material and capacity requirements planning (mrp and crp) part -1
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7/23/2019 Material and Capacity Requirements Planning (MRP and CRP) Part -1
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JL]KXDLC L@M GLVLGD]T XK\[DXKJK@]W
VCL@@D@E (JXV L@M GXV)
Vlrt -<
Mr. Jlbjnum Lhhls Jlbjnum Lc-@ldjd
Lssdstl`t Vrnikssnr
D `mustrd lc K`ed`kkrd `e Hrl`gb
Mkplrtjk`t ni Vrnmugtdn` K`ed`kkrd`e l`m Jktlccurey
[`dvkrsdty ni ]kgb`ncney
Hlebmlm - D rlqmr.jlbjnumlc`ldjdFuntkgb`ncney.kmu.dq
mr.jlbjnumlc`ldjdFylbnn.gnj
86<; - 86<9
7/23/2019 Material and Capacity Requirements Planning (MRP and CRP) Part -1
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986<-;86< Mr. Jlbjnum Lhhls JlbjnumVrnmugtdn` Vcl``d`e l`m Gn`trnc
<
9- JL]KXDLC L@M GLVLGD]T XK\[DXKJK@]W VCL@@D@E (JXV L@M
GXV)
9.< JXV L@M GXV NHOKG]DYKW
]bk mkjl`m inr l id`dsbkm ennm tk`ms tn hk d`mkpk`mk`t l`m rkcltdvkcy stlhck.
Bnwkvkr, idrjs typdglccy jlak jnrk tbl` n`k prnmugt n` tbk sljk ilgdcdtdks, sn
prnmugtdn` ds ek`krlccy mn`k d` cnts, k.e., ni mdiikrk`t k`m dtkjs nr jnmkcs. ]bk
qul`tdtdks l`m mkcdvkry tdjks inr tbk jltkrdlcs `kkmkm tn jlak tbnsk k`m dtkjs lrk
mktkrjd`km hy tbk prnmugtdn` sgbkmuck.
Jltkrdlc Xkqudrkjk`ts Vcl``d`e (JXV) ds l gnjputkr-hlskm tkgb`dquk inr
mktkrjd`d`e tbk qul`tdty l`m tdjd`e inr tbk lgqudsdtdn` ni mkpk`mk`t mkjl`m dtkjs
`kkmkm tn sltdsiy tbk jlstkr sgbkmuck rkqudrkjk`ts. Hy dmk`tdiyd`e prkgdskcy wblt,
bnw jl`y, l`m wbk` gnjpn`k`ts lrk `kkmkm, JXV systkjs lrk lhck tn rkmugk
d`vk`tnry gnsts djprnvk sgbkmucd`e kiikgtdvk`kss, l`m rkspn`m qudgacy tn jlrakt
gbl`eks.
Glplgdty Xkqudrkjk`ts Vcl``d`e (GXV) ds tbk prngkss ni mktkrjd`d`e wblt pkrsn``kc l`m kqudpjk`t glplgdtdks (tdjks) lrk `kkmkm tn jkkt tbk prnmugtdn`
nhokgtdvks kjhnmdkm d` tbk jlstkr sgbkmuck l`m tbk jltkrdlc rkqudrkjk`ts pcl`. JXV
ingusks upn` tbk prdnrdtdks ni jltkrdlcs , wbkrkls GXV ingusks prdjlrdcy upn` tdjk.
Lctbnueb hntb JXV l`m GXV gl` hk mn`k jl`ulccy l`m d` dsncltdn`, tbky lrk
typdglccy d`tkerltkm wdtbd` l gnjputkrdzkm systkj, l`m GXV (ls wkcc ls prnmugtdn`
lgtdvdty gn`trnc) iu`gtdn`s lrk nitk` lssujkm tn hk d`gcumkm wdtbd` tbk gn`gkpt ni –l`JXV systkj.‚ Gnjputkrdzkm JXV systkjs gl` kiikgtdvkcy jl`lek tbk icnw ni
tbnusl`ms ni gnjpn`k`ts tbrnuebnut l jl`uilgturd`e ilgdcdty. Inccnwd`e lrk snjk ni
tbk tkrjd`ncney uskm tn mksgrdhk tbk iu`gtdn`d`e ni JXV systkjs.
• JXV? L tkgb`dquk inr mktkrjd`d`e tbk qul`tdty l`m tdjd`e mkpk`mk`t mkjl`m
dtkjs.
• Mkpk`mk`t mkjl`m? Mkjl`m inr l gnjpn`k`t tblt ds mkrdvkm irnj tbk mkjl`m inr
ntbkr dtkjs.
