Handbook of MRP II and JIT: strategies for total manfacturing control
Saved in:
| Main Author: | |
|---|---|
| Format: | Book |
| Language: | English |
| Published: |
Englewood Cliffs, NJ
Prentice Hall
1993
|
| Subjects: | |
| Online Access: | Inhaltsverzeichnis |
| Physical Description: | XXII, 447 S. graph. Darst. |
| ISBN: | 0133741583 |
Staff View
MARC
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| adam_text | Table of Figures
Figure Title Pages
1.1 Average Scores of Past Winners of the
Malcolm Baldrige Award 11
2.1 End Item Demand Planning Cycle 23
2.2 Strategic Product Plan 25
2.3 Marketing Plan—Heavy Duty 34
2.4 Consumption Rule 1: Manufacture the
Forecast 39
2.5 Consumption Rule 2: Manufacture to
Order 39
2.6 Consumption Rule 3: Using a Time
Fence 40
2.7 Consumption Rule 4: Firmed Capacity
Inside of Time Fence 42
2.8 Consumption Rule 5: Manufacture the
Higher of Forecast or Actual 43
2.9 Calculating Mean Absolute Deviation
(MAD) 44
2.10 Calculating Tracking Signal 45
2.11 Distribution Requirements Planning 1
(DRP) 47
2.12 Distribution Requirements Planning 2 48
2.13 Time Phased Order Point 50
3.1 Pick List 55
3.2 Reorder Point and Safety Stock Model 58
3.3 Production Plan 64
3.4 Partial Production Plan for Rough Cut
Capacity Planning 77
3.5 Rough Cut Capacity Bill of Load Units 77
3.6 Rough Cut Capacity Load—Final
Assembly Department 79
3.7 Rough Cut Capacity Load—Frame Vendor 80
3.8 Rough Cut Capacity Load—Standard Cost 81
ziii
Xiv TABLE OF FIGURES
3.9 Rough Cut Capacity Load—Selling Price 83
3.10 Independent vs. Dependent Demand 86
3.11 MRP Planning Logic 88
3.12 Simple Bill of Material 89
3.13 Full Planning for Item A, Gross
Requirements for Items B and C 90
3.14 Full Planning for Items B and C. Gross
Requirements for D and E 92
3.15 Full Planning for Items D and E, Gross
Requirements for F and G 93
3.16 Full Planning for Items F and G 94
3.17 Winch with Modular Building Blocks 96
3.18 Detailed Capacity Plan 99
3.19 Input/Output Control 103
3.20 Work Center Dispatch List 105
5.1 Tabulated Drawing Where Drawing
Number is the Same as Part No. 135
5.2 Tabulated Drawing Where Drawing
Number is Independent of Part No. 136
5.3 End Item Bill of Material 155
5.4 Modular Bill of Material 158
5.5 Accessories and Options Bill of
Material 159
5.6 Family Bill of Material 160
6.1 Manufacturing Environments 173
7.1 Implementation Fast Track to Success 188
7.2 Program Evaluation Form 211
8.1 The Formal Business System 219
8.2 Disaggregating the Production Plan 222
8.3 Planning Bill—Boy s Dirt Bicycle 227
8.4 Accessories and Options Bill for a
Camera 228
8.5 Planning Worksheet 238
8.6 Make to Stock Plan 242
8.7 Make to Order Plan 248
8.8 Assemble to Order Plan 251
8.9 Master Production Schedule Time
Fences 254
8.10 Detail of Unit Load Requirements 256
8.11 Unit Load Profiles 257
TABLE OF FIGURES XV
8.12 Rough Cut Capacity Load Report 258
8.13 The Focal Point of the Master
Scheduler 261
9.1 Daily Queues in Hours 275
10.1 Conventional Job Shop Layout 291
10.2 Group Technology Layout 291
10.3 The Manufacturing Universe 298
10.4 Primary Metals 299
10.5 Commodities 300
10.6 Piece Parts 301
10.7 Typical Machined Component 301
10.8 Classifying a Typical Machined
Component 302
10.9 Brisch Birn System Example 303
10.10 CODE System Example 304
10.11 MICLASS System Example 305
10.12 TEKLA System Example 305
10.13 Opitz System Example 306
10.14 Accessories and Options 308
11.1 Fabricated Stud 324
11.2 Stud Frequency Distribution 325
11.3 Stud Histogram 325
11.4 Stud Histogram with Standard
Deviations 326
11.5 Stud Sample Measurements 327
11.6 Computing Control Limits 327
11.7 Stud Control Chart 328
11.8 Shift 329
