MED NITC MANUFACTURING REQUIREMENTS PLANNING (MNMRP) SOFTWARE PACKAGE

Transcription

1 MED NITC MANUFACTURING REQUIREMENTS PLANNING (MNMRP) SOFTWARE PACKAGE A tool for material planning and scheduling of components and subassemblies of assembled products A tool useful for MSME Dr. V. Madhusudanan Pillai Associate Professor Department of Mechanical Engineering National Institute of Technology Calicut Kozhikode , Kerala, India

2 Preface A software package developed as a part of my academic activities in the Department of Mechanical Engineering, National Institute of Technology Calicut in association with the Department of Computer Science & Engineering, National Institute of Technology Calicut. This package is useful for Micro, Small and Medium Enterprises as well as for academic purposes. MRP computation and records can be generated dynamically. Material plan and schedule on rolling horizon basis for components of end items can be prepared. This would not have been possible without the active participation of Mr. Neeraj Khanna (M110361CA) who has developed the codes for the software package as part of his MCA project in winter semester Dr. V. Madhusudanan Pillai Associate Professor Department of Mechanical Engineering National Institute of Technology Calicut Kozhikode , Kerala, India vmp@nitc.ac.in

3 MED NITC MANUFACTURING REQUIREMENTS PLANNING (MNMRP) SOFTWARE PACKAGE 1. INTRODUCTION 1.1 Preamble This software package is suitable for Micro, Small and Medium Enterprise (MSME) which produce assembled product. It can be used for material planning and scheduling of components and subassemblies. When production of finished goods (end item or product of a company) is planned or orders are received for end item, the production/purchase of components/subassemblies of the product is to be planned. The MNMRP package does this job. This package provide purchase schedule of components (parts), manufacturing schedule of parts from purchased parts, and manufacturing schedule of subassemblies and end product assembly so that the planned production will be completed with less in-process inventory at the right time. It is possible to update planned purchase quantity and manufactured quantity of components/subassemblies, in the package, as receipt happens at different points in time. That is, updated records (plans) of the components/subassemblies considering current status can be prepared using this package. Any inadequacy or shortage in quantity of any component or subassembly can affect the final planned end item. In this case, the package can identify which period planned quantity is affected and hence manager can take appropriate action to mitigate the shortage situation. All these type of updating is also possible in MNMRP. It is a Server based Desktop Application for Material Requirements Planning (MRP) of different products on basis of which companies can figure out multiple outputs. It enables multiple users to work on different machines sharing the same database. Figure 1 is the screenshot showing the initial interface to the software which provides the base of all activities. Material Requirements Planning or MRP is a basic tool for performing the detailed material planning function in the manufacture of component parts and their assembly into finished items. MRP s managerial objective is to provide the right part at the right time to meet the schedules for end products. It is central to developing detailed plans for part needs of companies assembling end items from components produced in batch manufacturing process.

4 The MRP output (time-phased requirement for a part number) can also be used as input to the detailed capacity planning. Figure 1: Starting screen of the package 1.2 Technologies used for Development 1. JAVA 2. JUNG 2 (JAVA API) 3. NETBEANS IDE 4. ITEXT 5. MySQL (v14.14 Distrib , for redhat-linux-gnu (i386))

