MRP物料需求计划

1、SIME, SHUFE物料需求计划（MRP） 物料需求计划（Material Requirement Planning，简称为 MRP）是对主生产计划的各个项目所需的全部制造件和全部采购件的数量需求计划和时间进度计划。物料需求计划物料需求物料库存SIME, SHUFE物料需求计划（MRP）2物料需求计划主要解决以下五个问题：2要生产什么？生产多少？（来源于MPS）2要用到什么？（根据BOM展开）2已经有了什么？（根据物品库存信息、即将到货或产出信息）2还缺什么？(计算出结果)2何时安排？(计算出结果)SIME, SHUFEMRP原理生产什么?要用什么？我们有什么？还需要什么？何时需要？主生产计

2、划 (MPS)按照物料单(BOM)库存记录物料需求计划 (MRP)工作单、采购单SIME, SHUFE主生产计划粗能力计划 MRP II逻辑流程图逻辑流程图 产品规划资源需求计划销售规划可行？可行？物料需求计划能力需求计划可行？采购作业车间作业成本会计业绩评价资源清单合同预测其它需求供应商信息销售与运作计划应收帐总帐应付帐库存信息物料清单工作中心工艺路线客户信息成本中心会计科目宏观微观经营规划123454个计划层次个计划层次1个执行层次个执行层次决策层 计划层 执行控制层SIME, SHUFE物料需求计划（MRP）2低层码（low-level code，简称LLC）2概念：物料的低层码是系统分

3、配给物料清单上的每个物品一个从0至N的数字码。在产品结构中，最上层的层级码为0，下一层的部件的层级码则为1，依此类推。一个物品只能有一个MRP低层码，当一个物品在多个产品中所处的产品结构层次不同或即使处于同一产品结构中的但却处于不同产品结构层次时，则取处在最低层的层级码作为该物品的低层码。SIME, SHUFE2作用：在展开MPS进行物料需求计算时，计算的顺序是从上而下进行的，即从产品的0层次开始计算，按从上到下的顺序进行计算，当计算到该产品的某一层次（如1层），但高于低层码时（物料的低层码为2），只计算该层的物料计算结果（毛需求量）暂时存储起来，总的需求量可以汇总存储，但不进行MRP需求计算

4、。只有到了低层码的层次，才计算净需求、需生产量等。因此，低层码是MRP的计算顺序。SIME, SHUFE物料需求计划（MRP）物料物料A的的MRP计算顺序示意图计算顺序示意图XABCDA0层1层2层SIME, SHUFE制造流程与BOM结构车间车间WIP生产和采购数据生产和采购数据MRP定义定义 Item(库存）库存）设计数据设计数据ENGBOM结构结构工艺路线工艺路线前提前提应用应用创建创建SIME, SHUFEBOM 类型计划计划 BOM模型模型 BOM选项组选项组 BOM标准标准 BOM矩阵式矩阵式 BOM加减加减 BOMSIME, SHUFE标准 BOM 标准物料清单是最通标准物料清单

5、是最通用的清单类型，并列有法用的清单类型，并列有法定组件、每个组件的要求定组件、每个组件的要求数量、在制品控制信息、数量、在制品控制信息、物料计划等信息物料计划等信息CABDESIME, SHUFE选项类 BOM 选项类作为一个项目选项类作为一个项目，成为模型物料清单中的，成为模型物料清单中的一层。选项类还可以具有一层。选项类还可以具有适用于其所有选项的法定适用于其所有选项的法定组件组件VGA-BVGA显示器显示器选项类BOM 可选标准BOM 可选VGA-A标准BOM 可选SIME, SHUFE模型 （超级）BOM 模型物料清单定义了选项清单和选项类，指定了法定组模型物料清单定义了选项清单和选

6、项类，指定了法定组件，您可以在件，您可以在 销售模块中选择以订购配置。模型清单可以是销售模块中选择以订购配置。模型清单可以是按订单装配或按订单挑库类型的按订单装配或按订单挑库类型的EGA显示器显示器计算机计算机VGA显示器显示器显示器显示器VGA真彩色真彩色VGA-AVGA标准标准VGA-B模型BOM 不可选标准BOM 可选选项类BOM 可选标准BOM 可选标准BOM 可选标准BOM 可选标准BOM 可选选项类BOM 不可选SIME, SHUFE计划 BOM 计划物料清单计划物料清单是一个包括组件百是一个包括组件百分比分配的物料清分比分配的物料清单结构单结构培训用培训用计算机计算机科研用计算机

