SCM_MRP（PPT72页)

UpstreamSupplyChainInventoryManagementFromDRPtoMRPTraditionalInventoryManagementSupplyChainInventoryIntegrationWhatifIUseTraditionalTechniques?•Insuchaninventorysystemswithdecentralizedcontrol,lotsize/reorderpointlogicwill:CreateandamplifylumpydemandLeadtothemal-distributionofavailablestock,hoardingofstock,andunnecessarystockoutsForcerelianceonlargesafetystocks,expediting,andre-distribution.■■■ImpactofbullwhipeffectCDCDemandPatternRDCOrderingPatternsRDCInventoryCyclesLayersofInventoryCreateLumpyDemandAsweknow,localoptimizationalwaysresultinun-globaloptimization.Weneed“SupplyChainInventoryIntegration”MRP/DRPIntegrationPurchaseOrdersMRPMPSDRPProductCDCRDCRetailRetailRetailRetailSales/MarketingPlanDistributionRequirementsPlanning(DRP)-review•Anticipatesdownstreamsupplychaininventorycontrol•Alwaysforindependentdemand.•DistributiondecisionfromVMImethod.DRPRequirements•InformationRequirements:BaseLevelUsageForecastsDistributionNetworkDesignInventoryStatusOrderingDataDRPProcess:RequirementsImplosionNetfromGrossRequirementsRequirementsTimePhasingPlannedOrderRelease■■■■■■■■SupposeweforecastdemandforWholesalerAforthenext8days(thebesttimehorizontousewilldependonmanyfactors)Basedonthis,weanticipatethatWholesalerAwillorderonDay3DRPExampleIWholesalerAROP=50,Q=200Day1Day2Day3Day4Day5Day6Day7Day8ForecastDemand2020202020202020EndingInventory856545225205185165145125ExpectedOrder200WeextendtheanalysistoincludeWholesalerBCombined,weexpecttoseeordersonDays3and4WholesalerAROP=50,Q=200Day1Day2Day3Day4Day5Day6Day7Day8ForecastDemand2020202020202020EndingInventory856545225205185165145125ExpectedOrder200WholesalerBROP=75,Q=200Day1Day2Day3Day4Day5Day6Day7Day8ForecastDemand1414141414141414EndingInventory108948066252238224210196ExpectedOrder200TotalOrders200200DRPExampleIIThedistributorthenusesthisinformationtoplanitsownorders.Inthiscase,supposeittakestwodaysforthesuppliertoreplenish;basedontheinformation,thedistributorwouldorderonDay1WholesalerAROP=50,Q=200Day1Day2Day3Day4Day5Day6Day7Day8ForecastDemand2020202020202020EndingInventory856545225205185165145125ExpectedOrder200WholesalerBROP=75,Q=200Day1Day2Day3Day4Day5Day6Day7Day8ForecastDemand1414141414141414EndingInventory108948066252238224210196ExpectedOrder200DistributorQ=400Day1Day2Day3Day4Day5Day6Day7Day8TotalExpectedOrders200200EndingInventory5050502505050505050PlannedReceipts400PlannedOrders400DRPExampleIIIADistributionNetworkPlantCentraWarehouseRegionalWarehouse2RegionalWarehouse1RegionalWarehouse3RetailerARetailerBRetailerCRetailerDRetailerERetailerERetailerGRetailerHRetailerIMITCenterforTransportation&Logistics-ESD.2608©ChrisCaplice,MITExample:TheDRPPlanRegionalWarehouseOneQ=50,SS=15,LT=1PeriodUsageGrossRqmtBeginInvSchedRcptNetRqmtPlanRcptEndInvPORtTheDRPPlanCentralWarehouseFacilityPeriodUsageGrossRqmtBeginInvSchedRecptNetRqmtPlannedRecptEndInvPlannedOrderPeriodUsageGrossRqmtBeginInvSchedRecptNetRqmtPlannedRecptEndInvPeriodUsageGrossRqmtBeginInvSchedRecptNetRqmtPlannedRecptEndInvPlannedOrderPeriodUsageGrossRqmtBeginInvSchedRecptNetRqmtPlannedRecptEndInvPlannedOrderExample:TheDRPPlanRegionalWarehouseTwoQ=30,SS=10,LT=1PeriodUsageGrossRqmtBeginInvSchedRcptNetRpmtPlanRcptEndInvPORNOWExample:TheDRPPlanRegionalWarehouseThreeQ=20,SS=10,LT=1PeriodUsageGrossRqmtBeginInvSchedRcptNetRpmtPlanRcptEndInvPORNOWTheDRPPlanforAllLocationsRollingUpOrdersNOW12345678CENTRALPeriodUsage10020503010001000POR200200200REGIONONEPeriodUsage2525252525252525POR50505050REGIONTWOPeriodUsage1010101010101010POR30303030REGIONTHREEPeriodUsage5151010015015POR20202020Example:TheDRPPlanCentralWarehouseQ=200,SS=0,LT=2PeriodUsageGrossRqmtBeginInvSchedRcptNetRpmtPlanRcptEndInvPORDRPBenefitsHelpsimprovecustomerserviceProvidesabetterandfasterunderstandingoftheimpactofshortagesand/orpromotionsHelpsreducecostsInventoryFreightProductionProvidesintegrationbetweenthestagesinthedownstreamsupplychainHowtointegrateupstreamsupplychaininventorymanagement?SupplyChainInventoryIntegrationSupplyChainInventoryIntegrationSupplyChainInventoryIntegrationSupplyChainInventoryIntegrationSupplyChainInventoryIntegrationSupplyChainInventoryIntegrationSupplyChainInventoryIntegrationSupplyChainInventoryIntegrationSupplyChainInventoryIntegrationSupplyChainInventoryIntegrationSupplyChainInventoryIntegrationSupplyChainInventoryIntegrationSupplyChainInventoryIntegrationSupplyChainInventoryIntegrationWe’vescheduled500chairstobereadyfiveweeksfromnow......Nowwhat?PerfectExample1-ChairinventorycontrolBacksupports(3)Siderails(2)Frontlegs(2)Crossbars(2)SeatMaterialNeededforaChairChairStructureTree(aka“BillofMaterials”orBOM)ChairLegAssemblySeatBackAssemblyLegs(2)CrossbarSiderails(2)CrossbarBackSupports(3)ChairAssembly(1week)Week5Week4Iffinalassemblytakesoneweek,thenwemuststarttheassemblyatthebeginningofWeek4...Lead-TimeIChairAssemblyBackAssemblyLegAssembly(1week)(1week)(1week)Seats(2weeks)Week5Week4Week3Week2WhichmeansthatthemajorsubassembliesandseatsmustbedonebythebeginningofWeek4...Lead-TimeIIChairAssemblyBackAssemblyLegAssembly(1week)(1week)(1week)B