11.9 Trend 330
11.10 Periodicity 331
11.11 Hugging 332
11.12 Point Beyond a Control Limit 333
11.13 Mixed Model Final Assembly Schedule 335
11.14 Ratio of Engineering Changes to Units
Produced—Japan 338
11.15 Ratio of Engineering Changes to Units
Produced—U.S.A. 339
11.16 Flow Progress Chart 350
1.1 Reorder Point Cycle 382
II. 1 Fixed Order Quantity 387
XVi TABLE OF FIGURES
11.2 Economic Order Quantity (EOQ) 388
11.3 EOQ (Economic Order Quantity) 390
11.4 Period Order Quantity 391
11.5 Lot for Lot 392
11.6 Least Unit Cost 393
11.7 Calculation of Lot Sizes in Figure II.6 394
11.8 Least Total Cost 395
11.9 Calculation of Lot Sizes in Figure II.8 396
III. 1 Calculating Control Factors for an
Independent Demand Item 404
111.2 Safety Factors for Calculating Safety
Stock 405
111.3 Safety Factor vs. Service Level 406
111.4 Safety Stock Study Before Adjustment 408
HI.5 Safety Stock Study After Adjustment 409
IV. 1 Typical ABC Distribution Pattern 412
IV.2 ABC Analysis 413 15
V.I Forecast Aggregation Pyramid 419
V.2 Integrated Feedback Loop 429
V.3 Selecting a Technique Based on
Purpose 430
V.4 Typical Product Life Cycle 432
V.5 Suggested Forecasting Techniques 432
V.6 Service Life Cycle 433
V.7 The Normal Distribution Curve 434
V.8 Analysis of Tracking Signal 437
TABLE OF CONTENTS
What This Handbook Will Do for You v
CHAPTER 1. Keys to Achieving World Class
Manufacturing Management 1
How to Stay Ahead of Your Competition (2)
Really Know What Your Competition Is Talking
About (5)
How to Implement Total Management: Being
Oriented Around One Department Is Doomed (13)
How to Ask for What You Want and Measure
It—Send the Right Signals (14)
How to Manufacture Your Master Production
Schedule—Every Day (15)
How to Use Exception Reports to Stay on
Schedule (17)
Six Steps to Make Your System Permanent (19)
Chapter 2. How to Plan the Right Things by Managing
Your Demands 21
Getting Started with a Strategic Product Plan (22)
How to Guide Product Strategy by Developing a
Marketing Plan (31)
How to Use the Sales Plan to Accommodate the
Present Production Schedule (37)
How to Use Distribution Requirements Planning
to Manage Finished Goods Inventory (46)
How to Use the Time Phased Order Point to
Manage Service Parts (49)
Chapter 3. How to Make the Right Things by Managing
Supplies xvii
XVill TABLE OF CONTENTS
How to Use the Reorder Point and Safety Stock
System (56)
How to Use the Launch and Expedite System (58)
How to Establish Your Production Plan for What
You Want to Manufacture (62)
How to Manage the Production Plan (67)
How the Master Production Schedule Tells What to
Make, Where, and When (70)
How to Use the Rough Cut Capacity Plan to
Manage Your Vendor and Manufacturing
Resources (75)
How to Use Your Material Requirements Plan to
Synchronize Buying and Manufacturing (84)
How to Use a Final Assembly Schedule to Ship the
Right Things (95)
How to Fine Tune with the Detailed Capacity
Plan (98)
How to Fulfill the Plan by Metering Out the
Work (101)
How to Use Input Output Control (102)
How to Reduce Throughput Time—The Fast
Factory (106)
Chapter 4. How to Integrate Accounting into Your
New System 109
How to Record Receipts (110)
How the Three Way Match Has Become
Obsolete (114)
Recognizing When Traditional Accounting
Orthodoxies Are Being Challenged (115)
How to Implement Activity Based Costs (ABC) (117)
How to Reconcile Accounting Rules with New Age
Accounting (122)
Chapter 5. Rules to Ensure a Successful MRP Based
System 123
Stop Abusing Your Master Production
Schedule (124)
How to Make Your Item Numbers Work (125)
TABLE OF CONTENTS Xix
How to Get the Most from Your Item Master
File (141)
How to Make One Bill of Material Support