5 1.3 A brief introduction on the use of the software package A first time user must undergo the following phases in order to makes use of the software. (It is assumed that a first time user has a blank database. The following data entry ensures necessary data for production planning information to generate.) 1. Data entry for the End product is using Add End Product in the Company button and Enter BOM button and finally pressing Low Level Code Display. This data entry is complete only after pressing the Low Level Code Display button and then pressing Display button. This will result in the display of the list of part for the end product and its low level code. Note: (1) To get more understanding on BOM data entry, watch the video available in the link: The same youtube link is available in the page opened up while pressing Help & Contact button of Figure 1. Click Complete Working Module available in the page, to have an understanding on BOM data entry and basic use of the software package. (2) Editing of data entered above is not possible and hence care should be taken to have proper details in hand before starting the data entry. (3) Upon completion of the above data entry the following buttons in Figure 1 can be used: Minimum Planning Horizon, Product Tree Structure, and Gantt Chart (Forward Schedule) 2. Data entry of inventory and other part related information using the button Inventory/Product Editing. 3. Data entry of Planned Order Release (POR) for the end product using the button Enter MPS. This is based on Master Production Schedule (MPS). Only after the above data are entered, the user can proceed with the following: 1. Run MRP calculations in the particular week for a rolling planning horizon. 2. Check Bottom-up re-planning for any items having negative value in their net requirements. 3. If there are no parts in bottom-up re-planning, proceed with planned order releases. 4. Click on individual items and they will be listed accordingly (either purchased or manufactured). 5. Allocation check is done for items (manufactured) and quantity required is allocated accordingly. 6. Material pick card is generated for all items and they automatically become scheduled receipts depending on their lead time. 7. Click on reports section and print the reports of the current planned order released. In the following week, add actual receipts corresponding to the products which are scheduled this week. 1.4 Inventory information required

6 1. Initial inventory. 2. Lot size if any. 3. If lot size is greater than 0, there are 2 options to select from. Select 1 for gross requirements more than the lot sizes, then planned order releases are the exact quantity as in the gross requirements. Select 2 for gross requirements more than the lot sizes, then planned order releases are the next higher multiple of the given gross requirements. 4. Safety stock. 5. Time. 6. Unit of measure of the part. 7. Type of the product (manufactured or purchased). 2. INPUT AND OUTPUT DETIALS The inputs for the generation of the MRP records which includes Master Production Schedule, Bill of Materials, Service Part Requirements and Schedule Receipts. The outputs that are expected from the software are as follows: 1. Material Requirements Planning(MRP) calculations 2. Bottom up re-planning 3. Pegging (where used info) 4. Product tree structure 5. Inventory report 6. Gantt chart (forward schedule) 7. Planned order release 8. Low level code display 9. Printing the MRP records in a pdf and saving it in database for future references 10. Minimum planning horizon 2.1 Inputting method for the software package As MRP is input dependent, we have given precise attention to the input format. The format for entering input details are described using screenshots. First, we deal with the inputs for the software and then we turn our attention towards the outputs. The inputs comprise of: 1. Master Production Schedule (MPS). 2. Bill Of Material files (BOM).

7 3. Inventory record file. 4. Lot size. 5. Safety stock. 6. Lead time. 7. Planning horizon length. Figure 1 shows the screenshot that is the initial interface to the software which provides the base of all activities. On pressing the buttons given in this figure, different functionalities can be performed. Figure 2: Add end item page On pressing the first button namely Add End Product in the Company, the software enables the user to enter any new product to the company s database. On the right side of Figure 2 has a table with all the products that a company deals with. On clicking Production Planner, Screen given in Figure 3 appears and user needs to select the year of production. Figure 3: End product production calendar Here the manager has to enter the production year for the given product and press the save

8 button. On pressing the save button, the screen shown in Figure 4 appears. Figure 4: Start date of end product production Here the manager has to enter the start date of production for the particular product which is the end product of the company. After pressing submit button, user is directed to BOM page where user has to insert the bill of materials in top down form. The parent child structure is generated with this particular input. The parents are automatically generated. User is expected to enter as in the BOM. For components that do not have any sub components, just press next to get the next level of inputs. If there is more than one component of a product, click 'Add new subassembly ' button and a new row will be generated for entry as shown in Figure 5. To get more understanding on BOM data entry, watch the video available in the link: The same youtube link is available in the page opened up while pressing Help & Contact button of Figure 1. Click Complete Working Module available in the page for BOM data entry and to have an understanding on the basic use of the software package.

9 Figure 5: Bill of materials entry page Next we move on to the input of Master Production Schedule (MPS). Figure 6 is a screenshot of the page for the input. Figure 6: Screen for MPS data entry The manager needs to enter the name of the product and press GO. On pressing GO details of the product is displayed on the adjacent table (See right side of Figure 6) with the product

10 ID, quantity and date of delivery if already entered. If new delivery date is to be entered then press 'Add New' button and the Date of Delivery with quantity appears and it needs to be entered and submit button need to be pressed. The updated order is displayed in the adjacent table. On clicking Service part button screen in Figure 7 appears. Hear the user can enter service part requirement for individual products. Figure 7: Service part requirement. On clicking on button named Scheduled Receipt in Figure 1 a screen as in Figure 8 appears. This window allows the user to edit and add new scheduled receipts in the company. Any preentered scheduled receipt is displayed on right side of the table as shown in Figure 8.

