DA NANG UNIVERSITY OF ECONOMICS

SUPPLY CHAIN MANAGEMENT

CHIN LC MRP Material requirement planning. Nhm 5

2012

[73- nG hNH SN- nNG]

DANH SCH THNH VIN NHM

CHIN LC MRP. Getting the right materials to the right place at the right time in right quantities.
A. TNG QUAN V MRP (Qunh)

I.

MRP L G?
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Trong mt ngnh cng nghip sn xut c hai loi hng tn kho: Hng tn kho hng ha thnh phm v tn kho nguyn liu. Vi tn kho thnh phm, cng ty kim c doanh thu, cn tn kho nguyn vt liu th l nhng thnh phn cn thit sn xut hng ha thnh phm mong mun.

MRP (Hoch nh nhu cu vt liu) ni n gin l mt h thng qun l tn kho nguyn liu, l mt h thng thng tin da trn my tnh kim sot hng tn kho v lp k hoch sn xut. MRP lin quan n vic lp k hoch sn xut v kim sot hng tn kho. y l mt h thng kim sot nguyn vt liu, c gng gi cho lng tn kho mc thch hp m bo rng nguyn vt liu lun sn c khi cn n.

Mc tiu chnh ca h thng MRP l nh sau: m bo nguyn vt liu , cc thnh phn cu to sn c cho qu trnh sn xut v sn phm cui cng c sn chuyn n khch hng. Duy tr mc tn kho thp nht c th. Lp k hoch cho hot ng sn xut, lch trnh giao hng v cc hot ng mua sm.

MRP c bit thch hp i vi h thng sn xut trong nhu cu ca cc b phn cu thnh sn phm v cc bn thnh phm ph thuc vo nhu cu ca cc sn phm phc v cho

nhu cu th trng. Nhu cu i vi sn phm cui cng c gi l nhu cu c lp. Ngc li, nhu cu i vi cc b phn cu thnh c dng cho vic sn xut ra sn phm cui cng li ph thuc vo nhu cu i vi sn phm cui cng. S khc nhau gia nhu cu c lp (independent demands) v nhu cu ph thuc (dependent demands) quan trng trong vic phn loi hng tn kho v trong vic pht trin h thng qun l cc mt hng trong phm vi mi loi nhu cu.

II.

LCH S HNH THNH. T nhng nm 50, hang IBM a cho ra i nhng chic may tinh thng mai u tin chay bng bong in t. Khai quc cng thn nay c goi la 701, co 1KB RAM va dung bia uc l, co kich thc bng ca gian phong va cn mt tram phat in ring. Nhng chic may nay luc u dung trong cac c s nghin cu khoa hoc va c quan qun s, nhng a nhanh chong thu hut s chu y cua cac cng ty co nhu cu ln v lu tr va x ly d liu nh cac cng ty tai chinh, ngn hang va bao him. Nhng nm 60 chng kin s ra i cua hang loat chng trinh quan ly d liu phat trin trn ngn ng COBOL (ngn ng nay vao cui th ky 20 lai tr nn ni ting mt ln na vi la thu pham chinh gy ra S c nm 2000 tn kem cua nhn loai nhiu ty la khc phuc). Rt nhiu d liu hin nay cua cac tp oan tai chinh ln vn con c lu trong CSDL dung COBOL, vi du nh h s bao him nhn tho cua mt ng John nao o bt u mua bao him vao nm 1960 khi ng ta 20 tui, hin nay ng ta 63 tui va vn ang tip tuc la mt khach hang. Khi may tinh ngay cang re hn, manh hn va thn thin vi con ngi hn, cac nha quan ly a sm nhn thy may tinh co th giup ho ng dung c nhiu ly thuyt quan ly quan trong nh Khi lng t hang kinh t (EOQ ) hay H thng quan ly kho tc thi (JIT) vao trong thc t. Nhng vic nay cn x ly d liu

va tinh toan nhanh ma khng th ap ng c nu phai lam bng tay. Do o t gia nhng nm 60 a ln lt xut hin nhiu h thng quan ly da trn may tinh, lam ao ln cac ky thut quan ly truyn thng. Dn dn vai tro cua CNTT a thay i, t n thun la mt cng cu tr giup nng cao nng sut a tr thanh cng cu chu ao giup doanh nghip tao s chuyn bin trit trong cach lam vic, tit kim chi phi, nng cao cht lng san phm cung nh cai thin ang k quan h vi khach hang.
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Trong nhng nm 1980,khi hot ng sn xut c m rng ,cc nh sn sut pht trin cc h thng tnh ton cc yu cu v ti nguyn ca mt hot ng sn xut da trn d bo doanh s bn hng . tnh ton cc nguyn liu cn thit dng trong sn xut sn phm v tin mua nhng vt liu cng vi my tnh v thi gian lao ng cn thit.T ,qun l sn xut nhn ra rng h cn phi s dng my tnh v cng ngh phn mm qun l thng tin.

