Professional Documents
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TEMA 1:
PROGRAMACIN MAESTRA DE
LA PRODUCCIN
(Master Production Scheduling: MPS)
Sesin 2: TEMAS:
TEMA 1: PROGRAMACIN MAESTRA DE LA
PRODUCCIN (MPS: Master Production Plan)
TEMA 2: PLANIFICACIN DE REQUERIMIENTOS DE
MATERIALES (MRP: Materials Requirement Plan)
TEMA 3: SISTEMAS JUSTO A TIEMPO (JIT: Just In Time)
1/
2/
1.
Proceso MPS
Estn
No
disponibles los
recursos?
Plan Maestro de
Produccin
(tentativo) (MPS)
Inventario
proyectado a
la mano al
final de la
semana
Si
Planeacin de
Requerimientos
de Materiales
(MRP)
Plan Maestro de
Produccin
(autorizado) (MPS)
3/
Inventario a la
mano al final de
la ltima semana
Requerimientos
proyectados de
la semana
Cantidad en el
MPS
pendiente al
inicio de esta
semana
4/
Ejercicio
Order Policy: 150 units
Lead Time: 1 week
Quantity on
Hand:
April
55
Forecast
Customer
orders
(booked)
Projected
on-hand
inventory
May
30
30
30
30
35
35
35
35
38
27
24
MPS quantity
MPS start
5/
Available-topromise (ATP)
inventory
6/
Solucin
El
tiempo
necesario para
el ensamble de
150 sillas es de
una semana. Por
consiguiente, el
depto
de
ensamble
deber
comenzar
el
ensamble de las
sillas
en
la
semana 1 para
poder tenerlas
listas
en
la
semana 2
May
Forecast
30
30
30
30
35
35
35
35
Customer
orders
(booked)
38
27
24
Projected
on-hand
inventory
17
137
107
77
42
122
87
150
150
150
150
17
91
MPS quantity
MPS start
Available-topromise (ATP)
inventory
55
Saldo
del
inventario
a
la
mano=17+150-30=137. La cantidad
necesaria para evitar una escasez de
30-17=13 sillas en la semana 2
Quantity on
Hand:
150
7/ la
El total de los pedidos de los clientes registrados, hasta
prxima recepcin del MPS es de 27+24+8=59.El invent
ATP=150-59=91
Dr. Omar Romero Hernndez
Semana
MPS
cantidad
10
150
150
Valla del
tiempo
de
demanda
Email: oromero@itam.mx
8/
Dr. Omar Romero Hernndez
Email: oromero@itam.mx
1. SISTEMA MRP
Order
1000 on
day 8
1500
Rims
Bicycles
1000
500
|
1
9/
(a)
Reorder point
| | | | | | |
5
Day
|
10
0
(b)
|
1
| |
5
Day
|
10
10/
PLANEACIN DE
REQUERIMIETOS DE
MATERIALES
(MRP: Materials Requirement Plan)
9 Provee
informacin
para
planificar
capacidades y requerimientos financieros.
9 Actualizacin automtica
11/
12/
Explosin de materiales
(Bill of Materials, BOM)
Transacciones
de
inventario
Registros de
inventarios
MRP
explosion
Plan de
Requerimientos
de Materiales
(MRP)
Tema : Gestin de Riesgos.
A
LadderLadder-back
chair
Otras
fuentes de
demanda
Bills of
Materials
(BOM)
Ingeneria
y procesos
de diseo
F (2)
Back
legs
B (1)
Ladder-back
subassembly
C (1)
Seat
subassembly
D (2)
Front
legs
G (4)
Back
slats
H (1)
Seat
frame
I (1)
Seat
cushion
E (4)
Leg
supports
J (4)
Seat-frame
boards
13/
Dr. Omar Romero Hernndez
Email: oromero@itam.mx
14/
Dr. Omar Romero Hernndez
Email: oromero@itam.mx
2. Explosin de materiales
(BILL OF MATERIALS)
2. Bill of Materials
1.
2.
3.
