Lecture 9 Flashcards
What is a manufacturing system?
A manufacturing system is a set of equipment and human resources that perform processing and/or assembly operations on raw materials, parts, or sets of parts. The system includes production machines, tools, material handling devices, and computer systems, with human operators involved full-time or periodically.
What is inventory control, and why is it important?
Inventory control is essential for balancing the cost of maintaining inventory with maximizing service to customers. It includes investment costs, storage costs, and potential obsolescence or spoilage. Effective inventory control ensures that internal and external customer needs are met efficiently.
What are the two types of manufacturing systems?
- Continuous Process: Non-stop production of the same product, usually involving chemical operations (e.g., sugar or fertilizer production).
- Discrete Goods Manufacturing: Producing distinct items through physical operations, often involving assembly (e.g., cars or smartphones).
What are the three types of discrete manufacturing systems?
- Job Shop (Low volume, high variety): Custom products, flexible equipment, highly skilled workers (e.g., prototypes).
- Batch Production (Medium volume, medium variety): Producing groups of products (e.g., pharmaceuticals).
- Mass Production (High volume, low variety): Large quantities of standardized products, highly automated (e.g., automotive parts).
What is the Order Point System (OPS) used for?
OPS addresses two key questions: How much to order and when to order. It uses Economic Order Quantity (EOQ) formulas to minimize inventory cost and a Reorder Point to trigger replenishment, ensuring stable demand is met efficiently.
What are the two types of demand in inventory control systems?
- Independent Demand: Demand unrelated to other products (e.g., a car). Managed by the Order Point System (OPS).
- Dependent Demand: Demand tied to another product (e.g., car tires depend on car production). Managed by Material Requirements Planning (MRP).
What is Material Requirements Planning (MRP), and what does it do?
MRP is a computational system designed to manage inventory by converting a master production schedule (MPS) into detailed schedules for raw materials and components. It determines what, when, and how much to order, ensuring efficient production with minimal stock levels.
What are the key components of an MRP system?
- Master Production Schedule (MPS): Specifies what products should be produced, when, and in what quantities.
- Bill of Materials (BOM): A detailed list of materials and components needed for production.
- Inventory Record: Information about the status of individual items, including ID, order quantity, and lead times.
What is lead time in MRP, and what are the two types?
- Ordering Lead Time: The time required from initiating a purchase to receiving the item.
- Manufacturing Lead Time: The time required to produce an item in-house from order release to completion.
What is Economic Order Quantity (EOQ), and when is it used?
EOQ is used for independent demand items to determine the optimal order quantity that minimizes the total cost of inventory and setup. It is commonly applied in make-to-stock scenarios and batch production.
What are the prerequisites for an MRP system to function effectively?
- A clear Master Production Schedule (MPS).
- A Bill of Materials (BOM) that accurately defines the structure of each item.
- Up-to-date inventory information.
- Known planning lead times for each planned part.
What is Manufacturing Resource Planning (MRPII), and how does it expand on MRP?
MRPII is an extension of MRP that incorporates additional factors like capacity planning and shop floor control (SFC). It is a company-wide information system used for planning, scheduling, and controlling resources to meet the master production schedule.
What is Shop Floor Control (SFC), and why is it important in MRPII?
SFC manages work-in-progress, ensures that production schedules are feasible, and assigns production orders to work centers. It also monitors progress and performance, ensuring efficient operations on the factory floor.
What is Enterprise Resource Planning (ERP), and how does it differ from MRPII?
ERP is a computer software system that integrates all business functions (sales, finance, manufacturing, human resources, etc.) into a single system. It uses a central database for real-time updates and manages large amounts of data, supporting business-wide decision-making.
How do MRP and ERP integrate with modern design tools and cloud computing?
Modern MRP and ERP systems integrate with design tools (e.g., SolidWorks) and use cloud computing for real-time data processing and storage. This integration allows companies to manage production efficiently while adapting to changing conditions.
