Orlicky's Material Requirements Planning, Third Edition

The classic MRP work up-to-date with new information on supply chain synchronizationThoroughly revised,Orlicky's Materials Requirements Planning, Third Editionreviews the poor business results embedded in most of today's business systems; discusses the core problems causing the results; presents and discusses an alternative pull structure for planning and controlling materials flow; and presents initial results from actual implementations. This new edition reveals the next evolutionary step for materials and supply chain synchronization in the modern manufacturing landscape. This update describes: A solution to a chronic MRP-related problem that plagues many manufacturers: shortages of materials, components that block the smooth flow of work through the plant A competitive edge through strategic lead time reductions Significant reductions in total inventory investment Significant increases in service levelsThis new edition helps companies tackle three pervasive problems: unacceptable inventory performance; unacceptable service level performance; and high related expenses and waste.New to This Edition: New section on manufacturing as the heart of the supply chain management, and specific challenges in the 21st century Covers supply chain management (SCM) and distribution requirements planning (DRP) Discusses the impact of Lean and the Toyota Production System Update of integration software Reviews the emergence of demand-driven strategies and the MRP "conflict" Introduces the new concept of ASR (Actively Synchronized Replenishment) and explains how to incorporate it into business processes Explains positioning and how Six Sigma can help achieve results In-depth discussion of buffers how to size, maintain, and adjust them New chapter on using MRP tools across the supply chain to enable pull-based approaches New case studies which illustrating the techniques described in the bookComprehensive coverage: The Whole and Its Parts; Manufacturing as a Process; Inventory Management; Prerequisites of MRP 3.0; Traditional Methodology; MRP Logic; Keeping MRP Up to Date; Lot Sizing and Safety Stock; Data Requirements and Management; MRP 3.0; Traditional MRP in Today's Environment; MRP 3.0 Component 1Strategic Inventory Positioning; Component 2Buffer Level Profiling; Component 3Dynamic Buffer Maintenance; Component 4Pull-Based Demand Generation; Component 5Highly Visible and Collaborative Execution; Dynamic Buffer Level Profiling; ASR Demand Generation; Applications; Developing Valid Inputs; Making Outputs Useful; Demand Driven Philosophies and MRP; Engineer to Order Environments; Lessons of the Past; Present State; The Future of MRP 3.0

Foreword by David Turbide
Preface
Part 1: Perspective
Chapter 1. Overview
Chapter 2. MRP in the Modern World
Chapter 3. The Four Critical Questions Answered
Part 2: Concepts
Chapter 4. Inventory in a Manufacturing Environment
Chapter 5. Principles of Materials Requirements Planning
Chapter 6. The Material Requirements Planning System
Chapter 7. Processing Logic
Chapter 8. Lot Sizing
Chapter 9. System Records and Files
Part 3: Managing with the MRP System
Chapter 10. A New Way of Looking at Things
Chapter 11. Product Definition
Chapter 12. Master Production Schedule
Chapter 13. More Than an Inventory Control System
Chapter 14. System Effectiveness: A Function of Design and Use
Chapter 15. Industry Effect on MRP
Chapter 16. Project Manufacturing
Chapter 17. Remanufacturing
Chapter 18. Process Industry Application
Chapter 19. Repetitive Manufacturing Application
Chapter 20. Sales and Operations Planning
Part 4: Looking Backward and Forward
Chapter 21. Historical Context
Chapter 22. Blueprint for the Future: Demand-Driven MRP Logic
Chapter 23. Strategic Inventory Positioning
Chapter 24. Buffer Profiles and Level Determination
Chapter 25. Dynamic Buffers
Chapter 26. Demand-Driven Planning
Chapter 27. Highly Visible and Collaborative Execution
Chapter 28. Demand-Driven Material Requirements Planning (DDMRP)
Chapter 29. DDMRP Future
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