MRP物料需求計劃物料需求計劃（MRP）物料需求計劃（MaterialRequirementPlanning，簡稱為MRP）是對主生產(chǎn)計劃的各個項目所需的全部制造件和全部采購件的數(shù)量需求計劃和時間進度計劃。物料需求計劃物料需求物料庫存物料需求計劃（MRP）物料需求計劃主要解決以下五個問題：要生產(chǎn)什么？生產(chǎn)多少？（來源于MPS）要用到什么？（根據(jù)BOM展開）已經(jīng)有了什么？（根據(jù)物品庫存信息、即將到貨或產(chǎn)出信息）還缺什么？(計算出結(jié)果)何時安排？(計算出結(jié)果)MRP原理生產(chǎn)什么?要用什么？我們有什么？還需要什么？何時需要？主生產(chǎn)計劃(MPS)按照物料單(BOM)庫存記錄物料需求計劃(MRP)工作單、采購單主生產(chǎn)計劃粗能力計劃

MRPII邏輯流程圖產(chǎn)品規(guī)劃資源需求計劃銷售規(guī)劃可行？可行？物料需求計劃能力需求計劃可行？采購作業(yè)車間作業(yè)成本會計業(yè)績評價資源清單合同預(yù)測其它需求供應(yīng)商信息銷售與運作計劃應(yīng)收帳總帳應(yīng)付帳庫存信息物料清單工作中心工藝路線客戶信息成本中心會計科目宏觀微觀經(jīng)營規(guī)劃123454個計劃層次1個執(zhí)行層次決策層

計劃層

執(zhí)行控制層物料需求計劃（MRP）低層碼（low-levelcode，簡稱LLC）概念：物料的低層碼是系統(tǒng)分配給物料清單上的每個物品一個從0至N的數(shù)字碼。在產(chǎn)品結(jié)構(gòu)中，最上層的層級碼為0，下一層的部件的層級碼則為1，依此類推。一個物品只能有一個MRP低層碼，當(dāng)一個物品在多個產(chǎn)品中所處的產(chǎn)品結(jié)構(gòu)層次不同或即使處于同一產(chǎn)品結(jié)構(gòu)中的但卻處于不同產(chǎn)品結(jié)構(gòu)層次時，則取處在最低層的層級碼作為該物品的低層碼。作用：在展開MPS進行物料需求計算時，計算的順序是從上而下進行的，即從產(chǎn)品的0層次開始計算，按從上到下的順序進行計算，當(dāng)計算到該產(chǎn)品的某一層次（如1層），但高于低層碼時（物料的低層碼為2），只計算該層的物料計算結(jié)果（毛需求量）暫時存儲起來，總的需求量可以匯總存儲，但不進行MRP需求計算。只有到了低層碼的層次，才計算凈需求、需生產(chǎn)量等。因此，低層碼是MRP的計算順序。物料需求計劃（MRP）物料A的MRP計算順序示意圖XABCDA0層1層2層制造流程與BOM結(jié)構(gòu)車間WIP生產(chǎn)和采購數(shù)據(jù)MRP定義Item(庫存）設(shè)計數(shù)據(jù)ENGBOM結(jié)構(gòu)工藝路線前提應(yīng)用創(chuàng)建BOM類型BOM計劃BOM模型BOM選項組BOM標(biāo)準BOM矩陣式BOM加減BOM標(biāo)準BOM標(biāo)準物料清單是最通用的清單類型，并列有法定組件、每個組件的要求數(shù)量、在制品控制信息、物料計劃等信息CABDE25311選項類BOM

選項類作為一個項目，成為模型物料清單中的一層。選項類還可以具有適用于其所有選項的法定組件VGA-BVGA顯示器選項類BOM可選標(biāo)準BOM可選VGA-A標(biāo)準BOM可選模型（超級）BOM模型物料清單定義了選項清單和選項類，指定了法定組件，您可以在銷售模塊中選擇以訂購配置。模型清單可以是按訂單裝配或按訂單挑庫類型的EGA顯示器計算機VGA顯示器顯示器VGA真彩色VGA-AVGA標(biāo)準VGA-B模型BOM不可選標(biāo)準BOM可選選項類BOM可選標(biāo)準BOM可選標(biāo)準BOM可選標(biāo)準BOM可選標(biāo)準BOM可選選項類BOM不可選計劃BOM