15/
16/
3. PLANIFICACIN DE MRP
4. REGISTRO DE INVENTARIO
April
1
Ladder-back chair
May
3
150
120
200
Aggregate
production plan
for chair family
150
Kitchen chair
Desk chair
200
120
200
670
200
670
17/
Requerimientos
brutos
Recepciones
programadas
Inventario
proyectado a la
mano
Recepciones
planeadas
Emisiones
planeadas de
pedidos
19/
18/
Ejemplo
Item: C
Description: Seat subassembly
Item: C
Description: Seat subassembly
Week
Week
Gross
requirements
150
120
150
120
Scheduled
receipts
230
Projected
on-hand
inventory
Requerimientos
brutos
150
120
150
120
Recepciones
programadas
230
117
117
117
-3
-3
- 153
- 273
- 273
Inventario
proyectado
a la mano
37
Planned
receipts
Recepciones
planeadas
Planned order
releases
21/
)(
Projected on-hand
inventory balance
Emisiones
at end of week t
planeadas
37
)(
Inventory on
hand at end
of week t - 1
)( )
Scheduled
or planned
receipts in
week t
Gross
requirements
in week t
22/
Week
1
Requerimientos
brutos
150
120
150
120
Recepciones
programadas
230
117
117
117
227
227
187
187
Inventario
proyectado
a la mano
37
Recepciones
planeadas
Emisiones
planeadas
230
230
77
230
230
Dr. Omar Romero Hernndez
Email: oromero@itam.mx
Dr. Omar Romero Hernndez
23/
24/
Dr. Omar Romero Hernndez
Email: oromero@itam.mx
Tema : Gestin de Riesgos.
Ejemplo POQ
Item: C
Description: Seat subassembly
POQ
(120 + 0 + 150)
Item: C
Description: Seat subassembly
Lot Size: P = 3
Lead Time: 2 weeks
Lot Size: P = 3
Lead Time: 2 weeks
Week
Week
1
1
Gross
requirements
150
Scheduled
receipts
230
Projected
on-hand
inventory
37
4
120
150
120
Gross
requirements
150
Scheduled
receipts
230
Projected
on-hand
inventory
117
37
4
120
117
25/
Planned order
releases
150
150
117
117
Planned
receipts
Planned
receipts
Planned order
releases
120
120
26/
Ejemplo
Item: C
Description: Seat subassembly
Week
1
150
120
153
153
Gross
requirements
150
Scheduled
receipts
230
Projected
on-hand
inventory
37
117
4
120
117
150
120
117
Planned
receipts
27/
Planned order
releases
28/
120 - 117 = 3
Item: C
Description: Seat subassembly
A
LadderLadder-back
chair
1
Gross
requirements
150
Scheduled
receipts
230
Projected
on-hand
inventory
37
117
120
150
C (1)
Seat
subassembly
D (2)
Front
legs
E (4)
Leg
supports
G (4)
Back
slats
H (1)
Seat
frame
I (1)
Seat
cushion
C (1)
Seat
subassembl
y
8
F (2)
Back
legs
120
J (4)
Seat-frame
boards
117
117
Planned
receipts
Planned order
releases
B (1)
Ladder-back
subassembly
150
150
H (1)
Seat
frame
120
29/
120
30/
J (4)
Dr. Omar Romero Hernndez
Seat-frame
Email:
oromero@itam.mx
boards
I (1)
Seat
cushion
7. EXPLOSIN MRP
Gross
requirements
Gross
requirements
Scheduled
receipts
Projected
on-hand
inventory
37
150
120
150
120
117
117
Planned
receipts
Planned order
releases
150
120
150
120
117
227
227
230
77
187
Lead
time: 1 week
187
Usage quantity: 1
Item: Seat cushion
Lot size: L4L
Week
Gross
requirements
230
230
Scheduled
receipts
300
Projected
on-hand
inventory
230
230
230
230
40
40
110
110
110
31/
Planned
order
releases
180
180
Week
2
Gross
requirements
230
230
Scheduled
receipts
180
Projected
on-hand
inventory
180
Lead
time: 1 week
300
300
230
Usage quantity: 1
Planned
receipts
230
230
Planned
order
releases
230
Planned
receipts
Week
Lead
time: 2 weeks
Week
Lead
time: 2 weeks
Planned
receipts
Planned
order
releases
230
230
230
230
32/
8. REQUERIMIENTOS DE CAPACIDAD
Week
Lead
time: 1 week
Gross
requirements
230
230
Planned
receipts
Gross
requirements
230
230
Planned
receipts
300
Planned
order
releases
Lead
time: 1 week
230
Planned
order
releases
300
230
230
Fecha:
Plant 01 Dept. 03: Lathe Station
Capacity: 320 hours per week
230
Semana: 32
Week
Se requieren 4 unidades
32
33
34
35
36
37
Hr planeadas
90
156
349
210
360
280
Hr reales
210
104
41
Hr totales
300
260
390
210
360
280
Gross
requirements
1200
Scheduled
receipts
200
200
200
500
500
500
500
500
Projected
200
on-hand
inventory
Planned
receipts
Planned
order
releases
1500
33/
1500
Figure 15.11
9. REPORTES
Priority reports
Dispatch lists
Supplier
Week: 32
Se permiten desviaciones
acumulativas de entre
-25 horas y +25 horas.