Everybody (152)
How to Manage Your Designs with Engineering
Change Control (162)
How to Define Your Work Centers (168)
How to Make It the Same Way Every Time by
Using Process and Routing (169)
Chapter 6. How to Prepare for Implementation of
the MRP II System 171
How to Analyze Your Business Needs (172)
How to Demonstrate Management s Dedication to
MRP (178)
How to Assemble Your Project Team (180)
How to Select a Steering Committee (181)
How to Organize for Success (184)
Chapter 7. How to Execute a Sound Implementation
of the MRP II System 187
How to Make and Use a Time Phased
Implementation Plan (187)
How to Start Operating Your New System (196)
How to Select Software that Suits Your
System (201)
Eleven Steps to Selecting Good Software (202)
How to Plan Your Education and Training (207)
Chapter 8. How to Manage with Your Master
Schedule 213
Three Goals of Master Scheduling (214)
How to Use Aggregate Planning in Developing the
Production Plan (217)
Preparing the Master Production Schedules by
Disaggregating the Production Plan (221)
How to Determine What Can or Should be Master
Scheduled (223)
XX TABLE OF CONTENTS
Identifying Types of MPS Items (225)
How the Master Planning Environment Affects the
Master Schedule (231)
How to Apply the Logic of Item Master
Scheduling (235)
How to Use Cumulative Lead Time and Fences in
Planning (253)
How to Use Rough Cut Capacity Planning with
Load Profiles (255)
Defining the Role of the Master Scheduler (259)
Conclusion (269)
Chapter 9. Managing Your Inventory
Investment 271
How Zero Inventory Improves Performance (271)
How to Minimize Purchased, Work in Process.
Semi Finished, and Finished Goods
Inventory (273)
How to Craft the Right Location Control
Techniques (277)
How to Achieve 95 Percent Inventory Accuracy with
Cycle Counting (279)
How to Set Goals, Measure Inventory Turns, and
Attack Excess and Obsolete Inventory (282)
How to Choose and Use Lot Sizing Rules (284)
Chapter 10. How to Incorporate Group Technology
and Standardization 289
How Group Technology Work Centers Outperform
the Traditional Job Shop Layout (290)
How to Analyze the Disadvantages of Group
Technology (294)
How to Analyze Your Manufactured Items Using
the Classification Coding Method (295)
How to Include Standardization in Your
System (302)
How to Accommodate Features and Options Within
Group Technology (307)
TABLE OF CONTENTS xxi
How to Integrate Group Technology with
MRP/JIT (308)
How to Eliminate the Fixation on Direct
Labor (310)
How to Link Group Technology into Cost
Accounting (310)
Conclusion (311)
Chapter 11. How to Apply Justin Time (JIT)
Ideas 313
How to Apply JIT to Material Control (314)
How to Apply JIT in Production Control (319)
How to Apply JIT to Engineering (336)
Three Changes You Need to Make in Your
Traditional Administrative Rules (342)
How Management Needs to Change to Implement
JIT (345)
How to Use Time Compression, the New
Competitive Tool (349)
Examining the Disadvantages of JIT (352)
Chapter 12. How to Implement a Program for
Continuous Improvement 357
How to Develop a Change Receptive
Environment (358)
How to Make MRP/JIT Part of Your Company Wide
Mission (363)
How to Develop World Class Goals (367)
Six New Measures You Can Start (369)
How to Make the Quest for Improvement
Permanent (375)
Appendix I. How to Calculate Reorder Points .... 381
How it Works (381)
Assumptions and Problems (383)
The Two Bin Variation (384)
Appendix II. How to Calculate and Use Lot
Sizes 385
XXii TABLE OF CONTENTS
Fixed Order Quantity (386)
EOQ (Economic Order Quantity) (387)
Period Order Quantity (390)
Lot for Lot (392)
Least Unit Cost (393)
Least Total Cost (394)
The Part Period Balancing Formula (395)