計劃物料清單是一個包括組件百分比分配的物料清單結(jié)構(gòu)培訓(xùn)用計算機科研用計算機車間生產(chǎn)用模型BOM35%不可選模型BOM25%不可選模型BOM40%不可選計劃BOM100%不可選電子掛鐘機芯花紋1花紋2花紋2花紋1紅黑電池特征件與可選件鐘盤指針盤面秒針短針長針鐘框塑料(紅)塑料(白)塑料(金)金屬(壓花）金屬(平)木雕(鷹)木雕(屋)木雕(輪)配不配金白黑金通用件特征件（基本組件）可選件（必選其一、可選其一）電子掛鐘字型2鐘框塑料木雕鷹屋紅白凸平通用件機芯鐘盤黑色金色字型1字型1字型2指針花紋1花紋2長針花紋2花紋1短針秒針紅黑電池可選件(1.0)(1.0)(1.0)(1.0)(0.5)(0.5)(0.2)(0.2)(0.3)(0.3)(0.3)(0.3)(0.1)(0.1)(0.1)(0.1)金屬(0.2)(0.2)(0.6)(1.0)(1.0)(1.0)(0.5)(0.5)(0.5)(0.5)(0.5)(0.5)(1.0)注：括號內(nèi)為預(yù)測百分比(0.5)模塊化產(chǎn)品結(jié)構(gòu)

模塊化物料清單1002030203050505050505010103030101050物料名稱：電子掛鐘物料號：10000層次物料號物料名稱選項號選擇件數(shù)量預(yù)測%實際需求11機芯鐘盤長針短針秒針鐘框電池(通用件)1234121212123456(可選件)黑色、字型1黑色、字型2金色、字型1金色、字型2花紋1花紋2花紋1花紋2花紋1花紋2塑料、紅色塑料、白色金屬、凸紋金屬、平紋木雕、鷹木雕、屋111111111111111112根據(jù)銷售定貨1100012000/112000/212000/312000/412100/112100/212200/112200/212300/112300/213000/113000/213000/313000/413000/513000/614000物料清單的表現(xiàn)類型單層物料清單縮排式物料清單 匯總的物料清單模塊式物料清單單層跟蹤縮行跟蹤（多級反查）成本物料清單匯總物料清單（通用件匯總）XB(1)K(1)CP(3)LMDM(2)B(4)K(4)AJHPHP物料號

數(shù)量

A1B5C1D1H2P5L1M3物料清單的構(gòu)建產(chǎn)生零件清單單級BOM的開發(fā)多級BOM及工藝路線的開發(fā)注意事項：唯一編碼替代物料及替代原則虛擬件為了控制某些環(huán)節(jié)（檢驗等），可視為不同零件物料清單的用途和用戶編制計劃的依據(jù)配套和領(lǐng)料的依據(jù)進行加工過程的跟蹤采購和外協(xié)的依據(jù)根據(jù)它進行成本的計算報價參考物料追溯使設(shè)計系列化、標(biāo)準化、通用化涉及設(shè)計、計劃、生產(chǎn)、財務(wù)等部門物料需求計劃（MRP）MRP子系統(tǒng)與其他子系統(tǒng)的關(guān)系圖生成生成獨立需求MRP采購管理MPSCRP制造標(biāo)準車間管理JIT管理平衡庫存管理銷售管理BOM庫存信息計劃信息物料需求計劃（MRP）MRP的策略因素 制造/采購標(biāo)志碼 提前期 安全庫存 損耗率、成品率 批量政策物料需求計劃（MRP）損耗率實際需求=凈需求＊（１＋損耗率）成品率總投入=有效產(chǎn)出/成品率物料需求計劃（MRP）批量政策●直接批量LotForLot●固定批量FixedQuantity●固定周期FixedTime●經(jīng)濟批量EOQ(EconomicOrderQuantity)●批量增量MRP的編制思路

訂貨/配銷

·生產(chǎn)什么？

·什么時候生產(chǎn)？

·生產(chǎn)多少？

主生產(chǎn)計劃

(MPS)

需求預(yù)測

·材料

·產(chǎn)品結(jié)構(gòu)