11 Figure 8: Scheduled receipt. User can enter new receipt by clicking initial entry button. A window appears where the user is supposed to enter the product name, week of receipt, and quantity of receipt. User can also edit the current receipt by clicking the table and then clicking the edit button. 2.2 Outputs generated from the software Figure 9 is the screenshot which displays the product tree structure of a product named 'F1' with multiple components and sub-dependencies. Figure 9: Product tree structure of a product F1 Figure 10 shows the low level codes of all components or products available in the database.

12 Figure 10: Low level codes for the parts in the database Here the manager can see the low level codes of all the sub-components. We begin with level 1 as level 0 is fixed for end products. Figure 11 shows the minimum planning horizon of a particular product based on the lead times of the components in the BOM of the product. Figure 11: Minimum planning horizon On clicking button named MRP Calculation in Figure 1, Figure 12 appears. Here the user needs to enter the planning horizon which is actually rolling planning horizon and has to press the button Go for the calculations to begin. On clicking, the table gets initialized with values for the weeks of calculation. On pressing the button Next, all the products are displayed one by one and their values are displayed on the screen. On clicking All at once, all the products get calculated one by one and then finally completed window is displayed. Figure 12 shows a current working window when all at once is pressed.

13 Figure 12: Progress of MRP Calculation On clicking the button Gantt Chart (Forward Schedule) Figure 13 appears. Figure 13: Product selection Here the user has to select the product whose Gantt chart needs to be displayed. With the button Ok, the screen in the Figure 14 appears. Figure 14: Minimum planning horizon On clicking ok, the Gantt Chart appears which is show in Figure 15. The Gantt chart shows a forward schedule.

14 Figure 15: Gantt chart Figure 15 shows the minimum planning horizon graphically. On clicking button labelled Pegging in Figure 1, Figure 16 appears which displays where used data. Figure 16: Pegging (where used info) On typing initial letter of a part whose where used is to be found, the software automatically displays the info on the table right of the figure above. The child and parent relation is displayed with their corresponding quantity and lead time. The quantity means number of units of child required to build 1 unit of the parent. Quantity and lead time can be edited in the child-parent relationship through this window. On clicking button labelled Planned Order Release in Figure 1, Figure 17 appears.

15 Figure 17: Planned order release Here the current week is displayed and all products which have their Planned Order Releases in the current weeks are displayed. For products which are not independent products, on clicking the product names on the table right of the Figure 17, separate list opens on the left showing its child and the number of individual units available. On pressing button labelled Inventory/Product Editing Figure 18 appears.

16 Figure 18: Inventory/Product editing Here the user is allowed to edit the current stock, lot size, safety stock, safety lead time and the type. For a particular product, if there is a scheduled receipt in current week then it is displayed in on hand updating button. On clicking the button, Figure 19 appears. Figure 19: On hand updating. On clicking the button named MRP Search in Figure 1, Figure 20 appears. Here one can check the MRP records of a particular part individually. It shows all related information about a part.

17 Figure 20: MRP Search. On clicking the button named Bottom-up re-planning, Figure 21 appears. Here if there is a problem in a part in a lower level, then which parent part s planned order releases would be affected is shown. Here the values in negative represent shortage of part, either by scheduled receipt or due to lead time conflict.

18 Figure 21: Bottom-up re-planning The user needs to click on any row in Figure 21, Figure 22 appears with all the affected parts with their week of planned order releases. Figure 22: Affected items list On clicking the button named Print all MRP records, the package would ask the user to select a directory and will save the entire MRP record in mrp_recordsxx.pdf format, where XX represents the current week number those records were generated on. A screen shot of the pdf created is given below in Figure 23.