Ban u,hot ng sn xut xy dng trn chng trnh phn mm ty chnh chy trn my tnh ln. Sau ,k hoch vt liu yu cu (MRP) dn dn c tch hp trn h thng thng tin c tm nhn . Cc MRP h thng thng tin gip cc nh qun l xc nh s lng ,thi gian ca nguyn liu mua hng v h tr qun l vi cc b phn khc ca qu trnh sn xut.

Qu trnh pht trin, trong khi MRP ch yu lin quan vi cc vt liu, MRPII c quan tm vi cc tch hp ca tt c cc kha cnh ca qu trnh sn xut, bao gm c vt t, ti chnh v quan h con ngi. Ging nh ngy hm nay ca h thng ERP, MRPII c thit k tch hp rt nhiu thng tin ,qun l mt c s d liu tp trung. Tuy nhin, phn cng, phn mm, v quan h cng ngh c s d liu ca nhng nm 1980 khng tin b cung cp cc tc v kh nng chy cc h thng ny trong thi gian thc, v chi ph ca cc h thng ny

l cao i vi hu ht cc doanh nghip. Tuy nhin, tm nhn c thnh lp, v thay i trong cc quy trnh kinh doanh c bn cng vi nhng tin b nhanh chng trong cng ngh dn n chi ph t hn trong vic thit lp h thng MRP ,nn h thng ny c cc doanh nghip ln v nhiu doanh nghip nh p dng ngy hm nay.

III.

H THNG MRP. H thng MRP gm c MPS (lch trnh sn xut tng th), Product Structure Records (bn ghi cu trc sn phm) hay gi l BOM (nh mc nguyn vt liu) v Inventory status records (bn ghi v tnh trng hng tn kho). y l nhng u vo c

bn ca h thng MRP, khng c chng, h thng MRP khng th hot ng. Nhu cu i vi sn phm cui cng c lp qua rt nhiu thi im v c ghi li trn bng MPS. Lch trnh sn xut tng th cho bit mi mt hng cn bao nhiu v khi no th n cn n. Bn ghi cu trc sn phm, hay c gi l bill of material (BOM), cha cc thng tin trn mi mt hng hay cc bn thnh phm c yu cu sn xut sn phm cui cng. Bn ghi v tnh trng hng tn cha cc thng tin v tnh trng tn kho ca tt c cc mt hng. Cc bn ghi ny phi c cp nht lin tc duy tr tnh trung thc ca cc bn ghi. MRP s xc nh tng nhu cu cc b phn cu thnh t lch trnh sn xut tng th v bn ghi cu trc sn phm.

1. u vo ca qu trnh MRP.

a. Demand Forecasting (D bo nhu cu)

Cho bit s lng nhu c hng nm hay theo tng n v thi gian cho nh sn xut bit s lng sn phm cn c sn xut.

b. Bill of material (BOM nh mc nguyn vt liu):

c xem l mt d liu tng th quan trng, l mt danh sch cha thng tin tt c cc nguyn liu, thnh phn cu to, cc thnh phn con v cc nguyn liu khc cn thit hon thnh sn phm cui cng. (Hay ngn gn hn l bng nh mc cc nguyn vt liu cn thit sn xut mt sn phm theo tng cng on).

Mi ha n thng c sp xp thnh cc phn ring bit cng ty c th nhn thy nhng vt liu no c s dng trong tng giai on sn xut, xc nh s lng vt liu cn thit cho vic hon thnh sn phm cui cng.

BOM c s dng trong cc t chc nh th no? C rt nhiu phn mm sn c lu tr cc thng tin v cc item v chun b ha n nguyn vt liu mt cch t ng. Thng tin c trn BOM: Quanlity (s lng mi b phn cn c cho mi d n), Item ID (m hng), Description of item (miu t v mn hng, cung cp vic xc nhn tnh chnh xc ca mn hng c t), Cost of item (chi ph mn hng), Total Project Cost (Tng chi ph d n).
c. Master Production Schedule (MPS)

MPS c pht trin t d bo v n t hng ca khch hng cng ty cho cc hng mc cui cng, yu cu tn kho an ton v n t hng ni b. MPS s cung cp cc chi tit nh bao nhiu n v sn phm cui cng bn s mun c trong nhng khong thi gian khc nhau. tc l, Sn phm cui cng c sn xut l g?

S lng ca mi loi sn phm? Khi no th sn phm sn sng gi i?

d. Inventory status File (ISF)

Cng ty s c bng bo co v tnh trng hng tn kho cho tt c cc b phn cu thnh sn xut sn phm cui cng... Thng tin c sn trong tp tin v hng tn kho cn phi chnh xc nu khng n s nh hng n MRP v vic k hoch sn xut. e. Leadtime. Lead time c gi l u vo c bn ca MRP. H thng MRP lin quan n 2 loi Lead time, Ordering leadtime v manufacturing Lead time: Ordering lead time gii quyt vn thu mua nguyn vt liu. C cc b phn cu thnh c sn xut trong phm vi cng ty v quy trnh ny cn tn nhiu thi gian. iu ny cp n manufacturing leadtime. Leadtime l u vo ch yu ca h thng MRP v c bt k d liu khng chnh xc no s gy hi n quy trnh sn xut. Manufacturing leadtime c th c thit lp bng vic quan st thi gian quy trnh da trn cc c s mt cch thng xuyn v duy tr vic cp nht cc h s mt cch nh k. Tuy nhin ordering leadtime l quan trng hn v n ph thuc vo cc nh cung ng ca chng ta. Do vy, ngi ta phi tin hnh vic kim sot thch hp hn i vi ordering leadtime chy h thng MRP hiu qu hn.

