Читать книгу Demand Driven Material Requirements Planning (DDMRP), Version 2 - Carol Ptak - Страница 4
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The Material Requirements Planning Revolution
Return on Asset Performance Degradation
The Inventory Bimodal Distribution
Establishing Flow as the Foundation
Relevant Information and Materials
Material Requirements Planning in the New Normal
Distortions to Relevant Information
Flattening the Bill of Material
Distortions to Relevant Materials
Amplifying the Distortions to Relevant Information and Materials—Batching Policies
Unlocking a Solution—The Power of Decoupling
Supply Order Generation and Execution for the New Normal
MRP Versus Lean—What Can We Learn?
Dependence Versus Independence
Supply Order Generation (Planning Versus Execution)
Demand Driven Material Requirements Planning
The History of “Demand Driven”
Strategic Inventory Positioning
Sales Order Visibility Horizon
Inventory Leverage and Flexibility
Applying the Positioning Criteria
A New Form of Lead Time
Advanced Inventory Positioning Considerations
Distribution Positioning Considerations
Summary
CHAPTER 7
Strategic Buffers
Inventory: Asset or Liability?
Introducing Decoupling Point Buffers
The Green Zone
The Yellow Zone
The Red Zone
Buffer Profiles
Factor 1: Item Type
Factor 2: Lead Time
Factor 3: Variability
Individual Part Attributes
Part Average Daily Usage
Part Lead Time
Part Minimum Order Quantity
Part Location
Calculating Replenished Part Buffer Levels and Zones
The Green Zone
The Yellow Zone
The Red Zone
Continuing with Company ABC
Iterations
Calculating Replenished Override Buffers
Calculating Min-Max Buffers
Summary
CHAPTER 8
Buffer Adjustments
Recalculated Adjustments
Planned Adjustment Factors
Demand Adjustment Factor
Zone Adjustment Factor
Lead Time Adjustment Factor
Summary
CHAPTER 9
Demand Driven Planning
The Shift to Actual Demand
The Net Flow Equation
Qualifying Order Spikes
Supply Order Generation Based on Net Flow Position
Simulating DDMRP Supply Order Generation
Calculating Average On-Hand Inventory
Average On-Hand Range
Average On-Hand Target
Average Open Supply Orders
Decoupled Explosion
Hybrid Model Supply Order Generation
Prioritized Share Supply Order Consideration
Discount Optimization
Freight Optimization
Coverage Optimization
Min-Max Supply Order Generation
Completing the Company ABC Example
Summary
CHAPTER 10
Demand Driven Execution
Buffer Status Alerts
Challenging Priority by Due Date
Planning Versus Execution Display
Current On-Hand Alert
Projected On-Hand Alert
Synchronization Alerts
Material Synchronization Alerts
Lead Time Alert
Summary
CHAPTER 11
DDMRP Impacts on the Operational Environment
DDMRP Strategic Buffer Criteria
The Decoupling Test
The Bidirectional Benefit Test
The Order Independence Test
The Primary Planning Mechanism Test
The Relative Priority Test
The Dynamic Adjustment Test
DDMRP Versus Safety Stock and Order Point
Safety Stock and the Buffer Criteria
Order Point and the Buffer Criteria
DDMRP Impacts on Scheduling
DDMRP and Master Production Scheduling Assumptions
DDMRP Shop Floor Scheduling Implications
Finite Scheduling with DDMRP?
Additional Scheduling Sequence Impacts
DDMRP and WIP Priority Management
Summary
CHAPTER 12
DDMRP Metrics and Analytics
Measuring Relevant Information (Signal Integrity)
Measuring Decoupling Point Integrity
Outlying Event Reports
Measuring Velocity
Driving Improvement in DDMRP
Summary
CHAPTER 13
The Demand Driven Adaptive Enterprise Model
Demand Driven Operating Model
Element #1: Pacing to Actual Demand
Element #2: Strategic Decoupling Points
Element #3: Strategic Control Points
Element #4: Dynamic Buffering
Demand Driven Sales and Operations Planning
Tactical Configuration and Reconciliation
Tactical Review
Tactical Exploitation
Tactical Projection
Strategic Recommendation
Strategic Projection
Adaptive Sales and Operations Planning
The DDAE Development Path
Stage 1: Operational Efficiency (Cost)
Stage 2: Operational Efficiency (Flow)
Stage 3: DDAE Level I
Stage 4: DDAE Level II
Stage 5: DDAE Level III
Summary
Contribution by Dick Ling
CHAPTER 14
Implications for Technology
Operations and Information Technology—Two Ships Diverging in the Night?
DDMRP Software Compliance Criteria
PART 3 APPENDICES
APPENDIX A
An MRP Example
The Scenario
Simulating the Scenario
APPENDIX B
Simulating DDMRP Buffers
About the Simulation
Widget Simulation Results
Gazoonk Simulation Results
Simulating the Impact of Minimum Order Quantities
Summary
About the Author
APPENDIX C
Applying DDMRP to the Apparel Retail Environment
The Need for a Retail Application of DDMRP
A Retail Apparel DDMRP Example
Special Characteristics and Challenges of the Apparel Retail Environment
The Proposed Model
Retail DDMRP Buffer Zone Considerations
Realized Results
About the Author
APPENDIX D
Demand Driven MRP Dictionary
APPENDIX E
The Innovations of DDMRP
Endnotes
References
Index
