MRP: En kort guide

Anslået læsetid: 10 Minutter

Planlægning er afgørende for at opnå succes med et mål. Antag for eksempel, at du planlægger en begivenhed eller
en rejse på forhånd, eller endda daglige aktiviteter som madlavning. I så fald har du brug for
organisering for at have den rette mængde ingredienser og alle de nødvendige værktøjer for at undgå
at bruge ekstra penge og for at kunne gennemføre som planlagt. Nu er disse aktiviteter mere
ligetil at arrangere end processerne i fremstillings- og serviceindustrien.

I dagens forretningsverden er det essentielt at kende mængden af det nødvendige lager og udstyr.
På den anden side kan lagerknaphed føre til flaskehalse og forsinkede leverancer,
hvilket gør en virksomhed hverken effektiv eller konkurrencedygtig. I dag findes der Material Requirements
Planning, som vil hjælpe i denne knibe, og andre funktioner, foruden at dette system vil
gøre disse processer til en leg.

Lad os finde ud af, hvordan Material Requirements Planning fungerer, og hvordan dette system kan tage en virksomhed
til det næste niveau.

Hvad er Material Requirements Planning?

Denne planlægning hjælper med at koordinere indkøbsordrer og en optimal produktionsplan, opretholde passende niveauer af tilgængeligt lager i henhold til nuværende og endda fremtidig efterspørgsel, og hjælper med at justere produktionsplaner for at undgå lagerknaphed. En MRP overvåger også, at produktionsprocesserne opfyldes uden fejl inden for den fastsatte tid.

Material Requirements Planning er et fremragende værktøj til at hjælpe virksomheder med at reagere mere effektivt på øget efterspørgsel og forhindre forsinkelser eller manglende tilgængelighed. Dette værktøj bruges hovedsageligt til produktbaserede virksomheder.

MRP-systemet opnår denne effektivitet ved at overveje flere faktorer, såsom mængden af tilgængeligt lager, en virksomheds produktionskapacitet, leveringstider og kundernes efterspørgsel. På denne måde arbejder en virksomhed så effektivt som muligt. MPR’s primære mål er at reducere lagerniveauerne og bruge dem mest effektivt uden at ignorere produktionsefterspørgslen.

MRP-typer

Der findes to typer Material Requirements Planning på markedet, som er:

MRP I

MRP I beregner antallet af råmaterialer og komponenter, udfører organiseret lagerstyring og stykliste-håndtering og opretter en detaljeret produktionsplan, som virksomheden bruger til at fremstille et specifikt produkt. Dette system bruger information fra virksomhedens tidligere erfaringer til at bestemme behovene i produktionsprocessen.

MRP II

Efterfølgeren til MRP I. Manufacturing Resource Planning (MRP II) er et mere sofistikeret system, da MRP II, udover at opfylde MRP I-funktionerne, også opretter prognoser for kundeefterspørgsel og tager hensyn til behov og krav fra andre afdelinger som finans og kvalitet. Denne løsning er ideel for små og mellemstore virksomheder.

MRP I og MRP II betragtes som de direkte forgængere til Enterprise Resource Planning (ERP), som understøtter andre nøglefunktionsprocesser i en virksomhed, såsom forsyningskædestyring, marketing, menneskelige ressourcer og regnskab. En virksomhed kan integrere MRP-systemer med et ERP-system for at få større synlighed i informationsflowet og få bedre kontrol over fremstillingsprocessen, identificere mulige flaskehalse og tage hånd om lagerniveauer.

Et ERP er essentielt for store virksomheder, fordi denne software kan centralisere forskellige processer inden for fremstilling og holde dem strømlinede, samt dele mere gennemsigtig information på tværs af forskellige afdelinger.

Processer i MRP

MRP følger forskellige procedurer for at sikre, at den nøjagtige mængde råmateriale og komponenter er tilgængelige til produktion, og at de fastsatte mål nås med succes. Material Requirements Planning tager også højde for markedstendenser for at være forberedt på en vækst i efterspørgslen, eller hvornår man skal stoppe med at købe ind, hvis lageret falder. For at opnå dette følger en MRP disse procedurer:

1. Calculates required material according to demand: The first step this tool performs. According to the purchase order and customer specifications, an MRP estimates the raw materials necessary for the company to manufacture the order.
   
2. Manages inventory: Material Requirements Planning allocates the stock in the right place. Suppose a company has several locations and resources in different areas. In that case, MRP will dictate where the raw materials and components should be placed to avoid bottlenecks in production and make the manufacturing process more agile. In addition, you can view the status of the resources and see which ones are in transit or have already been ordered.
   
3. Creates a scheduled production: After determining the amount of raw material and components needed, an MRP calculates the estimated time and labor required to manufacture a product or service. This work plan facilitates meeting the objectives established to guarantee customer satisfaction.
   
   A production schedule also includes which machinery should be used and on which workstations. If a machine has to be adapted and assembled with other parts to create a specific product, MRP considers this time to give a realistic time frame.
   
4. Keeps track of the processes: With a tool as useful as Material Requirements Planning, a company can keep the manufacturing processes under control as MRP alerts in cases of delays and even creates contingency plans if necessary.