2. u ra ca qu trnh MRP.

Cc thng tin ch yu t MRP c th gp thnh 5 nhm: Cc thng bo t hng xc nh s lng mi mt hng phi t trong thi k hin ti. Cc t hng theo k hoch xc nh s lng v thi hn cho cc t hng c t trong tng lai bo m tin . Thng bo xt li k hoch xc nh nhng thay i v s lng cn iu chnh i vi cc n hng d dang. Thng bo lp li k hoch tin : Xc nh thi hn han thnh t hng cn phi iu chnh cho t hng no v iu chnh n khi no.

IV.

TNH CHT H THNG MRP. - MRP cho bit c thng tin qu gi: + Khi no th khch hng yu cu v nhu cu phi c tho mn, nhu cu ny c th l cn trong khong thi gian no , hay l tt c u cn trong mt lc. + Khi no th lng d tr cn kit. + Khi no n t hng b sung c gi i. + Khi no nhn c hng. - MRP a ra yu cu hu b nhng n t hng khng cn thit. - MRP a ra cc xut ti u ho vic mua hng bng cch tnh ton li thi im c th nhn nguyn vt liu (t nh cung cp) v thi im tht s cn s hng cho sn xut. - MRP da trn s lng hng cn sn xut trn 1 giai on v: + Xc nh s lng tt c nguyn vt liu thnh phn sn xut ra hng ho . + Xc nh cc yu t v thi gian, thi im cn cc nguyn vt liu cho sn xut

Kt qu thu c l h thng hoch nh chi tit

cc loi nguyn vt liu, chi tit, thi gian biu c th nhm cung ng ng thi im cn thit..

V.

C IM CA H THNG MRP. (Ton+ Huyn) 1. u im: -

Tng hiu qu kinh doanh. Tng hiu qu sn xut. Thng tin kp thi v chnh xc. Gi mc tn kho mc ti thiu. Gim cc nguyn vt liu c. To tin cy cao i vi khch hng. Gim thi gian nhn ri. p ng nhanh hn vi nhu cu th trng. Thit lp mc tn kho an ton cho trng hp khn cp.

2. Nhc im: Khng tn dng ht din tch kho hng (nu kho ln). i ng nhn vin cha trnh thc hin hoch nh. Nu 1 mc xch trong quy trnh cung ng vt t gp tr ngi s nh hng n tt c nhng khu sau.
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Tng chi ph t hng.

Tng chi ph vn chuyn v chi ph n v. Chi ph ht hng cao. Vic thc hin h thng MRP c th tn rt nhiu chi ph v tn nhiu thi gian, v vy cc cng ty sn xut khi lng ln cc sn phm hon chnh c th thy MRP l c ch, trong khi c th khng ng i vi cc cng ty nh hn.

MRP to ra kt qu chnh xc, cn phi c thng tin u vo chnh xc, nu khng c th dn n vic lp k hoch sai, hng tn kho qu nhiu, khng c hng hay thiu cc ngun nguyn vt liu theo yu cu.

Ngun lc: MRP gi nh leadtime l c nh bt k c bao nhiu cng vic c thm vo trong h thng sn xut, MRP ngm gi nh nng lc l v hn, khng tnh n tnh hung b qu ti. MRP cha lin kt vi k hoch v yu cu nng lc ti thi im lp k hoch, nn MRP c khi phi iu chnh ti thi im bt u thc hin mt s cng on sn xut, dn n s chm tr hoc d tha hng tn kho. Do khng lin kt vi yu cu nng lc nn MRP s dng thi gian ch (Lead time) cho tng mt hng , cho cc cng on sn xut v ngun lc mt cch c lp vi nng lc sn xut ca cng ty. V vy trong thi k c nhiu n hng, ngun lc sn xut b gii hn th MRP s dn n mt cn bng gia yu cu v kh nng p ng sn xut. Lc ny, chng ta c RCCP (rough-cut capacity planning) c th gii quyt c vn ny bng cch kim tra ngun lc ca mt s cc ngun lc quan trng. RCCP xc lp nh mc ngun lc (bill of resources - BOR) cho mi mt hng trn MPS. BOR ch nh s gi yu cu mi ngun lc chnh xy dng sn phm cui cng c th v cc b phn cu thnh ca n, v sau tp hp s gi cn thit mi ngun lc chnh thng qua cc mt hng trong bng MPS. RCCP sau s kim tra liu cc ngun lc sn c c trang tri cho

MPS trn mi mc thi gian. Ch rng RCCP khng thc hin vic b p thi gian, v vy cc tnh ton v s gi yu cu c thc hin vi khong thi gian ln cho tt c cc b phn v thnh phn cu to c th c hon thnh trong phm vi cng mt khong thi gian. iu ny lm cho RCCP tr thnh mt s nh gi v ci g c th c thc hin.
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Long lead time: C nhiu nhm gy sc p v vic tng leadtime trong h thng MRP. MRP s dng leadtime c nh, tht ra leadtime bin i rt nhiu. b p cho vn ny, ngi k hoch in hnh la chn c lng bi quan. Leadtime di dn n s lng ln tn kho bn thnh phm (work-inprocess WIP) ln.

VI. -

NG DNG MRP. (Ton+ Huyn) MRP rt hu ch trong mi trng sn xut c tnh cht: Phc tp, khng chc chn. n t hng ca khch hng n tht thng. Lng hng bin i. Thi gian ch bin i. Thnh phm c lp rp theo n t hng.
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MRP c s d ng r ng ri trong cc doanh nghi p s n xu t cc s n phm phc tp bao gm nhiu b phn, chi tit linh kin nh l cng nghipin t, c kh , dt may Cc doanh nghip vn dng thnh cng phng php MRP l cc doanh nghip bao gm nhiu b phn, nhiu giai on snxut.
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Phng php MRP yu cu khi lng tnh ton nhiu v

vy c s tr gip ca cng c tin hc l iu cn thit. S qun l d liu trong sn xut l v n l n n h t t r o n g vn dng cng ngh thng tin. Hin c phn

mm thit k qun l sn xut trn phng php MRP , MRPII , c bit l E R P ( c p h t t r i n t M R P I I ) . T u y n h i n v i c p d n g p h n g p h p MRP c n c ngu i ph trch v c n ph i r sot ch nh n l i mi tr ng, khi qut dng thng tin, dng vt cht v m bo an ton ca s liu.
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Chng ta c ng c th p d ng MRP v i cc ph ng php qu n l hi n i khc nh KANBAN t hi u qu cao trong v n hnh s n xu t. (N i dung v ph ng php KANBAN s c th o lu n ph n d i)

VII.

M B O S THCH NG C A MRP V I NH NG THAY I C A MI TR NG. (Xu)

B. V D V MT S DOANH NGHIP NC NGOI NG DNG MRP

(anh Ha) I. CNG TY TOYOTA. 1. Gii thiu v cng ty Toyota.

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Toyota Motor Corporation (Nht: Toyota Jidosha Kabushiki-gaisha?) l mt cng ty a quc gia c tr s ti Nht Bn, v l mt trong nhng nh sn xut t ln nht th gii[3]. V mt cng nhn quc t, hng Toyota l nh sn xut xe hi duy nht c mt trong nhm top 10 xp hng cng nhn tn BrandZ. 2. Cc vn Toyota gp phi.

Trc nm 1980 th Toyota vn cha s dng MRP m s dng mt h thng y c to ra bi my tnh, nhng n khng xc nh v loi b cc sai st mt cch nhanh chng t ng truyn thng tin. H cho rng dng my tnh c xu hng y nhng h hng vo trm k tip, lm hng tn kho ngy cng tng v kh kim sot cht lng trong thi k mi trng lun thay i mun p ng nhanh vi nhu cu ca th trng th vic s dng nguyn vt liu l khng lin tc v rt khng n inh, nn qu trnh qun l nguyn vt liu tn kho hay vic xy dng lch trnh nhu cu nguyn vt liu gp rt nhiu kh khn..

Dn n mt kt qu l s lng hng tn kho nhiu nhiu, lch trnh sn xut gp vn , gy ra tnh trng thiu hng..,.

Khi iu xy ra th gii php ca cng ty lc by gi l p dng h thng MRP vo trong qu trnh hoch nh v xy dng lch trnh v nhng nhu cu nguyn vt liu , linh kin cn thit cho tng giai on 3. Kt qu t c sau khi s dng MRP.

C k hoch v lch trnh tn kho hiu qu, gim tn kho nhng vn m bo cht lng dch v khch hng.

Gim c thi gian sn xut v thi gian vn chuyn sn phm. Toyota mt 120 gi cng lao ng lm cho mt chic xe so vi 175-200 h M khi t chi khng p dng MRP .

Vo nm 1989 cng ty cng c nhn l cng ty vi chi ph thp v qun l hng tn kho v leadtime ngn nht.

Tng hiu qu hot ng. Phn ng nhanh chng vi nhu cu ca th trng.

II.

CNG TY MARUTI SUZUKI.