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986<-;86< Mr. Jlbjnum Lhhls JlbjnumVrnmugtdn` Vcl``d`e l`m Gn`trnc
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• Vlrk`t l`m gnjpn`k`t dtkjs? L plrk`t ds l` lsskjhcy jlmk up ni hlsdg plrts, nr
gnjpn`k`ts. ]bk plrk`t ni n`k suhernup jly hk l gnjpn`k`t ni l bdebkr-ckvkc plrk`t.
• Hdcc ni jltkrdlcs? L cdstd`e ni lcc gnjpn`k`ts (suhlsskjhcdks l`m jltkrdlcs) tblt en
d`tn l` lsskjhckm dtkj. Dt irkquk`tcy d`gcumks tbk plrt `ujhkrs l`m qul`tdty rkqudrkm
pkr lsskjhcy.
• Ckvkc gnmk? ]bk ckvkc n` wbdgb l` dtkj nggurs d` tbk strugturk, nr hdcc-ni-jltkrdlcs
inrjlt.
• Xkqudrkjk`ts kxpcnsdn`? ]bk hrklad`e mnw` (kxpcnmd`e) ni plrk`t dtkjs d`tn
gnjpn`k`t plrts tblt gl` hk d`mdvdmulccy pcl``km l`m sgbkmuckm.
• ]djk pblsd`e? Wgbkmucd`e tn prnmugk nr rkgkdvk l` lpprnprdltk ljnu`t (cnt) ni
jltkrdlc sn tblt dt wdcc hk lvldclhck d` tbk tdjk pkrdnms wbk` `kkmkm-`nt hkinrk nr
litkr.
• ]djk hugakt? ]bk tdjk pkrdnm uskm inr pcl``d`e purpnsks d` JXV-usulccy l wkka.
• Cnt sdzk? ]bk qul`tdty ni dtkjs rkqudrkm inr l` nrmkr. ]bk nrmkr jly hk kdtbkr
purgblskm irnj l vk`mnr nr prnmugkm d`-bnusk. Cnt sdzd`e ds tbk prngkss ni spkgdiyd`e
tbk nrmkr sdzk.• Cklm-tdjk niiskt? ]bk suppcy tdjk, nr `ujhkr ni tdjk hugakts hktwkk` rkcklsd`e l`
nrmkr l`m rkgkdvd`e tbk jltkrdlcs.
Ideurk 9.< mksgrdhks JXV l`m GXV lgtdvdtdks d` sgbkjltdg inrj. Inrkglsts l`m nrmkrs
lrk gnjhd`km d` tbk prnmugtdn` pcl`, wbdgb ds inrjlcdzkm d` tbk jlstkr prnmugtdn`
sgbkmuck (JVW). ]bk JVW, lcn`e wdtb l hdcc-ni-jltkrdlc (HNJ) idck l`m d`vk`tnry
stltus d`inrjltdn`, ds uskm tn inrjucltk tbk jltkrdlc-rkqudrkjk`ts pcl`. ]bk JXVmktkrjd`ks wblt gnjpn`k`ts lrk `kkmkm l`m wbk` tbky sbnucm hk nrmkrkm irnj l`
nutsdmk vk`mnr nr prnmugkm d`-bnusk. ]bk GXV iu`gtdn` trl`scltks tbk JXV mkgdsdn`s
d`tn bnurs ni glplgdty (tdjk) `kkmkm. Di jltkrdlcs, kqudpjk`t, l`m pkrsn``kc lrk
lmkqultk, nrmkrs lrk rkcklskm l`m tbk wnracnlm ds lssde`km tn tbk vlrdnus wnra gk`tkrs.
K`m dtkjs, sugb ls ]Y skts, blvk l` d`mkpk`mk`t mkjl`m tblt ds gcnskcy cd`akm tn tbk
n`end`e `kkms ni gn`sujkrs. Dt ds rl`mnj hut rkcltdvkcy gn`stl`t. Mkpk`mk`t mkjl`m
ds cd`akm jnrk gcnskcy tn tbk prnmugtdn` prngkss dtskci. Jl`y idrjs usk tbk sljk
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986<-;86< Mr. Jlbjnum Lhhls JlbjnumVrnmugtdn` Vcl``d`e l`m Gn`trnc
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ilgdcdtdks tn prnmugk mdiikrk`t k`m dtkjs hkglusk dt ds kgn`njdglc tn prnmugk clrek cnts
n`gk tbk skt-up gnst ds d`gurrkm. ]bk gnjpn`k`ts tblt en d`tn l ]Y skt, sugb ls 8=-d`gb
pdgturk tuhks, blvk l mkpk`mk`t mkjl`m tblt ds envkr`km hy tbk cnt sdzk. Mkpk`mk`t
mkjl`m ds prkmdgtlhck. JXV systkjs gnjputk jltkrdlc rkqudrkjk`ts l`m spkgdiy wbk`
nrmkrs sbnucm hk rkcklskm sn tblt jltkrdlcs lrrdvk kxlgtcy wbk` `kkmkm. ]bk prngkss ni
sgbkmucd`e tbk rkgkdpt ni d`vk`tnry ls `kkmkm nvkr tdjk ds tdjk pblsd`e.
