Manufacturing And Assembly Material Requirements Planning Training

Objectives:
• Understand the purpose and benefits of MRP in manufacturing.
• Identify the key inputs and outputs of an MRP system.
• Explain the role of MRP in inventory management and production planning.
• Differentiate between dependent and independent demand.

Topics:
• Overview of manufacturing planning and control.
• Definition and objectives of MRP.
• Key inputs: Bill of Materials (BOM), Master Production Schedule (MPS), Inventory Records.
• Dependent vs. independent demand.
• MRP outputs: Planned orders, order releases, rescheduling notices.
• Benefits of MRP: reduced inventory, improved efficiency.

Objectives:
• Define and construct a Bill of Materials (BOM).
• Understand different BOM types (single-level, multi-level, indented).
• Explain the relationship between BOM and product structure.
• Apply BOM explosion to determine component requirements.

Topics:
• BOM definitions and types.
• Product structure trees and levels.
• Creating and reading a multi-level BOM.
• BOM explosion process.
• Using BOM for cost estimation and planning.
• Common BOM errors and how to avoid them.

Objectives:
• Define the Master Production Schedule (MPS) and its role.
• Develop an MPS from customer orders and forecasts.
• Understand time fences and planning horizons.
• Apply MPS to drive MRP calculations.

Topics:
• Purpose of MPS in manufacturing.
• MPS inputs: forecasts, orders, capacity constraints.
• Time fences: demand, planning, and frozen.
• MPS creation process.
• MPS vs. aggregate planning.
• Using MPS to generate gross requirements.

Objectives:
• Understand the importance of accurate inventory records.
• Explain cycle counting and physical inventory methods.
• Calculate safety stock and reorder points.
• Apply inventory valuation methods (FIFO, weighted average).

Topics:
• Inventory record accuracy requirements.
• Cycle counting vs. physical inventory.
• ABC classification and its impact on counting frequency.
• Safety stock calculation.
• Reorder point (ROP) and economic order quantity (EOQ).
• Inventory valuation methods and their effect on MRP.

Objectives:
• Perform MRP net requirements calculations step-by-step.
• Understand gross requirements, scheduled receipts, and on-hand inventory.
• Calculate planned order releases and order quantities.
• Interpret MRP grids and reports.

Topics:
• MRP logic: gross to net requirements.
• Scheduled receipts and planned orders.
• Lot-sizing techniques: lot-for-lot, fixed order quantity, period order quantity.
• MRP grid example: manual calculation.
• Lead time offsetting.
• Rescheduling and exception messages.

Objectives:
• Explain the relationship between MRP and Capacity Requirements Planning (CRP).
• Calculate capacity requirements from planned orders.
• Identify capacity constraints and bottlenecks.
• Apply rough-cut capacity planning (RCCP) techniques.

Topics:
• Overview of CRP and its inputs.
• Load profiles and capacity calculations.
• Rough-cut capacity planning (RCCP).
• Capacity vs. load analysis.
• Bottleneck identification and management.
• Adjusting MPS or capacity to resolve issues.

Objectives:
• Outline steps for implementing an MRP system.
• Identify critical data integrity requirements.
• Understand the role of software in MRP.
• Discuss common implementation challenges and solutions.

Topics:
• Implementation phases: planning, data collection, testing, go-live.
• Data integrity: BOM accuracy, inventory accuracy, MPS stability.
• MRP software features and selection criteria.
• Change management and training.
• Pitfalls: garbage in, garbage out (GIGO).
• Case studies of successful implementations.

Objectives:
• Explore MRP II and its evolution to ERP.
• Understand closed-loop MRP concepts.
• Discuss integration with purchasing, production, and finance.
• Analyze MRP performance metrics.

Topics:
• MRP II: Manufacturing Resource Planning.
• Closed-loop MRP: feedback from shop floor and suppliers.
• Integration with purchasing and supplier scheduling.
• Integration with production activity control (PAC).
• Financial integration: cost accounting and budgeting.
• MRP performance metrics: inventory turnover, schedule adherence.

Objectives:
• Apply MRP concepts in a simulated manufacturing scenario.
• Complete a comprehensive MRP exercise from MPS to planned orders.
• Troubleshoot common MRP issues.
• Demonstrate understanding through a final assessment.

Topics:
• Hands-on MRP simulation using a case study.
• Complete MRP run: BOM explosion, net requirements, lot sizing, CRP.
• Review of exception messages and corrective actions.
• Group exercise: MRP system design recommendations.
• Final assessment: multiple-choice and practical problems.
• Course wrap-up and Q&A.