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CITATION

Ptak, Carol and Smith, Chad. Orlicky's Material Requirements Planning 3/E. US: McGraw-Hill Professional, 2011.

Orlicky's Material Requirements Planning 3/E

Authors: Carol Ptak and Chad Smith

Published:  May 2011

eISBN: 9780071755641 0071755640 | ISBN: 9780071755634
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  • Cover
  • Title Page
  • Copyright Page
  • Contents
  • Foreword
  • Preface
  • Part 1 Perspective
  • Chapter 1 Overview
  • Orlicky’s Vision
  • Focus and Organization of This Book
  • Bibliography
  • Chapter 2 MRP in the Modern World
  • Key Questions for Planning and Flexibility
  • Dealing with Variability
  • Materials or Capacity: Where to Focus First?
  • Chapter 3 The Four Critical Questions Answered
  • Question 1: Relevance of MRP
  • Question 2: MRP—Flawed Approach or Poorly Applied?
  • Question 3: The MRP Conflict with Lean or Pull
  • Question 4: MRP Progress in the Last 30 Years?
  • Part 2 Concepts
  • Chapter 4 Inventory in a Manufacturing Environment
  • Manufacturing Inventories
  • Distribution Inventory
  • The Logic of Manufacturing
  • Order-Point Versus MRP Systems
  • The Paradox of Inventory Management
  • A Distribution Positioning Example
  • Summary
  • Bibliography
  • Chapter 5 Principles of Materials Requirements Planning
  • Time Phasing
  • Inventory System Categories
  • Prerequisites and Assumptions of MRP
  • Part Numbers
  • Bills of Material (BOMs)
  • Applicability of MRP Methods
  • Bibliography
  • Chapter 6 The Material Requirements Planning System
  • Objectives of the System
  • The Purpose of the System
  • System Inputs and Outputs
  • Factors Affecting the Computation of Requirements
  • Chapter 7 Processing Logic
  • Inventory Status
  • Techniques of Time Phasing
  • Gross and Net Requirements
  • Coverage of Net Requirements
  • Explosion of Requirements
  • Time-Phased Order Point
  • Entry of External-Item Demand
  • System Nervousness
  • Bibliography
  • Chapter 8 Lot Sizing
  • Costs in Lot Sizing
  • Lot-Sizing Techniques
  • Lot-Size Adjustments
  • Evaluating Lot-Sizing Techniques
  • Bibliography
  • Chapter 9 System Records and Files
  • The Time-Phased Record
  • Updating Inventory Records
  • The Database
  • Input-Data Integrity
  • Bibliography
  • Part 3 Managing with the MRP System
  • Chapter 10 A New Way of Looking at Things
  • Planned Versus Actual Manufacturing Lead Time
  • Safety Stock in a New Light
  • A Fresh Look at Queues
  • Work-in-Process Revisited
  • Total Planning Hierarchy
  • Bibliography
  • Chapter 11 Product Definition
  • Assignment of Identities to Inventory Items
  • Product Model Designations
  • Modular Bills of Material
  • Pseudo-BOMs
  • Interface to Order Entry
  • Bibliography
  • Chapter 12 Master Production Schedule
  • Master Production Scheduling Concepts
  • The Final Assembly Schedule
  • Functions of Master Production Scheduling
  • MPS Development
  • Closing the Loop
  • Management and Organizational Aspects
  • Bibliography
  • Chapter 13 More Than an Inventory Control System
  • Use of System Outputs
  • An Inventory Planning and Control System
  • A Priority Planning System
  • Determining Capacity Requirements
  • Chapter 14 System Effectiveness: A Function of Design and Use
  • Critical System Design Features
  • The System and the Inventory Planner
  • Chapter 15 Industry Effect on MRP
  • Project Manufacturing Company
  • Make to Stock
  • Make to Order
  • Assemble to Order
  • Make to Stock/Assemble to Order
  • Chapter 16 Project Manufacturing
  • Project Life Cycles
  • Projects in MRP
  • Capacity Deployment
  • Material Allocation
  • Summary
  • Project Management Resources
  • Chapter 17 Remanufacturing
  • Remanufacturing Similarities and Differences
  • Managing Remanufacturing Material
  • Remanufacturing Bills of Materials
  • Remanufacturing Routings
  • Remanufacturing Inventory Management
  • Terms Related to the Remanufacturing Industry
  • Chapter 18 Process Industry Application
  • Process Industry Overview
  • Process-Flow Scheduling
  • MRP System Requirements
  • Summary
  • Chapter 19 Repetitive Manufacturing Application
  • General Repetitive Application
  • Kanban
  • Rate-Based Scheduling
  • Production-Sales-Inventory Analysis
  • Backflush
  • Period Costing
  • High-Volume Mixed-Model Manufacturing
  • Configurators
  • Summary
  • Chapter 20 Sales and Operations Planning
  • What’s in a Name?
  • Traditional Sales and Operations Planning
  • S&OP, the Unifier—Traditional S&OP Challenged
  • S&OP, the Reconciler and Integrator
  • Knowledge and Know-How Versus Drowning in Data
  • Uncertainty Versus a Single Set of Numbers
  • S&OP as the Aligner to Success and Future Sustainability
  • Discoveries Leading to Breakthrough S&OP
  • Application of S&OP to Various Environments
  • Summary
  • About the Authors
  • Bibliography
  • Part 4 Looking Backward and Forward
  • Chapter 21 Historical Context
  • Pre-MRP Inventory Control
  • The Story of MRP
  • Evolution of the Art
  • Evolution of MRP and Planning Systems
  • Planning, Execution, and Control
  • Chapter 22 Blueprint for the Future: Demand-Driven MRP Logic
  • The MRP Conflict
  • Demand-Driven MRP Introduction
  • The Five Primary Components of Demand-Driven MRP
  • Chapter 23 Strategic Inventory Positioning
  • ASR Lead Time: A New Type of Lead Time
  • ASRLT and Matrix BOMs
  • Chapter 24 Buffer Profiles and Level Determination
  • Inventory: Asset or Liability Revisited
  • Buffer Profiles
  • Buffer Zones
  • Calculating Buffer Levels
  • Buffer Level Summary
  • Summary
  • Chapter 25 Dynamic Buffers
  • Recalculated Adjustments
  • Planned Adjustments
  • Manual Adjustments
  • Chapter 26 Demand-Driven Planning
  • Part Planning Designations
  • The DDMRP Process
  • Supply Generation for Stocked Items
  • Supply Generation for Nonstocked Items
  • Decoupled Explosion
  • Chapter 27 Highly Visible and Collaborative Execution
  • Challenging Priority by Due Date
  • Buffer Status Alerts
  • Synchronization Alerts
  • Execution Collaboration
  • Chapter 28 Demand-Driven Material Requirements Planning (DDMRP) Performance Reporting and Analytics
  • Oregon Freeze Dry Results
  • LeTourneau Technologies Results
  • Chapter 29 DDMRP Future
  • Research Opportunities
  • Prediction of the Future
  • Success Leveraging Technology
  • Appendix A: Joseph Orlicky’s Contributions to Material Requirements Planning
  • Appendix B: Definitions: APICS Terms and Their Place in DDMRP
  • Appendix C: New Terms in Demand-Driven Material Requirements Planning
  • Appendix D: To My Best Recollection: The Eras of Material Requirements Planning (MRP) with Packaged Software
  • Index