T*tPT.gMTCHTATION CONSIDERATIONS FOR SOI SY3TBM& K wa £• FOR PRODUCTION ...

279 Pages·2014·7.78 MB·English

SY3TBM&
T*tPT.gMTCHTATION CONSIDERATIONS FOR SOI
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FOR PRODUCTION BLABBING. SCHEDULING AMD CONTROL
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A DISSERTATION SUBMITTED TO THE
FACULTY OP ENGINEERING,
UNIVERSITY OF THE WITWATERSRAND, JOHANNESBURG
FOR THE DEGREE OP MASTER OF SCIENCE
JOHANNESBURG, 1983
.
Thi. di.sertetion deal, with l^.lesent«llon o. — ---
syctaas tor production planning, achadullng and control
It attempt, to explain why Material. Mqulr.eent.
Planning (- MRP) y tee. have becoee .o popular all over
the world in the laet couple of year..
Further, an atteept 1. .ad. to judge the aucc... of .
# Hi
MRP implementation in general, aud
particular
'
Hotwith.tending an entire chapter is devoted to
•urvey. aimed at determinino the .utc... of MSP In
s. A., which investigated why and how coepanie.
inp lamented MSP. a. well a. th. benefit, which they
achieved.
The dl...station inve.tlg.te. the r.e.on. for the
failure of . high percentage of MSP implementation., and
highlight, factor, which determine failure or .ucce...
special con.ider.tion a. given to the pecuU.ritie. of
the S.A. companie. and their environment.
A concept 1. developed which .Uow. th. .tructuring of
the implementation proc... in a .i-Pla and logical way.
containing the mo.t i«.ort.nt factor., ta.*. and method,
for a successful MRP implementation.
■ w
FI
Many diff.r.nt »»y. of i-pl— nt.tion can b. foe.
through th. coobinhticn of th. «thoa. .xpl.in.djTh.
last =h.Pt.r put. forward po..ibl. prfiction, of how
MBP will d.v.lop in th. n.rt 10 to 20 yar.
DECLARATION
I declare that this dissertation is ay own,
unaided work. It is being sfub mitted for th*
degree of Master of Sci.cc. the University
of the Wltwatererand, Jthanreeburg. It ha.
1 not been submitted before for any degree or
examination in any other University.
JOSEF KLBBBINDER
/6A day of NOVEMBER, 1983
ABBREVIATIONS
American Production and Inventory
Society
Chief Executive
Core Factor
Climate of change
Capacity requirements
Dependency factor
Elementary method
Elementary
and Inventory
South Aft lean Production
Control Society
Managing Director
Master reduction Schedule
Material Requirements
Manufacturing Resource Planning
Order Control
OC
Shop Floor Control
SFC
; : ..
0
q
.1 The development of MRP fro* an Order
Launching technique to MRP II.
.2 is MRP a today's necessity?
1.2.1 Economical Factors
1.2.2 Benefits of MRP
1.2.3 Costs of MRP
1.3 Summary
Success of MRP implementations
How to measure "Success"
2.1
Criticism of the different methods
2.2
2.2.1 Criticism of way (a)
2.2.2 Criticism of way (b)
2.2.3 Criticism of way (c)
2.2.4 Criticism of way (d)
The success profile in the past
2.3
2.4 Summary
- :-
MRP in South Africa
3.1 Introduction
3.2 Study methodology
3.2.1 The research method and the sample
3.2.2 The questionnaire
3.2.3 Data analysis
Success of MRP implementation and
1.3
benefits received.
1.4 Reasons for and Initiator(s) of. MRP
research
1.5 implementation process
3.5.1 Information phase
3.5.2 Set up of the project
3.5.3 Humber and distribution of modules
and implementation sequence
■
53
_ , ,___
3.5.4 Education and training
3.5.5 Implementation time
3.5.6 Cut-over approach
3.6 Extent of computerization
66
3.7 Success factors
3.8 Problem areas
3.9 Costs
3.10 User involvement
3.11 Education and training
3.12 S C ... a» judg'd w P*cpl* at the
firing-line 76
76
3.13 impacts of M3P on their jobs
Reason. Jot not achl.vlng th. pwlbl. and/ot
80
expected benefits.