1. Gii thiu v cng ty Suzuki. Tp oan Suzuki c thanh lp vao thang 3/1920 Hamamatsu, Nht Ban vi tn goi Suzuki Loom Manufacturing Company. Sau o, Suzuki gia nhp nganh kinh doanh xe may vi san phm u tin la xe ap gn may nhan hiu "Power Free" san xut nm 1952, va tham gia vao nganh cng nghip t t nm 1955 vi nhan hiu xe hi "Suzulight", gop phn vao s ra i cua cuc cach mang t Nht Ban.
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Ngay nay, thng hiu Suzuki c tin cy qua nhiu san phm a dang t xe may, xe t, ng c tau thuy n nhiu loai san phm co lin quan khac nh may phat in, may han, ng c thng dung, tau thuy, xe ln gn may, xe ga khi ng in, cac san phm lin quan n siu m (may hut bui, may ct, v.v.) va thm chi ca nha va nha xng lam sn. Suzuki at doanh thu hang nm trn toan cu khoang 1,6 triu n vi san phm xe t va mt s lng tng ng i vi cac san phm xe may. iu nay cho thy Suzuki la mt nha san xut xe may va xe t ln kinh doanh co hiu qua.

Vi mang li toan cu gm nhiu nha may lp rap, chi nhanh phn phi va cng ty con, Suzuki hin co mt tai hn 190 quc gia trn khp th gii.

2. Gii thiu v cng ty Maruti Suzuki. Maruti Udyog c thnh lp gia cng ty Suzuki v Chnh ph n . Maruti l nh sn xut xe hi s lng cao nht chu , ngoi Nht Bn v Hn Quc, sn xut hn 5 triu xe ca thng 5 nm 2005. Maruti l mt trong cc lin doanh t thnh cng nht, v lm cho li nhun hng nm k t khi thnh lp cho n 01- 2000. 3. Cc vn chnh trong chui cung ng ca Suzuki.

Thch thc quan trng nht c xc nh ca Maruti l tch hp ton b chui cung cp v qun l n nh mt thc th tch hp duy nht.

Qun l logistics l mi quan tm chnh ca cc OEM cng nh Maruti, thc y bi nhng thch thc lin quan n tin cy ca leadtime, v thiu vng nhng ngi lm logistics cht lng.

Qun l sn phm v s tng trng

l vn th hai c

ngha thch thc i vi cng ty. Tng cnh tranh trong ngnh cng nghip t n dn n co rt ng k trong vng i sn phm v nhu cu cho sn phm thng xuyn v thng xuyn thay i chuyn tip v gii thiu sn phm mi. Trong khi iu ny dn n cc vn qun l mt danh mc sn phm rng ln, mt vn chnh lin phn, thc quan y l s bi s gia cn tng thit ca cc b phn / m hnh ngng.
4. Li ch ca cng ty khi s dng MRP

thnh

phi cung cp cc ph tng thay th cho hin ti l tt nh cc

Khi c MRP hoch nh, Maruti gim c lng nguyn vt liu tn kho, nng cao kh nng s dng mt cch ti u cc phng tin vt cht v lao ng.

MRP tng cng dch v khch hng thng qua vic gim n t hng cui. iu ny dn n tng mc sn xut v gip cng ty p ng nhanh hn vi bt k s thay i trong nhu cu.

Vi mc chi ph ban u ci t h thng MRP l kh cao, tuy nhin n gip cng ty tit kim sn xut t chi tiu thi gian lao ng.

III.

CNG TY COLLINS INDUSTRIES. 1. Gii thiu v cng ty Collins Industries.

Collins Industries: Collins Industries l mt cng ty chuyn sn xut xe but trng hc, v cng sn xut xe cu thng v xe chuyn dng khc.

Cng ty c thnh lp vo nm 1971 v nm 1998 n c c bn cng ty con: Cng ty Collins Bus, bnh xe Coach Industries, Inc; Trans World, Inc. v nng lc ca Texas, Inc. Collins mua nh sn xut xe but trung trong nm 1998, v cc ti sn ca nh sn xut Canada da trn Tng cng ty xe but Corbeil trong nm 2007. Cng ty c khong 900 nhn vin, trong s ba c s sn xut.

2. Vn ca Collins.

Trong qu trnh hot ng sn xut ca mnh cng ty lun lun phi duy tr mt s lng hng tn kho ln vi hn 18000 b phn khc nhau, v cng ty lun phi i mt vi tnh trng thiu nguyn vt liu khi c nhng bin ng t n t hng ln ca i tc ( mt 2 khch hng t Canada). Ring trong nm 1997: Collins phi chi 1,81 t USD cho hng tn kho. Cng ty rt kh khn trong vic kim sot thng tin lng hng tn cng nh vic quyt nh thi gian nhp hng. K hach nhp vt liu khng p ng c nhng yu cu ca lch trnh sn xut v cc kh nng ca phung tin sn xut. Thi gian giao hng, nhn l hng v cp nht thng tin t cc n dt hng ti cng ty cn km hiu qu.

3. Thnh cng khi p dng MRP: - Gim tn kho thp hn 30% ch trong vng 2 nm. - Hiu qu p ng khch hng c ci thin r rt: s n t hng lun c p ng ng s lng, kp thi gian. - K hoch sn xut c kim sot chc ch t khu s lng nguyn vt liu n thi im t mua hng. - Chnh xc v thng tin d liu tn kho: s lng, mt hng - Gi hng ha gim xung. - Tinh thn lm nhm tng cao. Hot ng kinh doanh ca Collins to tng trng v c c li th cnh tranh nh vo h thng MRP. ( li nhun tng 35%, t 8.36 t USD).

