CPIM DSP Session Two Study Notes.doc

session two inventory planning- order review methods# commonly used methods order point (fixed order quantity)order point system the inventory method that places an order for a lot whenever the quantity on hand is reduced to a predetermined level knows as the order point.op = ddlt + ss uses of order point:1) primarily for independent demand items (finished goods, mro)2) for dependent demand items such as raw materials when demand is stable and continuous3) not for high-value class a items because of inventory costs4) for limiting lot sizes due to truckload and storage capacity at the receiving warehouse periodic review (known as a fixed-internal order system | independent demand management model)q = t iwhere t = target inventory = demand for (review period + lead time) i = inventory at hand applications of period review system1) receiving deliveries of many different items from one source at one time is economical2) tracking and posting transaction of many small issues from inventory is expensive3) it is safe to assume that the sufficient inventory has been ordered to last until the next review interval4) items have a limited shelf life, such as farm produce, chemicals, and food products5) ordering costs are low; ordering once a week or month is not a cost issue* difference between the order point and periodic review methodscharacteristicperiodic review systemorder point systeminterval between ordersfixed and constantvaries depending on actual usageorder quantity varies by periodusually fixedconsignment and vmi (used to replenish both independent and dependent demand)see additional materials ? describe the best order review methods for dependent demand* types of demandindependent demand inventoriesdependent demand inventoriesretailassemblieswholesales finished goodssubassembliesmanufacturing finished goodsfabricated componentsservice/replacement partspurchased componentsmro suppliesraw materials material requirements planningthe job of mrp is to plan the release of orders to purchase, make, and assemble components of dependent demand items. * in service management, there is a process similar in approach to mrp. it is called “service requirements planning” (srp). srp is applicable to service activities of manufacturing as well as service industry companies. visual review (min-max system)in visual review, the order point is based on looking at the quantity on hand. it assumes that minimum and maximum levels have been established. when the minimum level is reached, inventory is replenished to the maximum level. the minimum could be determined by the order point formula.the maximum might be determined by shelf space or economic order considerations. kanbanthe kanban system is an important feature of pull systems that are characteristic of lean/jit environments. a kanban is a signal to an upstream workstation to start producing parts.- aggregate and disaggregate planningaggregate planning: conversion of strategic-level plans into the resource capacity a firm will need to meet demand (one to three years)disaggregate planning: decisions on capacity and timing necessary for product lines to meet demand (up to on year)resource scheduling: weekly, monthly, and quarterly (or rolling three-month) plans to match capacity with (fluctuations in) demand manufacturing planning and controlbusiness planningexecutiontioncapacity planningresourceschedulingaggregate planningdisaggregate planningexecutionpriority planningproduction activity controlmaterials requirementsplanningmaster schedulingsales and operations planninginput/output controloperation sequencingcapacity requirements planningrough-cut capacity planningresource planning mrpii for servicebusiness planningresourceschedulingdisaggregate planningaggregate planningmonitor performancecapacity requirements planningrough-cut capacity planningresource planningshop floor and inventory controlservice requirements planningmaster service schedulingaggregate service planning? explain the significance of aggregate and disaggregate planning- impact of lean production concepts shortening lead timeput a maximum cap on the amount of wip to predict lead timemaintain supply chain velocity by maintaining an even flow of wip, and ensuring that wip is related to current demandrelease material into the line in amounts consistent with appropriate batch sizes to prevent excess wip implementing the principles to reduce wip and therefore lead time use a pull system determine the strategic (finished goods) buffer increase flexibility to deal with product line complexity. this requires the ability to change volumes and product mix quickly using flexible machinery, cross-trained employees, and quick changeovers. implementing synchronous flow list and describe four lean production tools that increase supply chain velocity value stream mappingvalue stream mapping is a technique used to visualize the flow of the value stream. a value stream map is a graphic representation of the process steps from raw material to finished goods (or delivery of service to the customer), showing multiple process levels and the linkages among them. the companies need to analyze the value-added questions and the non value-added questions. pull system (see additional materials) setup reduction (four steps)1) separate external and internal setupinternal setup when the machine is shut down; external setup when the machine is running2) convert internal setup to external setup3) streamline internal setup4) eliminate (waste in) adjustment total production maintenancegoals of tpm are reducing downtime and increasing process flow;schedule prevention maintenance before problem occurs;train and empower operators to perform routine maintenance on their equipment;give operators a sense of responsibility for their machines and for reducing downtime. explain the logic of reducing work in process (wip) to shorten production lead time- accuracy, handling and storage# inventory accuracy inventory record accuracy three types of information must be accuratepart description or part numberquantitylocation negative consequence of inaccurate recordslost sales; excess production; low productivity; excessive expediting; high inventory levels; shortage; missed schedules; late delivery; excess freight costs; high levels of obsolescence# types of inventory accuracy methods cycle count vs. periodic inventorycycle countingperiodic countingefficient use of a few experienced people continuously throughout the yearinefficient use of many inexperienced people in a short, hectic period once a yearresulttimely detection (root cause analysis) and correction of errorsno correction of detection of causes of errorsfewer mistakes in item identificationmany mistakes in item identificationminimal loss production timeplant and warehouse shut down for inventorysystematic improvement of record accuracyone-time improvement of record accuracy cycle counting- sources of problemspoor design of formscarelessnessinaccurate supplier receiptsinadequate storage spacetiming for cutoff of transactionuntrained personnelpoor document controlitems not identified properlylack of discipline/ accountability- triggersabc classification items a should be counted morewhen a reorder is indicatedwhen a replenishment lot is receivedwhen a record balance becomes negativeafter a set number of transactions apply abc classification to cycle counting(see additional materials p2-49 to 55 p.g.)# storage and location of inventory items bins- materials in inventory are stored in areas usually referred to as “bins”, and each bin should have a location code to identify. bin location codes are used with a pick list to identify location of goods to be retrieved from inventory. inventory location systems fixed location system- each bin is designated to hold a particular item number. bins are assigned based on physical dimensions or other characteristics of the items. random location system- bins dont hold a particular item number and are assigned when the order arrives; bin selection is based on size and other characteristics of the item.- this system works better with automated tracking and retrieval. zone location system- this system is a compromise between fixed and random; an example is random placement of items in an outdoor storage yard or lot.- items placement may be based on size, flammability, dimensions, value, etc.# identification, tracking and handling of inventory automated storage and retrieval systemsas/ar may be used as a materials handling system in a storage facility or warehouse. with as/ar, goods are put away and retrieved using robotic arms or other kinds of automated devices. basic components: 1) racking and 2) the storage and retrieval machines such as a crane on wheels. bar coding and rfid (see additional 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