·用料標(biāo)準

·提前期（LT）

物料清單

(BOM)

·各種材料總需求量計算

·考慮庫存量計算凈需求量

·考慮批量計算計劃量

物料需求計劃

(MRP)

·在庫量

·預(yù)訂接收量

·倉儲位置

·收發(fā)料記錄

庫存記錄

(INV)

采購/外包/制造

·什么物料？

·什么時候？

·數(shù)量多少？

分段執(zhí)行

·制造工令

·采購/委外加工

計劃

·應(yīng)發(fā)哪些訂單？

·哪些訂單需提前或延緩安排？

·哪些料應(yīng)催收?

執(zhí)行

圖6-4系統(tǒng)處理邏輯圖

物料需求計劃（MRP）MRP的計算過程1、毛需求2、當(dāng)前預(yù)計可用庫存量=現(xiàn)有庫存量-已分配量3、PAB初值=上期末預(yù)計可用庫存量+計劃接收量-毛需求量4、凈需求量 當(dāng)PAB初值>=安全庫存，凈需求=0 當(dāng)PAB初值<安全庫存，凈需求=安全庫存-PAB初值物料需求計劃（MRP）5、計劃產(chǎn)出量 當(dāng)凈需求>0，計劃產(chǎn)出量=N*批量 滿足：計劃產(chǎn)出量>=凈需求>（N-1）*批量6、預(yù)計可用庫存量=計劃產(chǎn)出量+PAB初值7、考慮提前期，推算計劃投入量CooperstownCars,Inc.ProducestoycarsBodyAxles(2)Wheels(4)CooperstownCars,Inc.-EachcomponenthasaknownleadtimeCooperstownCars,Inc.Scheduleproductionfor:ToycarassemblyWheelassemblyBodyAxleWheelsDemandforToyCarinWeek8is100Time-PhasedProductStructure1weekToyCarTimeinWeeks45678Time-PhasedProductStructure1week1weekToyCarWheelAssemblyBody2weeks45678TimeinWeeksTime-PhasedProductStructure1week1weekToyCarWheelAssemblyBodyAxlesWheels2weeks1week2weeks45678TimeinWeeks12345678ToyCarRequiredDate100OrderreleasedataWheelassemblyRequiredDateOrderreleasedataBodyRequiredDateOrderreleasedataAxleRequiredDateOrderreleasedataWheelsRequiredDataOrderreleasedataWeekGrossRequirementsPlan12345678ToyCarRequiredDate100Orderreleasedata100WheelassemblyRequiredDateOrderreleasedataBodyRequiredDateOrderreleasedataAxleRequiredDateOrderreleasedataWheelsRequiredDataOrderreleasedataWeekGrossRequirementsPlan12345678ToyCarRequiredDate100Orderreleasedata100WheelassemblyRequiredDate200OrderreleasedataBodyRequiredDateOrderreleasedataAxleRequiredDateOrderreleasedataWheelsRequiredDataOrderreleasedataWeekGrossRequirementsPlan12345678ToyCarRequiredDate100Orderreleasedata100WheelassemblyRequiredDate200Orderreleasedata200BodyRequiredDateOrderreleasedataAxleRequiredDateOrderreleasedataWheelsRequiredDataOrderreleasedataWeekGrossRequirementsPlan12345678ToyCarRequiredDate100Orderreleasedata100WheelassemblyRequiredDate200Orderreleasedata200BodyRequiredDate100OrderreleasedataAxleRequiredDateOrderreleasedataWheelsRequiredDataOrderreleasedataWeekGrossRequirementsPlan12345678ToyCarRequiredDate100Orderreleasedata100WheelassemblyRequiredDate200Orderreleasedata200BodyRequiredDate100Orderreleasedata100AxleRequiredDateOrderreleasedataWheelsRequiredDataOrderreleasedataWeekGrossRequirementsPlan12345678ToyCarRequiredDate100Orderreleasedata100WheelassemblyRequiredDate200Orderreleasedata200BodyRequiredDate100Orderreleasedata100AxleRequiredDate200Orderreleasedata200WheelsRequiredDataOrderreleasedataWeekGrossRequirementsPlan12345678ToyCarRequiredDate100Orderreleasedata100WheelassemblyRequiredDate200Orderreleasedata200BodyRequiredDate100Orderreleasedata100AxleRequiredDate200Orderreleasedata200WheelsRequiredData400Orderreleasedata400WeekGrossRequirementsPlan12345678ToyCarGrossrequirements100ScheduledreceiptsProjectedon-hand|202020202020202020PlannedorderreceiptsPlannedorderreleasesNetRequirementsPlanWeek12345678ToyCarGrossrequirements100ScheduledreceiptsProjectedon-hand|202020202020202020Plannedorderreceipts80PlannedorderreleasesNetRequirementsPlanWeek12345678ToyCarGrossrequirements100ScheduledreceiptsProjectedon-hand|202020202020202020Plannedorderreceipts80Plannedorderreleases80NetRequirementsPlanWeek12345678ToyCarGrossrequirements100ScheduledreceiptsProjectedon-hand|202020202020202020Plannedorderreceipts80Plannedorderreleases80WheelassemblyGrossrequirements160ScheduledreceiptsProjectedon-hand|10PlannedorderreceiptsPlannedorderreleasesNetRequirementsPlanWeek12345678ToyCarGrossrequirements100ScheduledreceiptsProjectedon-hand|202020202020202020Plannedorderreceipts80Plannedorderreleases80WheelassemblyGrossrequirements160ScheduledreceiptsProjectedon-hand|1010101010101010PlannedorderreceiptsPlannedorderreleasesNetRequirementsPlanWeek12345678ToyCarGrossrequirements100ScheduledreceiptsProjectedon-hand|202020202020202020Plannedorderreceipts80Plannedorderreleases80WheelassemblyGrossrequirements160ScheduledreceiptsProjectedon-hand|1010101010101010Plannedorderreceipts150Plannedorderreleases150NetRequirementsPlanWeek12345678ToyCarGrossrequirements100ScheduledreceiptsProjectedon-hand|202020202020202020Plannedorderreceipts80Plannedorderreleases80BodyGrossrequirements80ScheduledreceiptsProjectedon-hand|4040404040404040PlannedorderreceiptsPlannedorderreleasesNetRequirementsPlanWeek12345678ToyCarGrossrequirements100ScheduledreceiptsProjectedon-hand|202020202020202020Plannedorderreceipts80Plannedorderreleases80BodyGrossrequirements80ScheduledreceiptsProjectedon-hand|4040404040404040Plannedorderreceipts40Plannedorderreleases40NetRequirementsPlanWeek12345678WheelassemblyGrossrequirements160ScheduledreceiptsProjectedon-hand|1010101010101010Plannedorderreceipts150Plannedorderreleases150AxlesGrossrequirements150ScheduledreceiptsProjectedon-hand|15PlannedorderreceiptsPlannedorderreleasesNetRequirementsPlanWeek12345678WheelassemblyGrossrequirements160ScheduledreceiptsProjectedon-hand|1010101010101010Plannedorderreceipts150Plannedorderreleases150AxlesGrossrequirements150ScheduledreceiptsProjectedon-hand|15151515151515Plannedorderreceipts135PlannedorderreleasesNetRequirementsPlanWeek12345678WheelassemblyGrossrequirements160ScheduledreceiptsProjectedon-hand|1010101010101010Plannedorderreceipts150Plannedorderreleases150AxlesGrossrequirements150ScheduledreceiptsProjectedon-hand|15151515151515Plannedorderreceipts135Plannedorderreleases135NetRequirementsPlanWeek12345678WheelassemblyGrossrequirements160ScheduledreceiptsProjectedon-hand|1010101010101010Plannedorderreceipts150Plannedorderreleases150WheelsGrossrequirements300ScheduledreceiptsProjectedon-hand|30PlannedorderreceiptsPlannedorderreleasesNetRequirementsPlanWeek12345678WheelassemblyGrossrequirements160ScheduledreceiptsProjectedon-hand|1010101010101010Plannedorderreceipts150Plannedorderreleases150WheelsGrossrequirements300ScheduledreceiptsProjectedon-hand|30303030303030Plannedorderreceipts270PlannedorderreleasesNetRequirementsPlanWeek12345678WheelassemblyGrossrequirements160ScheduledreceiptsProjectedon-hand|1010101010101010Plannedorderreceipts150Plannedorderreleases150WheelsGrossrequirements300ScheduledreceiptsProjectedon-hand|30303