19 Figure 23: Sample MRP pdf file On clicking button labelled Display MRP records from DB, window in Figure 24 appears. Here the user needs to select the week whose MRP records he wants to see. The records would be displayed to the user. The software creates a temp directory in the home/user folder and there it saves the downloaded file temporarily. The folder and the files get deleted automatically when you close the window. Figure 24: Records from database in pdf format Figure 25 shows an intended bill of material for product named Computer.

20 Figure 25: Intended bill of material 3. WORKING OF THE PACKAGE 3.1 Demonstration of the working of the package Following is an MRP problem- named Classic Coffee Table - reverse planning problem. You are scheduling production of your popular Classic Coffee Table. The table requires a top, 4 legs, 0.5 Kg of stain, 0.25 Kg of glue, 2 short braces between the legs and 2 long braces between the legs, and a brass cap that goes on the bottom of each leg. You have 400 Kg of glue in inventory, but none of the other components. All items except the brass caps, stain, and glue are ordered on a lot-for-lot basis. The caps are purchased in quantities of 1,000, stain and glue by Kg. Lead time is 1 week for each item. MPS for the coffee tables is 640, 530, 128, and 120 on weeks 22, 23, 24, and 25, respectively. The product structure is given in Figure 26. MRP records of the items are available below. COFFEE TABLE Top Stain Glue Base Assembly Short Braces Long Braces Legs Brass Cap Caps

21 Figure 26: Product structure of Coffee able (a) It has been identified at the end of week five that there is no sufficient quantity of glue. The on-hand inventory rechecking reveals that there was only 300 Kg of Glue at the beginning of week 1. If all other items are planned as per the given MRP records and lead time of the item, glue cannot be compressed, what is the effect of this error in meeting the MPS? (b) What will be the change in the inventory of each item, if the quantity cannot be produced due to shortage in a planned period is produced in subsequent possible period? Note: MRP Records of items are given below. Notations: GR Gross Requirement, SR Scheduled Receipt, PAB Projected Available Balance, POR Planned Order Release. We take for granted that the product is entered in the package and the bill of materials file has also been entered. The user must begin with the display of the low level codes before entering the master production schedule or viewing the intended bill of materials or product tree structure. As after the entry of the bill of materials file, the system needs to calculate the low level codes for all products as new dependencies might arise due to addition of the new product. Figure 18 shows the low level code display for all the items in the company s database.

22 Figure 27: Low level codes of all parts in database Serial numbers 2, 13, 20 and 21 in Figure 27 shows the low level code of some of the parts of the end product. This can be tallied by seeing the product tree structure or intended bill of materials. Figure 28 shows the product tree structure for the end product Coffee Table.

23 Figure 28: Product tree structure of Coffee Table Figure 29 shows the intended bill of materials for the end product Coffee Table Figure 29: Intended bill of materials of Coffee Table

24 Next we move on towards the entry of The Master Production Schedule (MPS). Here by MPS we actually mean the Planned Order Release (POR) of the end item. Figure 30 shows the page after the entry of MPS. Figure 30: MPS entry for Coffee Table As shown in the figure the week of delivery is actually 1 week prior to the weeks given in the question as lead time of all products including the end product is 1. Hence the POR would be 1 week prior to actual delivery. Next we move towards Inventory/Product editing page where the details of the individual child parts would be entered. Figure 22 shows the screen which enables the user to enter data individually. Figure 22: Inventory editing of the child parts

25 Individual items can be selected by typing initial characters in the search box and appropriate information gets displayed on the right side table. On clicking the table, its initial values automatically fills up the adjacent fields. Only inventory needs to be updates separately. The user can now precede with the materials requirements planning calculations. From the following sections, weekly calculations and planned order release techniques will be elaborated. Current week 19 The user starts the MRP calculation. Figure 23 appears on opening the window and selecting the planning horizon as 8. User selects All at once option for calculation. Figure 23: Initialization of the screen Figure 24 shows the running screen after All at Once is pressed. Figure 24: Running calculations

26 The planned order releases for the current week are automatically generated and can be seen by clicking the Planned Order Release button on the home screen. Figure 25 shows the screen with planned order release/s being shown on the adjacent table. Figure 25: Planned order releases Since Brass_Cap is a purchased item, it shows purchase allocation. The POR is released by clicking the Material Pick Card. Since this item has a lead time of 1 week, a scheduled receipt must have been added for week 20 (since current week is 19). User can check it by clicking Scheduled Receipt button and then checking by either week number or part name. Figure 26 shows the screen for scheduled receipt search by part name. Figure 26: Scheduled receipt MRP data can be printed by clicking the Print MRP Details. Figure 27 shows the calculation of the parts of Coffee Table.