7、科研用计算机车间生产用车间生产用模型模型BOM 35% 不可选不可选模型模型BOM 25% 不可选不可选模型模型BOM 40% 不可选不可选计划计划BOM 100% 不可选不可选SIME, SHUFE电 子 挂 钟机 芯花纹 1花纹 2花纹 2花纹 1红黑电 池特征件与可选件特征件与可选件钟 盘指 针盘 面秒 针 短 针 长 针钟 框塑 料(红)塑 料(白)塑 料(金)金 属(压花）金 属(平)木 雕(鹰)木 雕(屋)木 雕(轮)配不配金白黑金通用件特征件（基本组件）可选件（必选其一、可选其一）SIME, SHUFE电 子 挂 钟字型 2钟 框塑 料 木 雕鹰屋红白凸平通用件机 芯钟 盘黑色金

8、色字型 1字型 1 字型 2指 针花纹 1花纹 2长 针花纹 2花纹 1 短 针 秒 针红 黑电 池可选件(1.0)(1.0)(1.0)(1.0)(0.5)(0.5)(0.2)(0.2)(0.3)(0.3)(0.3) (0.3)(0.1)(0.1)(0.1)(0.1)金 属(0.2)(0.2)(0.6)(1.0)(1.0)(1.0)(0.5)(0.5)(0.5)(0.5)(0.5)(0.5)(1.0)注：括号内为预测百分比(0.5)模块化产品结构模块化产品结构SIME, SHUFE 模块化物料清单模块化物料清单100 20 30 20 30 50 50 50 50 50 50 10 10 30

9、 30 10 10 50物料名称： 电子挂钟物 料 号： 10000层次 物料号 物料名称选项号 选择件 数量 预测 % 实际需求11.2.2.211机芯钟盘 长针 短针 秒针钟框电池(通用件) 1 2 3 4 1 2 1 2 1 2 1 2 3 4 5 6(可选件)黑色、字型 1黑色、字型 2金色、字型 1金色、字型 2花纹 1花纹 2花纹 1花纹 2花纹 1花纹 2塑料、红色塑料、白色金属、凸纹金属、平纹木雕、鹰木雕、屋111111111111111112根据销售定货1100012000/112000/212000/312000/412100/112100/212200/112200/21

10、2300/112300/213000/113000/213000/313000/413000/513000/614000SIME, SHUFE物料清单的表现类型物料清单的表现类型 单层物料清单单层物料清单 缩排式物料清单缩排式物料清单 汇总的物料清单汇总的物料清单 模块式物料清单模块式物料清单 单层跟踪单层跟踪 缩行跟踪（多级反查）缩行跟踪（多级反查） 成本物料清单成本物料清单SIME, SHUFE汇总物料清单汇总物料清单（通用件汇总）（通用件汇总）XB(1)K(1)CP(3)LMDM(2)B(4)K(4)AJHPHP物料号 数量 A 1 B 5 C 1 D 1 H 2 P 5 L 1 M 3

11、SIME, SHUFE物料清单的构建物料清单的构建产生零件清单产生零件清单单级单级BOMBOM的开发的开发多级多级BOMBOM及工艺路线的开发及工艺路线的开发注意事项：注意事项：唯一编码唯一编码替代物料及替代原则替代物料及替代原则虚拟件虚拟件为了控制某些环节（检验等），可视为不同为了控制某些环节（检验等），可视为不同零件零件SIME, SHUFE物料清单的用途和用户物料清单的用途和用户编制计划的依据编制计划的依据配套和领料的依据配套和领料的依据进行加工过程的跟踪进行加工过程的跟踪采购和外协的依据采购和外协的依据根据它进行成本的计算根据它进行成本的计算报价参考报价参考物料追溯物料追溯使设计系列化

12、、标准化、通用化使设计系列化、标准化、通用化涉及设计、计划、生产、财务等部门涉及设计、计划、生产、财务等部门SIME, SHUFE物料需求计划（MRP）2MRP子系统与其他子系统的关系图生成生成独立需求MRP采购管理MPSCRP制造标准车间管理JIT管理平衡库存管理销售管理BOM库存信息计划信息SIME, SHUFE物料需求计划（MRP）2MRP的策略因素制造制造/ /采购标志码采购标志码提前期提前期安全库存安全库存损耗率、成品率损耗率、成品率批量政策批量政策SIME, SHUFE物料需求计划（MRP）损耗率损耗率实际需求实际需求= =净需求（损耗率）净需求（损耗率）成品率成品率总投入总投入=

