ch 9 (quick response)

Quick-ResponseManufacturing Systems

Quick-responsemanufacturing

system

Quick-responsemanufacturing

systemComputer Integrated

Manufacturing System (CIM)

Physicalmanufacturing

system

Physicalmanufacturing

system

Manufacturingresource planning

(MRP II)

Manufacturingresource planning

(MRP II)

CADDCADD CAMCAM MRPMRP

DistributeddatabasesDistributeddatabases

DistributeddatabasesDistributeddatabases

Advanced Integration Technologies

Computer-basedinformation

system

Computer-basedinformation

system

EDIEDIAutomatic

identificationAutomatic

identification

The Physical Manufacturing System

Two subsystems directly support thephysical manufacturing system.

CADD (computer-aided design and drafting)

CAM (computer-aided manufacturing)

Computer-Aided Designand Drafting (CADD)

Solids modeling

Finite element analysis

Automated drafting

Computer-AidedManufacturing (CAM)

Industrial robot

Statistical process control

Flexible manufacturing systems

The Manufacturing Resource Planning (MRP II) System

The MRP II system comprises thematerials requirements planning

(MRP) system and the related systemsfor sales, billing, and purchasing.

Materials RequirementsPlanning (MRP)

MRPMRP

Costaccounting

Costaccounting

Productionplanning

Productionplanning

ProductionschedulingProductionscheduling

ReportingReporting

Advanced Integration Technologies

Production Planning

Production planning involves thedetermination of which products

to produce and the schedulingof production to make optimaluse of production resources.

Production Planning

Demand for a product

Production requirements

Production resources available

Production Planning

Productionplanning

Productionplanning

Bill ofmaterials

Masteroperations list

MarketingMarketing 1

Inventorycontrol

Inventorycontrol

2

3 Productiondepartments

Productiondepartments

4

5

1 Sales forecast2 Finished goods status3 Raw materials status4 Factor availability report5 Production schedule

Production Planning

Productionplanning

program(s)

Masteroperations

file

Productionstatus

file

Bill-of-materials

file

Masterproduction

plan

Production Planning

Updatedproduction

statusfile

Productionorders

Materialrequisitions Routings

Production Scheduling

Productionstatusupdate

Productionstatus

file

Routingfile

Summaryreport

Updatedproduction

statusfile

Productionloading

file

Production Scheduling

Productionschedulingprogram

Summaryreport

Productionschedules

Productionloading

file

Production-Loading File

This is the major input to theproduction-scheduling application.

Cost Accounting

Cost accounting program(s)

Productionstatus file

Productiondata file

• Material requisition data• RTG data

Summaryreport

Updatedproductionstatus file

Completedproductionorder file

Resourceusage

file

Reporting

InventoryupdateInventory

file

Completedproductionorder file

Inventory Processing

Updatedinventory

file

Finished goodsstock status

report

Completedproductioncost report

Summaryreport

Reporting

Resourceusage

file

Reportgenerator

Resourceusage

reports

Resource Usage Reporting

Activity-Based Costing

Traditional cost accounting techniquesmay be inadequate in a computer

integrated manufacturing environment.

Because CIM reduces directlabor and increases overhead.

Variable costs decreaseand fixed costs increase.

Activity-Based Costing

Activity-based costing (ABC) calculatesseveral overhead rates, one for

each manufacturing activity.

Activity-Based Costing

What are some examples of activities?

Machine centers Material handling

Inspection stations

A single department may containseveral different activities.

Manual assembly

Major Processing Modules in MRP II

MRP IIMRP II

Bill-of-materialsmodule

Bill-of-materialsmodule

Routings filemodule

Routings filemodule

Inventory controlmodule

Inventory controlmodule

Productionactivity control

module

Productionactivity control

module

Master productionscheduling

module

Master productionscheduling

module

Production ordermodule

Production ordermodule

Implementing JIT in aMRP II/CIM Environment

Less emphasis might be placedon a complete MRP II system.