27 Part Name = Base_Assembly Low Level Code = 1 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Part Name = Top Low Level Code = 1 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Part Name = Stain Low Level Code = 1 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Part Name = Glue Low Level Code = 1 Week GR PAB NR POR Lot Size Lead time = 1 Safety Stock Time

28 Part Name = Long_Braces Low Level Code = 2 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Part Name = Short_Braces Low Level Code = 2 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Part Name = Legs Low Level Code = 2 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Part Name = Brass_Cap Low Level Code = 3 Week GR PAB NR POR On hand Lot Size = 1000 Lead time = 1 Safety Stock Figure 27: MRP calculations for week 19 Time

29 Week 20 A schedule receipt of 3000 is received for part Brass_Cap. MRP calculation is run. Following Figure 28 shows the calculated result for the current week. Part Name = Base_Assembly Low Level Code = 1 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Part Name = Top Low Level Code = 1 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Part Name = Stain Low Level Code = 1 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time

30 Part Name = Glue Low Level Code = 1 Week GR PAB NR POR Lot Size Lead time = 1 Safety Stock Time Part Name = Long_Braces Low Level Code = 2 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Part Name = Short_Braces Low Level Code = 2 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Part Name = Legs Low Level Code = 2 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time

31 Part Name = Brass_Cap Low Level Code = 3 Week GR PAB NR POR Lot Size = 1000 Lead time = 1 Safety Stock Figure 28: MRP calculations for week 20 Time On printing the planned order release for the current, Figure 29 shows the data that is printed. Figure 29: Planned order releases for week 20 On releasing the order, Figure 30 shows the image of scheduled receipts for the next week when printed. Figure 30: Scheduled Receipt for week 21 Now we move to the next week and update the inventory with the actual receipt.

32 Next week 21 Scheduled Receipts for the entire items displayed in figure 30 is received. User can tally it with printing the receipts again to see the actual received quantity. Figure 31 shows the received items of the current week. Figure 31: Actual receipt for week 21 Run MRP calculations. Figure 32 shows the calculations for week 21. Part Name = Base_Assembly Low Level Code = 1 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Part Name = Top Low Level Code = 1 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time

33 Part Name = Stain Low Level Code = 1 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Week GR PAB NR POR Lot Size Lead time = 1 Safety Stock Time Part Name = Long_Braces Low Level Code = 2 Week GR NR POR Lot Size Lead time = 1 Safety Stock Time Part Name = Short_Braces Low Level Code = 2 Week GR NR POR Lot Size Lead time = 1 Safety Stock Time

34 Part Name = Legs Low Level Code = 2 Week GR NR POR Lot Size Lead time = 1 Safety Stock Time Part Name = Brass_Cap Low Level Code = 3 Week GR PAB NR POR Lot Size = 1000 Lead time = 1 Safety Stock Figure 32: MRP calculations for week 21 Time On printing planned order releases for the current week, user gets the output in Figure 33, Figure 33: Planned order releases for week 21 On printing the scheduled receipts of the next period, user gets output in Figure 34,

35 Figure 34: Scheduled receipts for week 22 Next week 22 Scheduled Receipts for the entire items displayed in Figure 34 is received. User can tally it with printing the receipts again to see the actual received quantity. Figure 35 shows the received items of the current week. Figure 35: Scheduled receipt in week 22 Run MRP calculation for the current week. Figure 36 shows the calculations. Part Name = Base_Assembly Low Level Code = 1 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time

36 Part Name = Top Low Level Code = 1 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Part Name = Stain Low Level Code = 1 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Part Name = Glue Low Level Code = 1 Week GR PAB NR POR Lot Size Lead time = 1 Safety Stock Time Part Name = Long_Braces Low Level Code = 2 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time

