Now-a-days computers have become an integral part of nearly all business activities, and operations management is not far behind in this regard. One such application of computers in operations management is the MRP system. Primary objective of an MRP system is to manage dependent demand inventories and schedule production activities. It is useful when the product is complex and the production process involves many components and sub-assemblies. For example, in auto manufacturing, the production process involves purchasing numbers of parts and components, planning sub-assemblies and assemblies, etc.
MRP system helps an operations manager find the net requirement of a component after taking into consideration inventory on hand, scheduled receipts, and scheduled order releases.
MRP system generates schedule for material and component supply after considering end product requirements, product structure data (product production hierarchy), and historical lead-time information. Many firms have used computerized inventory systems for years, but they were independent of the scheduling system. But MRP combines inventory control with production planning.
In complex manufacturing processes, manual modifications in production schedules in response to the external market conditions take considerable time. Therefore the necessary inventory adjustments could not be made quickly to satisfy the material requirements of the production department. The use of computers has eliminated these problems. In this chapter, we look at the various facets of an MRP system and how it can be used to optimize the production process.
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