Page 348 - Orlicky's Material Requirements Planning

CHAPTER 19 Repetitive Manufacturing Application 327

■ Is the configurator a linear finite model, or does it have dynamic or parametric
capability? Linear finite models are models in which a limited number of choices
can be made. Dynamic or parametric models are models in which measurements
and sizes can be added. Dynamic configurators are used for the fabrication of
windows, doors, and wire cable lengths. The parametric configurator knows that
once a product gets to a certain size or complexity, the configuration may not be
feasible or additional parts may be required to make the configuration feasible.
■ Is the configurator an integral part of the MRP system, or is it a bolt-on that must
be interfaced? An integrated configurator will save countless hours of testing and
integration during implementation and through maintenance.
■ Does the configurator interface or integrate with the front-office tools to provide
seamless pricing and quoting capability?
■ Is the configurator Web-enabled to allow your customers to configure their own
products and determine prices before the order is placed?

SUMMARY

The repetitive operation is the most simple to comprehend, yet it can be the one of the
most difficult to manage. Any unexpected breakdown can cause the entire plant to shut
down. Material is closely synchronized with the production process. Traceability may be
required to the end-item level. If the BOMs have been flattened too much, critical stock-
ing points that would compress lead time may be missed. The goal to eliminate invento-
ry could end up making the entire supply chain too fragile.
The positive side of the repetitive manufacturing approach is that there are no piles
of inventory covering up the problems. Any disruption is quickly identified. A sense of
urgency is common in identification and resolution of the problems encountered in this
type of facility.
Capacity planning is more straightforward because products move down a highly
predictable series of machines or operations either on a transfer line or through a manu-
facturing cell. The routing in a repetitive operation is usually only one step. Lead times
through the process are less than one day. Processes that take more than one day are sup-
ported with tools such as pay-point backflushing.
A number of unique tools are available to the repetitive manufacturer. Kanban,
seiban, configurators, AATP, backflushing, postdeduct, and period costing all can be used
at the appropriate time and place in the process. When these tools are understood, includ-
ing when they are applicable, management of the repetitive enterprise can be simplified.
As William Milliron said, “Use the right tool for the right job, and the job is easy. Use the
wrong tool and you will fight the job every step of the way.”