13、有效产出有效产出/成品率成品率SIME, SHUFE物料需求计划（MRP）批量政策批量政策 直接批量直接批量Lot For LotLot For Lot 固定批量固定批量Fixed QuantityFixed Quantity 固定周期固定周期Fixed TimeFixed Time 经济批量经济批量EOQ(Economic Order Quantity)EOQ(Economic Order Quantity) 批量增量批量增量SIME, SHUFEMRP的编制思路的编制思路 订货订货 /配销配销 生产什么？生产什么？ 什么时候生产？什么时候生产？ 生产多少？生产多少？ 主生产计划主生产计划

14、(MPS) 需求预测需求预测 材料材料 产品结构产品结构 用料标准用料标准 提前提前 期（期（ LT ） 物料清单物料清单 (BOM) 各种材料总需求量计算各种材料总需求量计算 考虑库存量计算净需求量考虑库存量计算净需求量 考虑批量计算计划量考虑批量计算计划量 物料需求计划物料需求计划 (MRP) 在库量在库量 预订接收量预订接收量 仓储位置仓储位置 收发料记录收发料记录 库存记录库存记录 (INV) 采购采购 /外包外包 /制造制造 什么物料？什么物料？ 什么时候？什么时候？ 数量多少？数量多少？ 分段执行分段执行 制造工令制造工令 采购采购 /委外加工委外加工 计划计划 应发哪些订单？应发

15、哪些订单？ 哪些订单需提前或延缓安排？哪些订单需提前或延缓安排？ 哪些料应催收哪些料应催收? 执行执行 图图 6-4 系统处理逻辑图系统处理逻辑图 SIME, SHUFE物料需求计划（MRP）2MRP的计算过程1 1、毛需求毛需求2 2、当前预计可用库存量、当前预计可用库存量= =现有库存量现有库存量- -已分配量已分配量3 3、PABPAB初值初值= =上期末预计可用库存量上期末预计可用库存量+ +计划接收量计划接收量- -毛需求毛需求量量4 4、净需求量、净需求量当当PABPAB初值初值=安全库存，净需求安全库存，净需求=0=0当当PABPAB初值初值 00，计划产出量，计划产出量= =N

16、 N* *批量批量满足：计划产出量满足：计划产出量=净需求净需求 （N-1N-1）* *批量批量6 6、预计可用库存量、预计可用库存量= =计划产出量计划产出量+ +PABPAB初值初值7 7、考虑提前期，推算计划投入量、考虑提前期，推算计划投入量SIME, SHUFECooperstown Cars, Inc.vProduces toy carsBodyAxles (2)Wheels (4)Toy CarWheelAssembly(2)BodyAxle (1)Wheels (2)Bill of Materials for Toy CarSIME, SHUFECooperstown Cars,

17、 Inc.- Each component has a known lead timeToy CarLT = 1WheelAssembly(2)LT = 1BodyLT = 2Axle (1)LT = 2Wheels (2)LT = 1Bill of Materials for Toy CarSIME, SHUFECooperstown Cars, Inc.vSchedule production for:Toy car assemblyWheel assemblyBodyAxleWheelsvDemand for Toy Car in Week 8 is 100SIME, SHUFETime

18、-Phased Product Structure1 weekToyCarTime in Weeks45678SIME, SHUFETime-Phased Product Structure1 week1 weekToyCarWheelAssemblyBody2 weeks45678Time in WeeksSIME, SHUFETime-Phased Product Structure1 week1 weekToyCarWheelAssemblyBodyAxlesWheels2 weeks1 week2 weeks45678Time in Weeks12345678Toy CarRequir

19、ed Date100Order release dataWheel assembly Required DateOrder release dataBodyRequired DateOrder release dataAxleRequired DateOrder release dataWheelsRequired DataOrder release dataWeekGross Requirements Plan12345678Toy CarRequired Date100Order release data100Wheel assembly Required DateOrder releas

20、e dataBodyRequired DateOrder release dataAxleRequired DateOrder release dataWheelsRequired DataOrder release dataWeekGross Requirements Plan12345678Toy CarRequired Date100Order release data100Wheel assembly Required Date200Order release dataBodyRequired DateOrder release dataAxleRequired DateOrder r

21、elease dataWheelsRequired DataOrder release dataWeekGross Requirements Plan12345678Toy CarRequired Date100Order release data100Wheel assembly Required Date200Order release data200BodyRequired DateOrder release dataAxleRequired DateOrder release dataWheelsRequired DataOrder release dataWeekGross Requ

