Resource planning is a combination of materials and capacity
planning driven by the MPS. The material plan relates to what raw
materials, components and subassemblies are required to support the
MPS. The capacity plan relates to the number of machine and labor
hours required to support the same MPS, along with "Q" management.
These plans rely on specific files of information in the data base,
specifically; the bill of material, on hand and on order file for
MRP and the routing file for CRP. The ability to successfully
complete these plans depends directly on the levels of accuracy
contained in these data base files.
Relates to the level of success achieved from this particular plan.
Did we achieve the goals we planned for in each of the foregoing
planning areas? Since Manufacturing is not a perfect science, a goal
of 95% is considered laudable performance. Performance Measurement
deals primarily with "results." The results achieved from the
execution of the plans made. Measurements come after execution,
however, planning for a specific level of success comes as part of
the planning premise and is done beforehand.
The next area of discussion involves the execution of the plans made
during the planning cycle. The first given is that while the
planning cycle is a monthly, by family, weekly by code time frame,
the execution cycle is a daily, almost hourly time frame. Further,
while the planning premise is MRP II, the execution premise will be
JIT. Therefore, let us examine the concepts and principles of this
philosophy and in somewhat more detail than the better known one of
MRP II. What is JIT and why has it proven to be so successful? JIT
is a philosophy that has as its primary premise the elimination of
all waste. Waste can be recognized or eliminated as a part of the
planning, but, reveals itself best during the execution process.
JIT, therefore is an execution premise. What is "Waste" and where is
it found? Waste is anything other than the minimal amount of
materials, equipment, space, labor, energy and workers' time
required to successfully produce a product. The elimination, of all
waste in execution involves the incorporation of certain themes.
There are: Continuous improvement, development of people,
synchronization, simplicity, flexibility, visibility and teamwork.
The functions or areas of action that bring this elimination of
waste to fruition in all areas are the following:
While the implementation of MRP II concepts and principles involve
a considerable amount of education, the level and audience for JIT
education is much broader and goes much deeper in the organization.
Also, the presumption is that most manufacturers who utilize MRP II
Systems to address the planning premise have already done that
element of training. The switch to a JIT method of execution
involves an entire new training scenario.
The concept of housekeeping involves much more than just keeping the
place clean. It includes the old adage: "A place for everything and
everything in its place," and that place is importan too. It also
makes the first basic inroads into employee involvement.
Quality today is a given. It is the "ante" that you bring to the
table in order to play in the game. What is important
here is the source of the quality. Under JIT, the source of quality
is defined as the individual worker and his/her performance the
first time a function is performed.
This function is directed at change over time and the ability or
flexibility to go from product to product very quickly thereby
improving production time and facility utilization. It primarily
involves tooling, machine functions, and the modification of
behavior in this area between engineering and operating personnel.
This function addresses the flow of work through all phases of the
manufacturing process. This includes both the paperwork and material
flow, the alignment of work centers and just about everything that
takes place from the time an order or demand is received, until it
ships out the door of the factory. In a make-to-stock (DRP)
environment, it would also include the distribution network.
To be Continued
For balance of this article, click on the below link:
Lean Manufacturing Articles and go to Series 02
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