If you run a manufacturing operation, you know how important it is to schedule production and plan capacity efficiently. You need to balance customer demand, inventory levels, resource availability, and operational costs. How can you do that with MRP software and tools?
MRP stands for material requirements planning, a system that helps you calculate the quantity and timing of materials, components, and subassemblies needed for production. MRP software and tools use data from your sales orders, inventory records, master production schedule, and bill of materials to generate purchase orders, work orders, and production plans. MRP can help you reduce waste, avoid stockouts, optimize inventory turnover, and improve customer service.
What I would like to share and probably invest focus is not about only the tool, MRP is always a good tool, but the process of planning and scheduling and the data to leverage the benefits of right planning - higher service levels, higher efficiencies and lowering working capital. We are helping companies to assess and improve the process enabling best data in terms of installed, demonstrated and immediate available capacity. That is the vital game for manufacturing and supply chain value creation.
ERP, MRP, MPS, MES or any other acronyms for digital systems are based on data accuracy. Production planning is based on accurate inventories and proper settled parameters. "Garbage in" will always generate similar outputs. So, take care about the data imput discipline. My opinion ??
To schedule production with MRP, you need to have a master production schedule (MPS) that defines the quantity and timing of finished goods to be produced. The MPS is based on your forecasted and actual customer demand, as well as your production capacity and constraints. MRP software and tools can help you create and update the MPS by analyzing your demand patterns, lead times, safety stocks, lot sizes, and production rates. The MPS is then used to generate the net requirements for each material, component, and subassembly needed for production.
To plan capacity with MRP, you need to have a bill of resources (BOR) that specifies the type and amount of resources required for each production activity. The BOR includes information such as labor hours, machine hours, tooling, energy, and space. MRP software and tools can help you calculate the resource requirements for each production order, based on the BOR and the MPS. The resource requirements are then compared with the available capacity of each resource to identify any gaps or bottlenecks. MRP can also help you adjust the MPS or the BOR to resolve any capacity issues.
MRP can help you schedule production and plan capacity more effectively and efficiently, leading to a number of benefits. It can reduce inventory costs by minimizing excess or obsolete inventory and optimizing inventory levels, as well as improve customer satisfaction by meeting delivery deadlines and reducing backorders. Additionally, MRP can enhance production efficiency by reducing setup times, downtime, and rework, while also supporting strategic decision making with accurate and timely information on demand, supply, and capacity.
MRP is not a perfect system and it has some limitations and challenges. Accurate and updated data from various sources, such as sales, inventory, production, and purchasing, is required for the system to function properly. Additionally, MRP assumes constant demand, lead times, and production rates, which may not reflect the reality of a dynamic and uncertain market. This can cause difficulty in coping with sudden changes in demand or supply or with variability in production performance. Furthermore, complex and detailed plans generated by the MRP may be difficult to communicate and execute due to the lack of consideration for human factors or external factors such as quality, safety, and environmental standards.
El principal reto es la gestión del cambio y capacitación adecuada a todos los actores del proceso, una herramienta es optima si es comprendida y aceptada por quien la ejecuta. adicional es importantes la calidad, el manejo correcto, una definición acertada y la depuración continua de los datos.
The challenges of MRP software is that it's very good in retaining database of parts and FG's but it cannot predict the situation for production, the process interferences and by process phenomenons like parts unable to reach the production line for JIT due to the negligence of the production line employee responsible for managing the line supply.
When searching for the right MRP software and tool for your manufacturing operation, there are many factors to consider. Firstly, you need to ensure the size and complexity of your operation is compatible with the software and tool. Secondly, you must find a solution that is flexible and scalable, so it can adapt to changing needs and grow with your business. Lastly, you should focus on user-friendliness, intuitiveness, customizability, and the availability of adequate training, documentation, and technical support.
Es importante tener la visión del proceso completo incluyendo sus oportunidades de mejora, alcances del proceso, tiempos requeridos, presupuestos asignados, importante elegir herramientas que esten a la vanguardia de las nuevas tecnologias, para no pecar por obsolescia en un corto plazo.
Uma boa análise de demandas, atrelado a um excelente planejamento na gest?o de estoques, com um ótimo planejamento de capacidades de produ??o implantadas a um sistema MRP e se possível a um MPS podemos alcan?ar excelentes resultados. Acima de tudo os dados a serem alimentados no sistema MRP devem ser o mais assertivo possível, pois sem esta condi??o podemos ter um desastre como resultado.
Tenga en cuenta siempre ir de la mano con un equipo de gestión del cambio, para que la solución sea aceptada, la aceptación es el primer paso para que su usabilidad sea la adecuada, de lo contrario sera archivada y el personal seguira en la operatividad y en el desconocimiento.