Other Lot Sizing Formulas (397)
Lot Size Modifiers (397)
How to Choose the Right Formula (397)
Beware of Nervousness (399)
Appendix III. How to Manage Safety Stocks .... 401
Why Have Safety Stock? (402)
Safety Stock to Cover Forecast Error (402)
Safety Stock to Cover Other Problems (407)
Appendix IV. How to Do an ABC Analysis 411
What Is an ABC Analysis? (411)
Calculating an ABC Analysis (411)
Using an ABC Analysis (412)
Appendix V. Forecasting 417
How to Prepare a Forecast (417)
What You Should Forecast (420)
Approaches to Forecasting (420)
Forecasting Techniques Defined (421)
How to Select the Right Forecasting
Technique (428)
Product Life Cycle (431)
Service Parts (433)
Forecast Accuracy (434)
Conclusion (436)
Index 439
|
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| id | DE-604.BV008330203 |
| illustrated | Illustrated |
| indexdate | 2024-07-09T17:18:25Z |
| institution | BVB |
| isbn | 0133741583 |
| language | English |
| oai_aleph_id | oai:aleph.bib-bvb.de:BVB01-005502810 |
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| physical | XXII, 447 S. graph. Darst. |
| publishDate | 1993 |
| publishDateSearch | 1993 |
| publishDateSort | 1993 |
| publisher | Prentice Hall |
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| spelling | Petroff, John N. Verfasser aut Handbook of MRP II and JIT strategies for total manfacturing control John N. Petroff Englewood Cliffs, NJ Prentice Hall 1993 XXII, 447 S. graph. Darst. txt rdacontent n rdamedia nc rdacarrier Just-in-time-productie gtt Logistiek (economie) gtt Just-in-time-systems Manufacturing resource planning Production control Fertigungskontrolle (DE-588)4016901-7 gnd rswk-swf MRP II (DE-588)4266305-2 gnd rswk-swf Just-in-time-Produktion (DE-588)4140040-9 gnd rswk-swf Fertigungskontrolle (DE-588)4016901-7 s Just-in-time-Produktion (DE-588)4140040-9 s DE-604 MRP II (DE-588)4266305-2 s HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=005502810&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Petroff, John N. Handbook of MRP II and JIT strategies for total manfacturing control Just-in-time-productie gtt Logistiek (economie) gtt Just-in-time-systems Manufacturing resource planning Production control Fertigungskontrolle (DE-588)4016901-7 gnd MRP II (DE-588)4266305-2 gnd Just-in-time-Produktion (DE-588)4140040-9 gnd |
| subject_GND | (DE-588)4016901-7 (DE-588)4266305-2 (DE-588)4140040-9 |
| title | Handbook of MRP II and JIT strategies for total manfacturing control |
| title_auth | Handbook of MRP II and JIT strategies for total manfacturing control |
| title_exact_search | Handbook of MRP II and JIT strategies for total manfacturing control |
| title_full | Handbook of MRP II and JIT strategies for total manfacturing control John N. Petroff |
| title_fullStr | Handbook of MRP II and JIT strategies for total manfacturing control John N. Petroff |
| title_full_unstemmed | Handbook of MRP II and JIT strategies for total manfacturing control John N. Petroff |
| title_short | Handbook of MRP II and JIT |
| title_sort | handbook of mrp ii and jit strategies for total manfacturing control |
| title_sub | strategies for total manfacturing control |
| topic | Just-in-time-productie gtt Logistiek (economie) gtt Just-in-time-systems Manufacturing resource planning Production control Fertigungskontrolle (DE-588)4016901-7 gnd MRP II (DE-588)4266305-2 gnd Just-in-time-Produktion (DE-588)4140040-9 gnd |
| topic_facet | Just-in-time-productie Logistiek (economie) Just-in-time-systems Manufacturing resource planning Production control Fertigungskontrolle MRP II Just-in-time-Produktion |
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