Ngun tham kho: http://www.collinsbus.com

http://www.corbeilbus.com/

C. V D V DOANH NGHIP VIT NAM NG DNG MRP.

I. -

GII THIU V CNG TY. Tn cng ty: X nghip thp v vt liu xy dng H Ni trc thuc Cng ty vt liu xy dng v lm sn B thng mi Tr s ca X nghip : S 463 ph Minh Khai Phng Vnh Tuy Qun Hai B Trng Thnh ph H Ni. S in thoi: 04.8622747 Nhim v:X nghip c nhim v chuyn kinh doanh cc mt hng vt liu nh : xi mng, st thp, giy du (a chng loi ).Tuy nhin,nhim v chnh l sn xut cc loi thp p ng cho nhu cu ni a .X nghip c mng li tiu th sn phm rng khp nc. xng sn xut ca X nghip c hn 300 cng nhn lao ng Hin nay, trong nn kinh t th trng, mc tiu ca doanh nghip u hng ti ti a ho li nhun v ngy cng nng cao li ch kinh t x hi. V vy cn phi c bin php qun l NVL mt cch tit kim, s dng ng i tng, ng mc ch, hao ph t nht, mang li hiu qu kinh t cao nht. t c mc ch ny, x nghip phi s dng ng b nhiu bin php t khu k thut n qun l, trong doanh nghip p dng thnh cng chin lc MRP trong vic cung ng nguyn vt liu.

II.

THC T V TNH HNH CNG TC HOCH NH NGUYN VT LIU TI X NGHIP. Th t x nghip p dng m hnh hoch nh nhu cu nguyn vt liu MRP, nhng di dng c iu chnh cho ph hp vi iu kin ca x nghip. 1. Trong s quy trnh hoch nh:

 u vo: x nghip c thm h s mc tng quan cc yu t u vo. N phn nh vic d bo v kh nng p ng nhu cu cng nh mc thch ng vi cc yu t u ra. Qu trnh x l: x nghip dng chng trnh my tnh MRP nh sau: H s ha n nguyn vt liu, h s nguyn vt liu d tr v h s mc tng quan ca cc yu t u vo c thc hin bng chng trnh qun l Word access and Power Point. Lch trnh sn xut c thc hin bng phn mm qun l Eras.

u ra: x nghip khng p dng vic bo co nhu cu NVL hng ngy m thc hin 2 tun mt ln cho hot ng sn xut.

2. Trnh t hoch nh nhu cu:

Bc 1: Phn tch kt cu sn phm. X nghip ngoi vic phn loi nhu cu thnh nhu cu c lp v nhu cu ph thuc cn phn thnh nhu cu thit yu trong tng giai on. c th trong 3 thng u nm, cc qu Nhm to ra s lin kt trong qu trnh hoch nh gip cho vic hoch nh chi tit trnh tnh trng thiu ht NVL trong qu trnh sn xut.

Bc 2: Tnh tng nhu cu. Thc t, x nghip dng phn mm k ton Excel cp nht thng xuyn nhu cu cc thng, qu. Trn c s tnh tng nhu cu thc t p dng cho hot ng sn xut kinh doanh ca x nghip

Bc 3: Tnh nhu cu thc.

X nghip loi tr mt t l ph phm theo k hoch khng cn thit nn nhu cu thc khng c thm phn ph phm. Nhu cu thc= tng nhu cu d tr hin c + d tr an ton

Bc 4: Xc nh thi gian pht n t hng hoc lnh sn xut. Thc t x nghip xc nh thi gian phi t hng hoc t sn xut= thi im cn c khong thi gian cung ng hoc sn xut cn thit cung cp ng lng hng yu cu.

V d: C s liu sau x nghip. Trong k hoch nm 2002, x nghip nhn c 2 n t hng lm ca st c ln cho cng ty xy dng c gii 26- B Quc phng. C th:
-

Lm 200 chic giao vo tun th 4 v 300 chic giao vo tun th 8, mi cnh gm 4 thanh thp loi 32 v 2 khung (c kch thc 2x 3m)

Cc thanh thp c sn xut ti x nghip, mi thanh mt 1 tun. khung c nhp ngoi vi thi gian cung ng l 2 tun.

Vic lp rp cnh ca mt khong 1 tun. c lch tip nhn (d tr ban u) ca tun l 100 thanh thp. Thc t x nghip hoch nh theo phng php lng t hng theo l (nhu cu thc)

* Xy dng lch trnh sn xut: Tun S lng 1 2 3 4 5 6 7 8

200

30 0

* Xc nh kt cu sn phm.

Cnh ca

Khung (2)

Thanh thp (4)

* Thi gian biu lp rp

Tun 1

T2

T3

T4

T5

T6

T7

T8

Sn xut thanh thp Lp rp cnh ca Mua khung

sn xut thanh thp Lp rp cnh ca Mua khung

Bi v phi c 200 cnh ca giao vo u tun th 4 v do khng c d tr sn c vo thi k nn nhu cu thc s l 200 cnh ca. Lch tip nhn ca tun th 4 s l 200 cnh ca. Do vic lp rp tn 1 tun nn lch t hng pht ra vo u tun th 3.