Ide. 9.< Jltkrdlc l`m glplgdty pcl``d`e icnwgblrt
9.8 JXV D@V[]W L@M N[]V[]W
]bk kssk`tdlc d`puts l`m nutputs d` l` JXV systkj lrk cdstkm d` tlhck 9.<?
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986<-;86< Mr. Jlbjnum Lhhls JlbjnumVrnmugtdn` Vcl``d`e l`m Gn`trnc
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]lhck 9.<
9.8.< Hdcc ni Jltkrdlcs
L hdcc ni jltkrdlcs (HNJ) ds l cdstd`e ni lcc tbk jltkrdlcs, gnjpn`k`ts, l`msuhlsskjhcdks `kkmkm tn lsskjhck n`k u`dt ni l` k`m dtkj. Jlonr iu`gtdn` ni tbk hdcc
ni jltkrdlcs ds tn prnvdmk tbk prnmugt strugturk bdkrlrgby tblt eudmks tbk kxpcnsdn`
prngkss. Mdiikrk`t jktbnms ni mksgrdhd`e l HNJ lrk d` usk. Ideurk 9.8 sbnws (l) l
prnmugt strugturk trkk, l`m (h) l` d`mk`tkm HNJ. Hntb lrk gnjjn` wlys ni mkpdgtd`e
tbk plrk`t-gnjpn`k`t rkcltdn`sbdps n` l bdkrlrgbdglc hlsds. A`nwckmek ni tbds
mkpk`mk`gy strugturk rkvklcs gcklrcy l`m djjkmdltkcy wblt gnjpn`k`ts lrk `kkmkm inr
klgb bdebkr-ckvkc lsskjhcy. L tbdrm jktbnm (g) ds tn usk sd`eck-ckvkc hdccs ni jltkrdlc.
9.8.8 Cnw-ckvkc Gnmd`e
Ideurk 9.8 lcsn d`gcumks ckvkc gnmd`e d`inrjltdn`. Ckvkc 6 ds tbk bdebkst (k.e., tbk k`m-
dtkj gnmk) l`m ckvkc 7 tbk cnwkst inr tbds plrtdguclr HNJ. @ntk tblt tbk inur gcljps
(G 86) gn`stdtutk l suhlsskjhcy tblt ds gnjhd`km wdtb hlsk (L <6) l`m twn sprd`es (H
<<) tn gnjpcktk tbk k`m-dtkj hrlgakt (_ <66). Bnwkvkr, tbk sljk gcljp (G 86) ds lcsn
l gnjpn`k`t ni tbk hlsk (L <6). ]n ilgdcdtltk tbk glcgucltdn` ni `kt rkqudrkjk`ts, tbk
prnmugt trkk bls hkk` rkstrugturkm irnj wbkrk tbk gcljp gnjpn`k`ts jdebt blvk hkk`
(sbnw` mlsbkm) tn tbk cnwkr ckvkc gn`sdstk`t wdtb tbk ntbkr (dmk`tdglc) gcljp. ]bds
cnw-ckvkc gnmd`e k`lhcks tbk gnjputkr tn sgl` tbk prnmugt strugturk ckvkc-hy-ckvkc,
stlrtd`e lt tbk tnp, l`m nhtld` l` lggurltk l`m gnjpcktk gnu`t ni lcc gnjpn`k`ts
`kkmkm lt n`k ckvkc hkinrk jnvd`e n` tn tbk `kxt.
Hdcc ni jltkrdlcs inr _ <66 hrlgakt ds sbnw` hkcnw?
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986<-;86< Mr. Jlbjnum Lhhls JlbjnumVrnmugtdn` Vcl``d`e l`m Gn`trnc
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Ide. 9.8 Vrnmugt strugturk trkk
]lhck 9.<(l ) D`mk`tkm hdcc ni jltkrdlcs
WD@ECK-CKYKC HNJ
]lhck 4.< (l) mkpdgts l sd`eck-ckvkc hdcc ni jltkrdlcs inr _ <66 hrlgakt. Dt ds l ckss
d`tudtdvk hut jnrk kiidgdk`t jkl`s ni stnrd`e tbk d`inrjltdn` n` gnjputkr. D` tbk
sd`eck-ckvkc hdcc klgb k`try (n` tbk ckit) gn`tld`s n`cy l` dtkj nr plrt `ujhkr inccnwkm
hy l cdst ni tbk plrt `ujhkrs l`m qul`tdtdks ni gnjpn`k`ts `kkmkm tn jlak up tbk
plrk`t dtkj n`cy. ]bds typk ni cdstd`e lvndms tbk sklrgbks inr mupcdgltk dtkjs mnw`
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tbrnueb skvkrlc ckvkcs ni l trkk. N` tbk ntbkr bl`m, dt `kgkssdtltks tblt tbk gnjputkr
sklrgb tbrnueb jl`y sd`eck-ckvkc hdccs tn id`m lcc tbk gnjpn`k`ts tblt lrk d`gcumkm d` l
prnmugt tblt bls skvkrlc ckvkcs ni gnmk. Wd`eck-ckvkc hdccs irkquk`tcy gn`tld` –pnd`tkrs‚
tn cd`a tbk rkgnrms ni gnjpn`k`ts wdtb tbkdr plrk`ts l`m lggnjjnmltk tbk rktrdkvlc ni
l gnjpcktk hdcc ni jltkrdlcs inr l` dtkj.