MRP-input

Opdateret information er nødvendig for at få bedre resultater og en mere effektiv produktion. Derudover kan ledere endda tilføje flere data, kendt som MRP-input; blandt de vigtigste er:

• Bills of materials (BOM): This is a precise list, usually arranged in a hierarchical way, of the raw materials, components, and detailed instructions of the assembly process to manufacture a product or provide a service.
  
• Master Production Schedule (MPS): A realistic production plan, determining what, how, when, and how many products should be manufactured by analyzing the demand and production capacity of the company.
  
• Inventory Status File (ISF): The up-to-date information on the status of available inventory and how much is needed to fulfill a purchase order.
  
• Forecast Demand: An MRP makes a forecast considering the number of confirmed orders, sales history, market circumstances, and trends. This forecast helps always have production resources available to meet anticipated demand.

MRP-output

Der er nogle output genereret af dit MRP-program, som din fremstillingsproces kan
bruge, såsom:

• Purchase orders: A detailed purchase scheduling that must be followed. With this schedule, a company can place a purchase order for the supplier to supply the raw materials and components required for production.
  
• Material plan: This plan incorporates details like the raw material specifications, assembly parts, and components required to finish the end product. The material plan also includes the quantities of each one and the schedule for when these resources will be needed.
  
• Work orders: This includes the work concerned with producing the end product. The work order details the raw materials and components required, the start and finish dates of the end product, and all the department-wise responsibilities to work cohesively.
  
• Primary and secondary reports: MRP elaborates two types of accounts. The first includes the purchase order, material plan, and work order, while the secondary reports show performance details, errors, and customer demand forecasting.

Fordele ved Material Requirements Planning

Mange typer virksomheder, såsom teknologiproducenter, møbelproducenter, fødevareindustrien eller endda serviceindustrien; der er flere grunde til, at en virksomhed kan drage fordel af at have et MRP-system i deres fremstillingsprocesser, såsom:

1. Better inventory management: The availability of accurate raw materials and components is essential for product manufacture and prevents delays. An MRP calculates inventory costs and helps to maintain the resources at an optimal level according to the data determined by the production schedules and forecasting customer demand, preventing shortages and bottlenecks due to a lack of resources.
   
2. Purchase planning: An MRP dictates what, how much, and when to buy raw materials and components. This system is an excellent tool that makes the work of purchasing managers flow more efficiently since the MRP can be configured to contact suppliers automatically when the software detects that a purchase must be made, matching the production plan.
   
3. Creation of contingency plans: Despite good inventory control management and predicting buyer demand, a company can have intermittent problems. If this situation arises, an MRP can suggest a new production redirection to detect bottlenecks in the manufacturing processes due to resource reduction or lack thereof to mitigate the setbacks generated.
   
4. Optimizes productivity: By scheduling manufacturing and ensuring the availability of required raw materials and components, production processes become more efficient, making better use of machinery and workforce. This work schedule also helps managers better manage the manufacturing operations to be carried out, calculate more precise operating costs and determine an accurate delivery time.
   
5. Efficient resource management: The function of an MRP is to guarantee the availability of raw materials and components for production, including the equipment and labor necessary to carry out the manufacturing process. An MRP system allows a company to have accurate data for better resource management, preventing bottlenecks and delays.
   
6. Provides data organization: Manufacturing processes generate a large amount of information, such as available inventory data, deliveries, invoices, purchases, and other reports that must be analyzed and documented in an organized manner. An MRP will help to process this tedious task, better managing the information being collected within the company.
   
7. Reduces purchasing costs: When an MRP calculates the quantity and costs necessary for manufacturing, this also includes storage, transportation, and storage costs, making Material Requirements Planning an exact tool that seeks the best, most useful, and economical option, avoiding over-purchasing raw materials and components.
   
8. Better use of time: Material Requirements Planning helps save time and makes a company more competitive. An MRP system is fully automated, so this software streamlines the production of goods with little human intervention. Otherwise, inventories would be done by hand, contact suppliers individually, calculate delivery times, and estimate a production time prone to errors and bottlenecks.
   
9. Increases customer satisfaction: Using good production planning and avoiding the risk of raw materials and components shortages, an MRP helps reduce delivery times, creating customer loyalty and building a good reputation for the company, making the business more trustful for future customers.

En MRP har dog visse ulemper; blandt de vigtigste er manglen på fleksibilitet i produktionsplanen, da systemet antager, at leveringstiden altid vil være den samme for et specifikt produkt, stigningen i lageromkostninger og fremfor alt afhængigheden af opdateret dataindtastning for at oprette tidsplanerne og for at kunne bestemme råmaterialer og komponenter.

Alligevel påtager et MRP-system sig den hårde opgave med at beregne de nødvendige råmaterialer og komponenter og styre produktionsplaner mere kompetent og effektivt end ved manuelt gætteri og brug af kedelige regneark.

Gør din virksomhed mere effektiv på ingen tid!

MRP er et værktøj, der vil lette arbejdet for SME-virksomheder med at holde lageret under kontrol uden at have for meget eller manglende lager, udføre en effektiv arbejdsplan i henhold til virksomhedens kapacitet og opretholde kundetilfredshed. Hos SkyPlanner kan vi skræddersy et MRP-system i henhold til virksomhedens behov eller rådgive, hvis du ønsker at opgradere til et ERP-system. Vores team er klar til at hjælpe dig.

Opdag, hvordan vi kan hjælpe dig med at opdatere og gøre din virksomhed mere konkurrencedygtig.