Week Ending
Capacity reports
Capacity requirements planning
Finite capacity scheduling
Input-output control
schedules
9. REPORTE DE INPUT-OUTPUT
MRP
explosion
Action notices
Releasing new
Los requerimientos
de capacidad
proyectados
exceden las horas34/
semanales de
Dr. Omar Romero Hernndez
capacidad.
Email: oromero@itam.mx
28
29
30
31
32
160
145
- 15
155
160
- 10
170
168
- 12
160
177
+5
165
170
165
-5
170
165
- 10
160
150
- 20
160
148
- 32
Inputs
Routings
and time
standards
Planned
Actual
Cumulative deviation
Outputs
Manufacturing resources plan
Performance
reports
Cost and
price data
35/
Planned
Actual
Cumulative deviation
Figure 15.13
La desviacin acumulativa
excede
el
lmite
de
tolerancia inferior, lo cual
indica que las horas reales
160
de produccin han cado
demasiado por debajo de las
horas
de
produccin
36/
planeadas y es necesario
Dr. Omar Romero Hernndez
hacer algo al respecto.
Email: oromero@itam.mx
TEMA:
Level 2
Intermediate care
Level 6
Postoperative care
(Angiogram)
Level 3
Postoperative care
(Step down)
Nurse
(6 hr)
MD
(1 hr)
Therapy
(1 hr)
Bed
(24 hr)
Lab
(3 tests)
Kitchen
(1 meal)
Pharmacy
(10
medicines)
Level 4
Postoperative care
(Intensive)
Level 5
Surgery
Level 6
Postoperative care
(Angiogram)
Level 7
Postoperative care 37/
(Testing)
38/
Introduccin
Introduccin
The Wall Street Journal, An automaker tries the Dell way, Agosto 1999.
-Procesos alineados
-Un mnimo (cero?) de manejo de materiales
-Corridas de produccin pequeas (una unidad?)
-Costos mnimos de set-up
-Niveles mnimos de inventario
39/
40/
Introduccin
inputs
Process
outputs
Customer
inputs
Process
outputs
Customer
43/
Information Flow:
Tema : Gestin de Riesgos.
44/
Material
Dr. OmarFlow:
Romero Hernndez
Email: oromero@itam.mx
100
100
Average cycle
inventory
75
On-hand inventory
On-hand inventory
Average cycle
inventory
50
25
10
Figure 16.1
15
Time (hours)
20
25
30
50
25
45/
75
10
Figure 16.1
15
Time (hours)
20
100
Average cycle
inventory
75
On-hand inventory
On-hand inventory
Average cycle
inventory
50
Lot size = 50
25
Figure 16.1
46/
100
30
25
10
15
Time (hours)
20
25
30
47/
75
50
Lot size = 50
25
0
Figure 16.1
10
15
Time (hours)
20
25
30
48/
Minimizacin de desperdicios:
(Parte 1)
(Parte 2)
Un diseo de planta dividido conforme a clulas de
manufactura reduce el movimiento innecesario ed materiales y
en consecuencia aumenta la productividad (Ley de Little:
I=RT)
Saw
Saw
Grinder
Grinder
Grinder
Saw
Lathe
Lathe
Press
Lathe
Press
Heat Treat
Heat Treat
Grinder
Lathe
Lathe
Lathe
Press
Press
Press
Saw
Lathe
49/
50/
Minimizacin de desperdicios:
Cargas de trabajo uniformes
Sistema JIT
Not uniform
Jan. Units
Feb. Units
Mar. Units
Total
1,200
3,500
4,300
9,000
or
Uniform
Jan. Units
Feb. Units
Mar. Units
Total
3,000
3,000
3,000
9,000
QU ES?