22、irements Plan12345678Toy CarRequired Date100Order release data100Wheel assembly Required Date200Order release data200BodyRequired Date100Order release dataAxleRequired DateOrder release dataWheelsRequired DataOrder release dataWeekGross Requirements Plan12345678Toy CarRequired Date100Order release d

23、ata100Wheel assembly Required Date200Order release data200BodyRequired Date100Order release data100AxleRequired DateOrder release dataWheelsRequired DataOrder release dataWeekGross Requirements Plan12345678Toy CarRequired Date100Order release data100Wheel assembly Required Date200Order release data2

24、00BodyRequired Date100Order release data100AxleRequired Date200Order release data200WheelsRequired DataOrder release dataWeekGross Requirements Plan12345678Toy CarRequired Date100Order release data100Wheel assembly Required Date200Order release data200BodyRequired Date100Order release data100AxleReq

25、uired Date200Order release data200WheelsRequired Data400Order release data400WeekGross Requirements PlanSIME, SHUFE12345678Toy CarGross requirements100Scheduled receiptsProjected on-hand | 202020202020202020Planned order receiptsPlanned order releasesNet Requirements PlanWeekSIME, SHUFE12345678Toy C

26、arGross requirements100Scheduled receiptsProjected on-hand | 202020202020202020Planned order receipts80Planned order releasesNet Requirements PlanWeekSIME, SHUFE12345678Toy CarGross requirements100Scheduled receiptsProjected on-hand | 202020202020202020Planned order receipts80Planned order releases8

27、0Net Requirements PlanWeekSIME, SHUFE12345678Toy CarGross requirements100Scheduled receiptsProjected on-hand | 202020202020202020Planned order receipts80Planned order releases80Wheel assembly Gross requirements160Scheduled receiptsProjected on-hand |10Planned order receiptsPlanned order releasesNet

28、Requirements PlanWeekSIME, SHUFE12345678Toy CarGross requirements100Scheduled receiptsProjected on-hand | 202020202020202020Planned order receipts80Planned order releases80Wheel assembly Gross requirements160Scheduled receiptsProjected on-hand |1010101010101010Planned order receiptsPlanned order rel

29、easesNet Requirements PlanWeekSIME, SHUFE12345678Toy CarGross requirements100Scheduled receiptsProjected on-hand | 202020202020202020Planned order receipts80Planned order releases80Wheel assembly Gross requirements160Scheduled receiptsProjected on-hand |1010101010101010Planned order receipts150Plann

30、ed order releases150Net Requirements PlanWeekSIME, SHUFE12345678Toy CarGross requirements100Scheduled receiptsProjected on-hand | 202020202020202020Planned order receipts80Planned order releases80BodyGross requirements80Scheduled receiptsProjected on-hand |4040404040404040Planned order receiptsPlann

31、ed order releasesNet Requirements PlanWeekSIME, SHUFE12345678Toy CarGross requirements100Scheduled receiptsProjected on-hand | 202020202020202020Planned order receipts80Planned order releases80BodyGross requirements80Scheduled receiptsProjected on-hand |4040404040404040Planned order receipts40Planne

32、d order releases40Net Requirements PlanWeekSIME, SHUFE12345678Wheel assembly Gross requirements160Scheduled receiptsProjected on-hand |1010101010101010Planned order receipts150Planned order releases150AxlesGross requirements150Scheduled receiptsProjected on-hand | 15Planned order receiptsPlanned ord

33、er releasesNet Requirements PlanWeekSIME, SHUFE12345678Wheel assembly Gross requirements160Scheduled receiptsProjected on-hand |1010101010101010Planned order receipts150Planned order releases150AxlesGross requirements150Scheduled receiptsProjected on-hand | 15151515151515Planned order receipts135Pla

34、nned order releasesNet Requirements PlanWeekSIME, SHUFE12345678Wheel assembly Gross requirements160Scheduled receiptsProjected on-hand |1010101010101010Planned order receipts150Planned order releases150AxlesGross requirements150Scheduled receiptsProjected on-hand | 15151515151515Planned order receip

35、ts135Planned order releases135Net Requirements PlanWeekSIME, SHUFE12345678Wheel assembly Gross requirements160Scheduled receiptsProjected on-hand |1010101010101010Planned order receipts150Planned order releases150WheelsGross requirements300Scheduled receiptsProjected on-hand | 30Planned order receip

36、tsPlanned order releasesNet Requirements PlanWeekSIME, SHUFE12345678Wheel assembly Gross requirements160Scheduled receiptsProjected on-hand |1010101010101010Planned order receipts150Planned order releases150WheelsGross requirements300Scheduled receiptsProjected on-hand | 30303030303030Planned order