Cng tng t nh vy ta c lch t hng pht ra vo u tun th 7 tun th 8 c 300 cnh ca. Lch t hng pht ra vo u tun th 3, ngha l thi im tng nhu cu phi c 200 x 2 = 400 khung. Do khng c d tr mong i nn nhu cu thc l 400 khung vo u tun th 3. Nhng thi gian t hng v phi mua ngoi mt 2 tun nn phi t hng vo tun th nht. Tng t nh vy c tng nhu cu v nhu cu thc i vi n hng 300 cnh ca l bng nhau v bng 600 khung. Thi gian t hng phi vo u tun th 5. i vi cc thanh thp khi xt n hng 200 cnh ca cng cn phi c 800 thanh vo u tun th 3. y do c 100 thanh d tr nn nhu cu thc l: 800 - 100 = 700 thanh. Ta phi pht n hng theo k hoch vo u tun th 3 v lch sn xut bt u tun th 2. Tng t vi n hng cnh ca 300 phi pht lnh n hng vo u tun th 7 vi tng nhu cu l 1200 thanh v lch sn xut 1200 thanh phi bt u t tun th 6. * t hng theo l (nhu cu thc) Tun S lng 1 2 3 4 200 5 6 7 8 300

Cnh ca Thi gian lp rp bng 1 tun

Tng nhu cu Lng tip nhn theo tin D tr hin c Nhu cu thc Lng tip nhn t hng theo k hoch

200

300

200 200

300 300

Lng n hng pht ra theo k hoch

20 0

30 0

Khung Tng nhu cu ca Thi gian lp rp bng Lng tip nhn theo tin D tr hin c Nhu cu thc tip nhn t

40 0

60 0

40 0 40 0 60 0

60 0 60 0

2 tun Lng

hng theo k hoch Lng n hng pht ra 40 theo k hoch 0

Thanh Tng nhu cu g Thi gian sn xut bng 1 tun Lng tip nhn t hng theo k hoch Lng n hng pht ra theo k hoch 70 0 Nhu cu thc Lng tip nhn theo 10 tin D tr hin c 0 10 0 10 0

80 0

120 0

10 0 70 0 70 0 120 0 120 0 120 0

3. Phng php xc nh kch c l hng a) Mua theo l Theo phng php ny l cn bng no mua bng y, ng thi im cn. X nghip p dng phng php ny l hp l bi cc l hng ca x nghip t thng xuyn, lng d tr cung cp ng lc tn t chi ph lu kho. b) Phng php cn i cc giai on b phn Thc cht l phng php ghp l sao cho tng chi ph d tr t mc thp nht c th: C l c xc nh Chi ph t hng EPP = Chi ph lu kho 1 n v hng trong 1 giai on

4. T chc cng tc hoch nh X nghip phn b cng tc hoch nh cho phng k hoch. Nhng thc t c s phi hp cht ch gia phng k hoch vi phng k ton tng hp cng nh cc phng ban khc. C th: c cc s liu chi tit v NVL cng nh tnh hnh nhp xut, tn kho sm phm phc v cho vic phn tch, a ra k hoch th phng k hoch cn c s h tr ca phng KT - TH. Cng tc ny phn cng c th hn cho cn b phng k hoch * Cn b ph trch k hoch vt t: chu trch nhim phn tch s liu chi tit m phng KTTH cung cp v kh nng cung ng ca NVL. T vch ra k hoch chin lc. Kt hp vi cn b ph

trch k hoch ti chnh hoch nh kh nng cung cu NVL mt cch tit kim nht v hiu qu nht. Di s iu phi chung ca trng phng k hoch, cn b ph trch vt t v ti chnh thng xuyn bo co tnh hnh mt cch chi tit, c th. T , phng k hoch mi xut cho vic hoch nh nhu cu NVL cho giai on tip theo. III. KT QU CA CNG TY KHI P DNG CHIN LC MRP: Trc y , X nghip thp v vt liu xy dng H Ni gp nhiu kh khn. Mt phn do cha c s gn kt hon ton , ng b gia cc phng ban trong X nghip. Nhng phn ln l do th trng vt liu c s bin ng mnh.Doanh nghip cha c bin php qun l hiu qu nguyn vt liu
-

Vi nm tr li y,nh p dng chin lc MRP, X nghip qun l tt nguyn vt liu: X nghip xy dng k hoch ch o linh hot, thu mua vt t vi phng chm u c vt t r, c cht lng l mua tng cng kh nng d phng vt t, phuc v sn xut. Cc k hoch v nguyn vt liu u c hoch nh, vch ra mt cch c th , hoch nh lun lun tin hnh trc mt bc so vi nhu cu, nhng c tnh dn s bin ng ca th trng nh: nhu cu th trng, th trng tim nng Nh vy,X nghip tng bc n nh v pht trin.