37 Part Name = Short_Braces Low Level Code = 2 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Part Name = Legs Low Level Code = 2 Week GR NR POR On hand Lot Size Lead time = 1 Safety Stock Time Part Name = Brass_Cap Low Level Code = 3 Week GR PAB NR POR Lot Size = 1000 Lead time = 1 Safety Stock Figure 36: MRP calculations for week 22 Time On printing the planned order releases, user gets the output illustrated in Figure 37, Figure 38: Planned order releases for week 22

38 The scheduled receipts for the next week are displayed in figure 39, Figure 39: Scheduled receipts for week 23 Next week 23 Scheduled Receipts for the entire items displayed in Figure 39 is received. User can tally it with printing the receipts again to see the actual received quantity. Figure 40 shows the received items of the current week. Figure 40: Actual receipts in week 23 Run MRP calculations for the current week; Figure 41 shows the calculations, Part Name = Base_Assembly Low Level Code = 1 Week GR NR POR Lot Size Lead time = 1 Safety Stock Time

39 Part Name = Top Low Level Code = 1 Week GR NR POR Lot Size Lead time = 1 Safety Stock Time Part Name = Top Low Level Code = 1 Week GR NR POR Lot Size Lead time = 1 Safety Stock Time Part Name = Glue Low Level Code = 1 Week GR PAB NR POR Lot Size Lead time = 1 Safety Stock Time Part Name = Long_Braces Low Level Code = 2 Week GR NR POR Lot Size Lead time = 1 Safety Stock Time

40 Part Name = Short_Braces Low Level Code = 2 Week GR NR POR Lot Size Lead time = 1 Safety Stock Time Part Name = Legs Low Level Code = 2 Week GR NR POR Lot Size Lead time = 1 Safety Stock Time Part Name = Brass_Cap Low Level Code = 3 Week GR PAB NR POR Lot Size = 1000 Lead time = 1 Safety Stock Figure 41 MRP calculations for week 23 On printing the planned order releases for week 23, display in Figure 42 appears, Time Figure 42: Planned order releases for week 23

41 On POR launching, the scheduled receipts can be checked from the scheduled receipts section, Figure 43 shows it, Figure 43: Scheduled receipts for week 24 Next week 24, Scheduled Receipts for the entire items displayed in figure 43 is received. User can tally it with printing the receipts again to see the actual received quantity. Figure 44 shows the received items of the current week. Figure 44: Scheduled receipts in week 24 During this week the user finds the current inventory for glue is 7.5, user can directly update it by the initial entry field in Inventory/Product Editing section. User runs MRP calculations and finds out a negative quantity in the net requirements of glue. This leads to bottom up replanning. Figure 45 shows the mrp calculations for the current week. Part Name = Base_Assembly Low Level Code = 1 Week GR NR POR Lot Size Lead time = 1 Safety Stock Time

42 Part Name = Top Low Level Code = 1 Week GR NR POR Lot Size Lead time = 1 Safety Stock Time Part Name = Stain Low Level Code = 1 Week GR NR POR Lot Size Lead time = 1 Safety Stock Part Name = Glue Low Level Code = 1 Time Week GR NR POR Lot Size Lead time = 1 Safety Stock Time Part Name = Long_Braces Low Level Code = 2 Week GR NR POR Lot Size Lead time = 1 Safety Stock Time

43 Part Name = Short_Braces Low Level Code = 2 Week GR NR POR Lot Size Lead time = 1 Safety Stock Time Part Name = Legs Low Level Code = 2 Week GR NR POR Lot Size Lead time = 1 Safety Stock Time Part Name = Brass_Cap Low Level Code = 3 Week GR PAB NR POR Lot Size = 1000 Lead time = 1 Safety Stock Figure 45: MRP calculations for week 24 Time Here the negative value record of glue is highlighted. Figure 46 shows the bottom up replanning required for the item glue whose current week requirements could not be fulfilled resulting affecting higher orders.

44 Figure 46: Bottom-up re-planning. Now it is manager s decision to how to deal with the above shortage problem.