PRODUCTION MANAGEMENT MRPII GAME

placed in the box with the number corresponding to the lot size. A lot progresses one box per day. - It is not .... Totally for the six references (between 16 and 25.
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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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