C th ta thy c kt qu mt s nm trc y sau khi doanh nghip qun l tt nguyn vt liu:

Nm

Doanh ng) Kinh doanh

thu Sn xut 6.75 8.64 8.92

(t Tng sn lng

Tng qu lng

Li (1000) Kinh

nhun Sn xut 52340 12852 13062

(1000) doanh 68570 8627 8934 686850 794860 823468 282370 248965 297360

2000 2001 2002

14.652 12.630 16.850

D. KANBAN. I. NH NGHA V KANBAN. KANBAN l mt cng c vn hnh h thng JIT. mt chic nhn, thng c bc bn trong mt bao b nha. Trn KANBAN, thng cha nhng thng tin sau:

Tn chi tit, sn phm c sn xut. Sc cha container. a ch, k hiu ca quy trnh lm vic trc. a ch, k hiu ca quy trnh sau.

Ngoi cc thng tin ch yu , th tu vo loI KANBAN v tu vo tnh hnh c th ca mI doanh nghip m c th c thm nhng thng tin khc.

VD: Mt s mu Kanban

II.

CHU TRNH DUY CHUYN CA TH KANBAN.

CC LOI TH KANBAN.

Kanban vn chuyn ( transport kanban): y l loi dng thng bo cho cng on trc cn chuyn chi tit, sn phm cho cng on. Kanban sn xut (production kanban):y l loi dng bo cho dy chuyn sn xut chi tit, sn phm b vo lng giao. Kanban cung ng ( suppiler kanban): y l loi dng thng bo cho nh cung cp bit cn phi giao hng. Kanban tm thi(temporary kanban): Kanban c pht hnh c thi hn trong cc trng hp thiu hng. Kanban tn hiu(singal kanban): l loi dng thng bo k hoch cho cc cng on sn xut theo l.

III.

CHC NNG CA KANBAN.

Hng dn: l cng c hng dn sn xut v vn chuyn.(sn xut chi tit, sn phm no, vn chuyn bao nhiu) T kim tra: ngn nga sn xut tha. MI cng on t kim tra m bo ch sn xut nhng chi tit, sn phm vI s lng cn thit, tI thI im cn thit. Kim tra bng mt: th KANBAN khng ch cha thng tin bng s m cn cha thng tin vt l. ( V d: cc th KANBAN mu trng, xanh l, v vng: mu trng hoc xanh th cha cn sn xut ngay, mu vng l tn hiu vic sn xut phI c bt u) Ci tin hot ng: KANBANduy tr mc tn kho tI thiu, gim chi ph sn xut, nh vy doanh nghip hot ng c hiu qu hn. Gim chi ph qun l: H thng KANBAN cng gip gim chi ph qun l do hoch nh ngn hn khng cn na, bi bn cht ko ca h thng. IV. CC NGUYN TC S DNG KANBAN.

Nguyn tc 1: Qu trnh sau ch ly i cc sn phm cn thit t qu trnh trc vi s lng cn thit thi im cn thit. Nguyn tc 2: Qu trnh phi sn xut s lng bng s lng ly i. Nguyn tc 3: Nhng chi tit sn phm b li khng c chuyn n qu trnh sau. Nguyn tc 4: Ti thiu s KANBAN. Nguyn tc 5: KANBAN c s dng hiu chnh i vi s thay i nh trong nhu cu. Nguyn tc 6: S lng cc b phn chi tit sn phm thc t cha trong hp hoc ng gi phi bng vi s lng ghi trn KANBAN.
V.

IU KIN P DNG KIN THC KANBAN. 1. 2. H thng thng tin phi r rng, minh bch. Dng sn xut linh hot v thng sut.

3. 4. 5. 6. trin. 7. 8.

Thit b, my mc phi c b tr mt cch hp l. Cc sn phm c thi gian thay i ngn. Cc bin ng ngu nhin cn c loi b. Mi quan h vi nh cung cp phi c cng c v pht Lao ng a nng, c kh nng thay i ch lm vic, c th Tiu chun ha cc b phn v n v lp rp sn phm.

iu chnh v bo dng my mc.

NGHA CA KANBAN I VI CHIN LC JIT. u im: -Cho thy c vn ln cn gii quyt ca phn xng. -Gip nm c tnh hnh my mc thit b, ph phm pht sinh da vo dng di chuyn thng tin nhanh gia cc ch lm vic. -Phi hp chc ch gia cc ch lm vic. -Thch ng qu trnh sn xut v nhu cu. -S lng tn kho l t nht. -Khng cn lp k hoch hng ngy. -Cho php dao ng 10% so vi nhu cu. -Trong phn xng, h thng kim tra KANBAN l then cht. -C kh nng hiu chnh chnh xc k hoch c lp trn MRP II. Nhc im. -Khi p dng h thng KANBAN, xng s khng c tn kho, v vy khng p ng c dao ng ln. -S ri lon ca mt cng on s lm nh hng n tan h thng. ( khc phc bng cch s dng kt hp MRPII)