Evolusi ERP: MRP

Materi Kuliah Minggu 2

ISS3205 - Enterprise Resource Planning
Organizational Silos

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 Evolusi SI

• Pada awalnya Sistem Informasi hanya mendukung aktivitas

pada satu area fungsional pada bisnis (marketing information
system, production information system).
• Masing-masing memiliki hardware, software, dan metode
pengolahan data dan informasi yang dikenal dengan istilah Silo.
• Masalah yang timbul:
– Duplikasi data dan biaya untuk penginputan
– Tingkat kesalahan yang lebih tinggi
– Keterlambatan update informasi
– Format penyimpanan yang berbeda-beda

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 Evolusi ERP

Evolusi sebagai hasil dari:

1. Kemajuan teknologi hardware dan software
(tenaga komputasi, memori, dan komunikasi).
2. Perkembangan visi untuk sistem informasi
terintegrasi.
3. Reenginering dari perusahaan untuk beralih dari
fokus fungsional kepada fokus proses bisnis.

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 Manufakturing Merupakan Akar dari
ERP
Konsep dari sistem informasi terintegrasi mengambil
bentuk dari lantai pabrik.
Software manufacturing berkembang pada awal
1960-1970-an, berevolusi dari:
1. Inventory Tracking System
2. Material Requirement Planning
3. Electronic Data Interchange (EDI)

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 MRP & EDI

• MRP adalah metodologi penjadwalan produksi yang menentukan waktu dan

kuantitas dari produksi, purchase order yang dilepas untuk memenuhi master
production schedule (MPS).
• MRP memungkinkan manajer pabrik untuk merencanakan produksi dan kebutuhan
bahan baku secara backward dari peramalan penjualan.
• Forecasting dilakukan berdasarkan data Demand Customer oleh Marketing dan
Sales, dan dilakukan penjadwalan produksi untuk memenuhi demand, kebutuhan
bahan baku, dan proyeksi biaya untuk bahan baku.
• Pada perusahaan dengan banyak produk, bahan baku, dan sumber daya produksi
yang dipakai bersama, adalah sulit dilakukan tanpa bantuan komputer.
• Proses dilakukan pada Main Frame, dan menghasilkan data untuk bagian
pembelian yang dilewatkan dengan EDI kebagian SCM.

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 Overview of the MRP System

Master
Product Structure Inventory Master
Production
File File
Schedule

Material Requirements
Planning

Manufacturing
Purchase Orders Various Reports
Orders
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 MRP Inputs

• Product Structure File

• Master Production Schedule
• Inventory Master File

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 Product Structure File

• Bill of Materials
Contains a listing of all of the assemblies,
subassemblies, parts, and raw materials
that are needed to produce one unit of a
finished product.

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Bill of Materials
Independent Demand

A Dependent Demand

B(4) C(2)

D(2) E(1) D(3) F(2)

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 Bill of Materials (continued)

Level Chair
0

1 Leg Back
Assembly Seat Assembly

Cross Side Cross Back

2 Legs (2)
bar Rails (2) bar Supports (3)

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 Master Production Schedule

• Schedule of Finished Products

• Represents Production, not Demand
• Combination of Customer Orders and Demand Forecasts
• What Needs to be Produced

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 Inventory Master File

• On-Hand Quantities
• On-Order Quantities
• Lot Sizes
• Safety Stock
• Lead Time
• Past-Usage Figures

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 MRP Process

• Schedules the Production of all items using an MRP Matrix

MRP Matrix
Item: Low-Level Code:
Lot Size: Lead Time: PD 1 2 3 4 5
Gross Requirements
Scheduled Receipts
Projected on Hand
Net Requirements
Planned Order Receipts
Planned Order Releases

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 Terms Defined

• Item – name or number for the item being scheduled

• Low-Level Code – the lowest level of the item on the product
structure file
• Lot Size – order multiples of quantity
• Lead Time – the time from when an order is placed to when it
is received
• PD – Past Due Time Bucket, orders behind schedule

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 Terms Defined
• Gross Requirements – demand for an item by time period
• Scheduled Receipts – material already ordered
• Projected on Hand – expected ending inventory
• Net Requirements – number of items to be provided and
when
• Planned Order Receipts – net requirements adjusted for lot
size
• Planned Order Releases – planned order receipts offset for
lead times

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 Example of the MRP Process
Item: A Low-Level Code: 1
Lot Size: 25 Lead Time: 1
PD 1 2 3 4 5
Gross Requirements 10 15 25 25 30
Scheduled Receipts 25
Projected on Hand 20
Planned Order Receipts

Planned Order Releases

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 Example of the MRP Process
Item: A Low-Level Code: 1
Lot Size: 25 min Lead Time: 1
PD 1 2 3 4 5
Gross Requirements 10 15 25 25 30
Scheduled Receipts 25
Projected on Hand 20 10 20 20 20 15
Planned Order Receipts 25 25 25
Planned Order Releases 25 25 25

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 Study Case

Sebuah kursi mempunyai

LT (lead time) = 2 minggu
LS (lot size) = 50 unit
SS (safety stock) = 0.
Tunjukkan perhitungan MRP bila diketahui GR, POH0 dan SR
sebagai berikut:

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 Perioda (minggu)

0 1 2 3 4 5

Gross requirements (GR) 50 60 40 20 40

Scheduled receipts (SR) 50 50

Projected on hand (POH) 70

Planned order receipts (PORec)

Planned order release (PORel)

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 Perioda (minggu)

0 1 2 3 4 5

Gross requirements (GR) 50 60 40 20 40

Scheduled receipts (SR) 50 50

Projected on hand (POH) 70 70 60 20 0 10

Planned order receipts (PORec) 50

Planned order release (PORel) 50

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 MRP Outputs

• Manufacturing Orders
• Purchasing Orders
• Various Reports

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Example of the MRP Process

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 Terimakasih

• Ada pertanyaan?

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