Page 52 - MetalForming September 2016

MRP
materials in stock and finished products awaiting distribution. A lack of proper MRP processes jeopardizes the ability to reliably and consistently manufacture products in a timely and efficient manner.
Bad Data
Can Undermine the System
Data integrity lies at the root of most MRP problems. The classic piece of computer conventional wisdom still holds true: Garbage in, garbage out. Any discrepancies in inventory data, bill-of-material (BOM) data or the mas- ter production schedule will result in faulty output data.
Data integrity also can be compro- mised by inaccurate cycle-count adjustments, mistakes in receiving input and shipping output, scrap not reported, waste, damage, box-count errors, supplier-container errors, pro- duction-reporting errors, and general system issues. Many of these data errors can be minimized by imple- menting pull systems and using bar- code scanning. Most MRP experts rec-
MRP Must-Haves
To ensure an optimal process, an MRP system should have the follow- ing capabilities:
• Inventory management
• Production definition and costing
• Master scheduling
• Capacity planning
• Work-order management
• Purchase-order management
• Sales-order management
a solid commitment from top manage- ment and proper education of the exec- utives and workforce tasked with using it as a strategic-planning tool and day- to-day operational resource. Several potential issues can be stumbling blocks to successful implementation.
Proper MRP implementation starts with avoiding incorrect or obsolete MRP policies. ERP and MRP systems essen- tially are sophisticated calculators, uti- lizing mathematical inputs to determine how much stock to buy and keep in inventory, how long lead times should be and other policies affecting the man-
• Shipping and receiving • Sales analysis
ommend data integrity of at least 99 percent in order for an MRP system to
provide useful and effective results.
MRP Implementation: Avoid These Problems
Implementing an MRP system can challenge any organization. It requires
Just go to
a
some planners “set ‘em and forget ‘em.”
They set up the system to manufacture
a certain product, input some numbers
that may or may not be based in reality,
and then never revisit the numbers once they’re in place. Incorrect inputs will deliver faulty planning.
Even with correct policies in place, companies can stumble because key personnel lack an understanding of planning fundamentals. Proper MRP is
Stay informed of the latest occurrences within
ufacturing operation. Unfortunately,
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50 MetalForming/September 2016
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