030303030Plannedorderreceipts270Plannedorderreleases270NetRequirementsPlanWeekMorecomplexity/ScheduledreceiptsExplanation:Grossrequirementsarethetotaldemandforwheels.Projectedon-handinventoryinweek1is30+200heelsGrossrequirements150120150120Scheduledreceipts200Projectedon-hand|30PlannedorderreceiptsPlannedorderreleasesNetRequirementsPlanWeekMorecomplexity/ScheduledreceiptsProjectedon-handinventorybalanceatendofweektInventoryonhandatendofweekt-1GrossrequirementsinweektScheduledorplannedreceiptsinweekt=+–12345678WheelsGrossrequirements150120150120Scheduledreceipts200Projectedon-hand|3080PlannedorderreceiptsPlannedorderreleasesNetRequirementsPlanWeek12345678WheelsGrossrequirements150120150120Scheduledreceipts200Projectedon-hand|30808080PlannedorderreceiptsPlannedorderreleasesNetRequirementsPlanWeekMorecomplexity/ScheduledreceiptsLeadtime=1week12345678WheelsGrossrequirements150120150120Scheduledreceipts200Projectedon-hand|30808080PlannedorderreceiptsPlannedorderreleasesNetRequirementsPlanWeekLot-SizingRules:L4LL4L-ordertheamountneededtofulfillrequirementsLeadTime=1week12345678WheelsGrossrequirements150120150120Scheduledreceipts200Projectedon-hand|30808080Plannedorderreceipts40Plannedorderreleases40NetRequirementsPlanWeekLot-SizingRules:L4LLeadTime=1week12345678WheelsGrossrequirements150120150120Scheduledreceipts200Projectedon-hand|30808080000Plannedorderreceipts40150Plannedorderreleases40150NetRequirementsPlanWeekLot-SizingRules:L4LLeadTime=1week12345678WheelsGrossrequirements150120150120Scheduledreceipts200Projectedon-hand|308080800000Plannedorderreceipts40150120Plannedorderreleases40150120NetRequirementsPlanWeekLot-SizingRules:L4LLeadtime=1week12345678WheelsGrossrequirements150120150120Scheduledreceipts200Projectedon-hand|30808080PlannedorderreceiptsPlannedorderreleasesNetRequirementsPlanWeekLot-SizingRules:EOQEOQ-ordertheEOQLeadtime=1week12345678WheelsGrossrequirements150120150120Scheduledreceipts200Projectedon-hand|30808080Plannedorderreceipts116Plannedorderreleases116NetRequirementsPlanWeekLot-SizingRules:EOQEOQ-ordertheEOQLeadtime=1week12345678WheelsGrossrequirements150120150120Scheduledreceipts200Projectedon-hand|308080807676Plannedorderreceipts116Plannedorderreleases116NetRequirementsPlanWeekLot-SizingRules:EOQEOQ-ordertheEOQ80+116-120=76Leadtime=1week12345678WheelsGrossrequirements150120150120Scheduledreceipts200Projectedon-hand|308080807676Plannedorderreceipts116116Plannedorderreleases116116NetRequirementsPlanWeekLot-SizingRules:EOQEOQ-ordertheEOQLeadtime=1week12345678WheelsGrossrequirements150120150120Scheduledreceipts200Projectedon-hand|30808080767642Plannedorderreceipts116116116Plannedorderreleases116116116NetRequirementsPlanWeekLot-SizingRules:EOQEOQ-ordertheEOQLeadtime=1week12345678WheelsGrossrequirements150120150120Scheduledreceipts200Projectedon-hand|308080807676423838Plannedorderreceipts116116116Plannedorderreleases116116116NetRequirementsPlanWeekLot-SizingRules:EOQEOQ-ordertheEOQ物料需求計算(逐級展開)XA(1)C(2)O(1)C201010A1010O提前期=2提前期=1提前期=1批量=40批量=1批量=1X提前期=1批量=1時段計劃投入量計劃產(chǎn)出量123456789101112現(xiàn)有量=0時段計劃投入量計劃產(chǎn)出