80
4.1 Introduction
60
Reasons for failure of MRP
4.2
4.2.1 The difficulty of the
implementation itself
*.2.2 No or unrealistic expectations
but... 85
4.2.3 Realistic expectations
Detailed explanation of
4.2.3.1
the most frequent mistakes
4.3 Summary
How the characteristic, o* th. S.A. company
anvironmant affect th. implementation and th.
success of the system.
5.1 Introduction
5.2 special (uniqu.) character!.tic. of the
S.A. company environment
5.2.1 Communication
Education
Industry itself
Management and other employees on
different levels in the company
Character1sticc on
5.2.4.1
management level
Charncterietlce on lower
5.2.4.2
lave Is
Characteristics on all
5.2.4.3
levels i
5.2.4.4 Immigration and
emigration.
How the peculiarities affect the
5.3
implementation and increases or
diminishes the chances for success.
5.3.1 Introduction
5.3.2 Communication
5.3.2.1 Communication problems
,">V
between the different
management levels
5.3.2.2 Communication problems
between management and
shop floor personnel
5.3.3 Education
5.3.4 Industry itself
Reasons for the late
5.3.4.1
start of MRP in S.A.
Reasons for the boom in
5.3.4.2
1981/82/83
Factors which foster MRP
5.3.4.3
success in S.A.
Factors which can
5.3.4.4
diminish MRP success
5.3.5 Management and other employees on
different levels in the company
hierarchy.
5.3.6 Summai/.
6. The concept of core and elementary tasks and
elementary methods.
6.1 Th. concept of .le.entary teak, end
methods
PA3A
I mk
6.2 Applicability omf the concept to mMrRpP
137
implementation
6.3 The advantages and disadvantages of the
H, gsms * the 140
concept
■
6.3.1 Advantages
141
.3.2 Disadvantac es
142
Factors for success
142
7.1 Introduction
143
Success factors
143
7.2.1 Climate of change
145
Consultant advice
148
Cost/benefit analysis
150
Data accuracy and integrity
152
Education and Training
156
Hard/software selection
156
Keep it simple
157
7.2.8 Planning
160
Set up of the project
160
7.2.9.1 Project team
162
7.2.9.2 Steering team
162
. Management
7 2.10
E-tasks and E-methods for solving the
166
different C-tasks
166
8.1 introduction
Dependency between the various methods of
8.2
166
the different tasks
Characteristics and influence of the
8.3
D-factors on the C-tasks, B-tasks and
169
B-imethods
169
Influence on the "COC"
8.3.1
Influence on "Data accuracy and
8.3.2
170
integrity"
Influence on "Education and
8.3.3
170
Training
Hard/So jEtware
tasks
of the informal syste
E-sethods for E-task -Involvement
8.4.4
of users"
160
E-methods for E-task "Check COC
3.4.5
E-methods for E-task "Announce
8.4.6
decision to implement MRP"
E-methodsjfor E-task "involve and
8.4.7
educate".
The influence of the D-factors
8.5.1 The influence of the D-factor (a)
8.5.1.1 The E-tasks and methods
for the creation of an
excellent COC on top and
first line management
level
The influence of the D-factor (h)
8.5.2
8.5.2.1 D-factors (hi) and (b2)
8.5.2.2 D-factors (b3) and (b4)
The influence of the D-factor (c)
8.5.3
8.6 Data accuracy and integrity
8.6.1 Cl task: Data accuracy and
integrity before the cutover to
the MRP system
. C2 task: Data accuracy and
8 6.2
integrity after the cutover to
188
the MRP system
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