1. COMPUTER INTEGRATED MANUFACTURING
Unit – 2 / Topic :4
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ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

2. Materials Requirement Planning
TOPICS TO BE DISCUSSED
Materials Requirement Planning
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ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech 2

3. PRODUCTION PLANNING
It is a pre-production activity. It is the pre-determination of
manufacturing requirements such as manpower,
machines and manufacturing process.
Activities of Production Planning
Aggregate production planning
Master Production Schedule
Material Requirement Planning(MRP)
Capacity Planning
materials,
8/1/2017
ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

4. Inputs & Outputs from APP
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ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

5. Master Production Schedule
Intermediate planning stage next to Aggregate Production Planning
The Aggregate plan is to be disaggregated (broke into parts) to include information about the different models of the product to be produced
Master Production Schedule also known as MPS or Master Schedule is the result of disaggregation of an aggregate plan
8/1/2017
ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

6. Master Production Schedule
Month
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
No. of
Motors 75 60 80 40 50 55
MASTER PRODUCTION SCHEDULE
AC 5 Hp 25 10 5 -
AC 25 Hp 30 15 20
DC 20 Hp
DC 10 Hp
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ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

7. Objectives of MPS To Schedule end items to be completed
promptly and when promised to customers
To avoid overloading or under loading the production facility so that production capacity is efficiently utilized and results in low production cost
8/1/2017
ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

8. Functions of MPS To translate aggregate plans into specific end terms
To evaluate alternate schedules
To generate material requirement
To generate capacity requirements
To facilitate information processing
To maintain valid priorities
To effectively utilize capacity
8/1/2017
ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

9. 8/1/2017
ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

10. Materials Requirement Planning
MRP-I converts the Master Schedule into a detailed schedule for the raw materials and parts used in the final products
It identifies the quantities of each raw
material and part items
It indicates when each item must be ordered and delivered so as to meet the master schedule for the final products
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ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

11. Inputs to MRP Master Production Schedule Bill of materials file and
Inventory record file
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ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

12. 8/1/2017
ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

13. Bill of Materials
Bill of Materials designates what items and how many of each are used to make up a specified final product
BOM file is used to compute the raw materials and component requirement for each products listed in the master schedule
Provides information on the product structure by listing the component parts and sub assemblies
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ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

14. BOM - Sample
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15. Inventory Record file
Item master data segment : provides item identification by part number and other data like lead time, cost and quantity
Inventory status data: provides a time-phased
record of inventory status
Subsidiary data segment: provides subsidiary data like purchase orders, scrap or rejects, engineering changes etc
8/1/2017
ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

16. Inventory Record - Sample
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17. MRP Output Report
Primary Output Report: Order release notice Planned order release report Rescheduling notices Cancellation notices
Report on inventory status
Secondary Output Report: Performance report Inventory forecasts
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ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech

18. Benefits of MRP Reduced inventory levels Better production schedule
Reduced production lead time
Reduced setup time & cost
Reduced product changeover cost
Improved product quality
Quicker response to change in demand
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ME 6703/ CIMS / UNIT- 2 / Mr.B.Balamurali/ AP / Mech