]lhck 9.< (h ) Wd`eck-ckvkc HNJ
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986<-;86< Mr. Jlbjnum Lhhls JlbjnumVrnmugtdn` Vcl``d`e l`m Gn`trnc
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DCC[W]XL]DN@ <? Mktkrjd`k tbk qul`tdtdks ni L<6, H<<, G86, M8c, K76, I7c, l`m
E78 `kkmkm tn gnjpcktk ;6 ni tbk _<66 hrlgakts mkpdgtkm d` Ide. 9.8.
WNC[]DN@
]lhck 9.8 Mktkrjd`d`e HNJ rkqudrkjk`ts
Idrst mktkrjd`k tbk rkqudrkjk`ts inr n`k hrlgakt ls sbnw` d` ]lhck 9.8, l`m tbk`
juctdpcy hy ;6. @ntk tblt plrts G l`m K lrk uskm d` twn mdiikrk`t suhlsskjhcdks, sn
tbkdr skplrltk ljnu`ts just hk sujjkm. Inr ;6 hrlgakts, klgb ni tbk rkqudrkjk`ts
gncuj` ljnu`ts just hk juctdpcdkm hy ;6 tn nhtld` tbk ernss rkqudrkjk`ts.
DCC[W]XL]DN@ 8? Edvk` tbk prnmugt strugturk trkk sbnw` d` Ideurk 9.7 inr
wbkkchlrrnw U644, mkvkcnp l` d`mk`tkm hdcc ni jltkrdlcs.
Ide. 9.7
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986<-;86< Mr. Jlbjnum Lhhls JlbjnumVrnmugtdn` Vcl``d`e l`m Gn`trnc
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]lhck 9.7
DCC[W]XL]DN@ 7? (l) L iclsbcdebt ds lsskjhckm irnj tbrkk jlonr suhlsskjhcdks? l
bklm lsskjhcy, twn hlttkrdks, l`m l hnmy lsskjhcy. ]bk bklm lsskjhcy gn`sdsts ni l
pclstdg bklm, l ck`s, l huch suhlsskjhcy (gnjprdsd`e l huch l`m huch bncmkr), l`m l
rkickgtnr. ]bk hnmy lsskjhcy gn`sdsts ni l gndc sprd`e l`m l sbkcc lsskjhcy, wbdgb d`
tur` ds jlmk up ni l` n`-nii swdtgb, twn gn``kgtnr hlrs, l`m l pclstdg sbkcc. ]bk n`-nii
swdtgb ds lsskjhckm irnj l a`nh l`m twn sjlcc jktlc scdmks. ]bk pclstdg bklm ds jlmk
irnj n`k u`dt ni nrl`ek pclstdg pnwmkr, l`m tbk pclstdg sbkcc ds jlmk irnj tbrkk u`dts
ni nrl`ek pclstdg pnwmkr. Mkvkcnp l prnmugt strugturk trkk ni tbk iclsbcdebt, l`md`gcumk tbk ckvkc gnmd`e inr klgb gnjpn`k`t.
Vclstdg bklm Ck`s Huch lsskjhcy Wprd`eWbkcc lsskjhcyXkickgtnr
Bklm lsskjhcy Hnmy lsskjhcyHlttkrdks
Iclsbcdebt
Vclstdg pnwmkr
Huch bncmkr Vclstdg sbkccN@-nii swdtgbHuch
A`nh Jktlc scdmks (8) Vclstdg pnwmkr(7)
Gn``kgtnr hlrs
8
Ckvkc 6
Ckvkc <
Ckvkc 8
Ckvkc 7
Ckvkc =
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986<-;86< Mr. Jlbjnum Lhhls JlbjnumVrnmugtdn` Vcl``d`e l`m Gn`trnc
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(h) Mksde` l` d`mk`tkm hdcc ni jltkrdlcs inr tbk iclsbcdebt d` (l). (@ntk? Lssde`
lpprnprdltk inur-mdedt plrt `ujhkrs tn tbk gnjpn`k`ts.)
]lhck 9.=