. Rules to produce R1-R8 - R1 and R2 (Delivered without lead time); R3 to R8 (Lead time : 10 days) Rules: R1 and R2: Assembled in advance and stocked; R3 to R8: Assembled to order (no stock) 2° Method to manage the stock of R1 and R2 -> Reorder point method -> Determine Order point (Pt) and Order Quantity (Q) Pt = D x DL D: average demand; DL: Delivery Lead time 3° How to determine D (Average Demand) -> From sale records we know: R1: Maximum sale = 21 per month; R2: Maximum sale = 9 per month -> D (R1) = 21/20 days = 1,1/day; D (R2) = 9/20 days = 0,45/day 4° How to determine de lead time (DL) : Attention: Lead time depends quantity to produce -> First we must determine the quantity (lot size) -> Line 1 load (21 + 9) x 0,5 day = 15 days -> We have 5 days for PREPARATION (Change lot) -> Number of release maximum per month : 5 - By caution we take 4
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