37、receipts270Planned order releasesNet Requirements PlanWeekSIME, SHUFE12345678Wheel assembly Gross requirements160Scheduled receiptsProjected on-hand |1010101010101010Planned order receipts150Planned order releases150WheelsGross requirements300Scheduled receiptsProjected on-hand | 30303030303030Plann

38、ed order receipts270Planned order releases270Net Requirements PlanWeekSIME, SHUFEExplanation:Gross requirements are the total demand for wheels. Projected on-hand inventory in week 1 is 30 + 200heelsGross requirements150120150120Scheduled receipts200Projected on-hand | 30Planned order r

39、eceiptsPlanned order releasesNet Requirements PlanWeekSIME, SHUFEProjected on-hand inventory balance at end of week tInventory on hand at end of week t - 1Gross requirements in week tScheduled or planned receipts in week t=+12345678WheelsGross requirements150120150120Scheduled receipts200Projected o

40、n-hand | 3080Planned order receiptsPlanned order releasesNet Requirements PlanWeekSIME, SHUFE12345678WheelsGross requirements150120150120Scheduled receipts200Projected on-hand | 30808080Planned order receiptsPlanned order releasesNet Requirements PlanWeekSIME, SHUFELead time = 1 week12345678WheelsGr

41、oss requirements150120150120Scheduled receipts200Projected on-hand | 30808080Planned order receiptsPlanned order releasesNet Requirements PlanWeekSIME, SHUFELead Time = 1 week12345678WheelsGross requirements150120150120Scheduled receipts200Projected on-hand | 30808080Planned order receipts40Planned

42、order releases40Net Requirements PlanWeekSIME, SHUFELead Time = 1 week12345678WheelsGross requirements150120150120Scheduled receipts200Projected on-hand | 30808080000Planned order receipts40150Planned order releases40150Net Requirements PlanWeekSIME, SHUFELead Time = 1 week12345678WheelsGross requir

43、ements150120150120Scheduled receipts200Projected on-hand | 308080800000Planned order receipts40150120Planned order releases40150120Net Requirements PlanWeekSIME, SHUFELead time = 1 week12345678WheelsGross requirements150120150120Scheduled receipts200Projected on-hand | 30808080Planned order receipts

44、Planned order releasesNet Requirements PlanWeekyearunitswkunitsD/3510/5 .678/ )120150120150(11652100)3510(22*HDSQyearunitweekunitHS/52$/1$100$SIME, SHUFELead time = 1 week12345678WheelsGross requirements150120150120Scheduled receipts200Projected on-hand | 30808080Planned order receipts116Planned ord

45、er releases116Net Requirements PlanWeekSIME, SHUFELead time = 1 week12345678WheelsGross requirements150120150120Scheduled receipts200Projected on-hand | 308080807676Planned order receipts116Planned order releases116Net Requirements PlanWeek80+116-120 = 76SIME, SHUFELead time = 1 week12345678WheelsGr

46、oss requirements150120150120Scheduled receipts200Projected on-hand | 308080807676Planned order receipts116116Planned order releases116116Net Requirements PlanWeekSIME, SHUFELead time = 1 week12345678WheelsGross requirements150120150120Scheduled receipts200Projected on-hand | 30808080767642Planned or

47、der receipts116116116Planned order releases116116116Net Requirements PlanWeekSIME, SHUFELead time = 1 week12345678WheelsGross requirements150120150120Scheduled receipts200Projected on-hand | 308080807676423838Planned order receipts116116116Planned order releases116116116Net Requirements PlanWeekSIME

48、, SHUFE物料需求计算物料需求计算(逐级展开逐级展开)XA (1)C (2)O (1)C201010A1010O提前期提前期=2提前期提前期=1提前期提前期=1批量批量=40批量批量=1批量批量=1X提前期提前期=1批量批量=1时时 段段计划投入量计划投入量计划产出量计划产出量12345678910 1112现有量现有量=0时时 段段计划投入量计划投入量计划产出量计划产出量12345678910 1112现有量现有量=0现有量现有量=0时时 段段计划投入量计划投入量计划产出量计划产出量12345678910 1112计划接收量计划接收量现有量现有量=50时时 段段计划投入量计划投入量计划产出量计划产出量12345678910 1112计划接收量计划接收量 毛毛 需需 求求净净 需需 求求预计库存量预计库存量1010101010101010 510101010101010 51010101020202020102