QU HACE?
Filosofa de gestin
Sistema de arrastre
a lo largo de la planta
QU REQUIERE?
QU ASUME?
Ambiente estable
51/
52/
Email: oromero@itam.mx
Receiving post
Storage
area
Empty containers
Assembly line 1
O2
O1
Fabrication
cell
O3
O2
53/
Assembly line 2
Full containers
54/
Figure 16.3
Dr. Omar Romero Hernndez
Email: oromero@itam.mx
Storage
area
Empty containers
Storage
area
Empty containers
Assembly line 1
O1
Assembly line 1
O2
O2
Fabrication
cell
Fabrication
cell
O3
O2
Assembly line 2
Full containers
55/
Figure
Dr. Omar Romero Hernndez
Email: oromero@itam.mx
Tema : Gestin de Riesgos.
O1
O3
O2
16.3
Assembly line 2
Full containers
56/
Figure
Dr. Omar Romero Hernndez
Email: oromero@itam.mx
Tema : Gestin de Riesgos.
16.3
Storage
area
Empty containers
Storag
e area
Empty containers
Assembly line 1
Assembly line 1
O2
O1
O2
Fabrication
cell
O3
Assembly line 2
Fabrication
cell
Full containers
O2
Assembly line 2
Full containers
58/
16.3
Figure
Dr. Omar Romero Hernndez
Email: oromero@itam.mx
O3
O2
57/
Figure
Dr. Omar Romero Hernndez
Email: oromero@itam.mx
Receiving post
O1
Storage
area
Empty containers
Storage
area
Empty containers
Assembly line 1
O1
Assembly line 1
O2
O2
Fabrication
cell
Fabrication
cell
O3
O2
Assembly line 2
Full containers
59/
Figure
Dr. Omar Romero Hernndez
Email: oromero@itam.mx
Tema : Gestin de Riesgos.
16.3
O1
O3
O2
16.3
Assembly line 2
Full containers
60/
Figure
Dr. Omar Romero Hernndez
Email: oromero@itam.mx
Tema : Gestin de Riesgos.
16.3
Nmero de contenedores
Nmero de contenedores
Westerville Auto Parts
d = 2000 units/day p = 0.02 day = 0.10
w = 0.08 day c = 22 units
k=
d( w + p )( 1 + )
c
61/
62/
Dr. Omar Romero Hernndez
Example
Email: oromero@itam.mx
Nmero de contenedores
Nmero de contenedores
k=
k=
22
63/
Dr. Omar Romero Hernndez
Example
Email: oromero@itam.mx
Tema : Gestin de Riesgos.
16.1
64/
16.1
16.1
Nmero de contenedores
Nmero de contenedores
k = 10 containers
k = 10 containers
k=
d( w + p )( 1 + )
c
65/
Dr. Omar Romero Hernndez
Example
Email: oromero@itam.mx
Tema : Gestin de Riesgos.
66/
16.1
Nmero de contenedores
Nmero de contenedores
k = 10 containers
k=
k = 10 containers
2000(0.06 + 0.02)(1.10)
k=
22
2000(0.06 + 0.02)(1.10)
22
67/
Dr. Omar Romero Hernndez
Example
Email: oromero@itam.mx
Tema : Gestin de Riesgos.
16.1
68/
16.1
16.1
Nmero de contenedores
JIT en servicios
k = 10 containers
k = 8 containers
69/
Dr. Omar Romero Hernndez
Example
Email: oromero@itam.mx
Tema : Gestin de Riesgos.
16.1
71/
Beneficios operativos
70/
72/