LOG_17: JIT & MRP

Level of Audience: Pillar Leader

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World Class Manufacturing

For Internal Use Only
 Safety / Hygiene & Working Environment

JIT &

1st Revision
Cost Deployment

MRP_P_26012012:
Focused Improvement

Autonomous Activity

Professional Maintenance

Quality Control

Logistics / Customer Service

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Early Product / Equipment Management

For Internal Use Only

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People Development

Environment
Logistics / Customer Service Pillar

2
 Training Objectives
After this training the attendees will:

Understand the differences between JIT & MRP

Understand where JIT & MRP methods are applied

Understand how to apply JIT & MRP methods

JIT & World Class Manufacturing

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JIT and MRP

• The MRP (Material Requirement Planning) systems define the necessary materials and
the moment when an order mut be put in process using previsional data, with the aim
of guaranteeing the abvailabitliy of the products at the moment and in the ways desired
by the customer. MRP systems represent a way to make the palanning and of the
materials for the production.
• In this way of working the control of the progress of production is done only at the end,
by comparision of the plannes vs. the output.

• JIT system , like kanban with suppliers, JIT/JIS deliveries, kanban with machining
processes, etc., the production order is transferred upstream from downstream in a pull
logic. The kanban for example provides in each takt or multiple takts the instruction for
production and displacement of the parts in the plant where they are exactly needed,
giving the possibility of a detailed control of any abnormality in the production or
supplying process.

• The use of both previsional systems and Lean system such as kanban, allow the
management of the downstream production and guarantee the synchronization of the
supply chian customer-supplier from downstream upstream. We can say that MRP and
JIT systems do not exclude one than other.
JIT &
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Comparison between JIT and MRP

Planning
• Production planning of capacity and load

MRP (at plant and process level)

Production • Production planning of the prodcut mix

planning • Planning of standard schedule
Optimization • Planning of increase and dicrease of the
Scheduling workload
• Check of the production progress and
feedback towards production dept.
Kanban
Production • Synchronization of the flows dei flussi
Progress
Control

JIT &
World Class Manufacturing
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Comparison between JIT and MRP

N
A S+1 S+2 S+3 S+4
N+1 N+2 N+3 N+4 N+5 N+6

Months
Programmazione mesi (rolling)
Monthly schedule Rolling plan
N+1 N+2 ----- MRP
A 20 20 30 30
B 15 30 26 25 C
C 28 40 38 45
S+3
L M M G V
(meta mese N-1)
Weeklysettimanale
Programmazione schedulemese N
S+1 S+2 S+3 S+4 Days/ hrs
A 4 5 4 5 Kanban
B 4 6 5 6 B
C 6 7 5 8

JIT &
World Class Manufacturing
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Comparison between JIT and MRP
MRP
MRP

supplier
customer

MRP & JIT

MRP

supplier
customer

JIT &
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Comparison between JIT and MRP

• With referral to the previous slide, in the joined approach

JIT & MRP, the advantages can be:
• flow production
• self control and levelling of the production
• control of the stock
• reduction of the stock and the WIP
• less unesful communication between departments.

JIT &
World Class Manufacturing
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Comparison between JIT and MRP
JIT MRP
Pulls the production Pushs the production
Schedules only the last phase of the process, from
Schedules every department of the entire process.
this the orders go back upstream.
It’s quite easy to manage It’s a complex and integrated system
Enphasys is on the physical processes Enphasys is on the IT processes
Ideal in repetitive productions, well balanced and Ideal in production with a very high variety of
with relatively stable programs. finished goods and a very instable mix.
MRP+JIT: JIT tools (Kanban, FIFO, Heijunka…) are used in the single unit of time (a multiple of
the takt), previously schedukled by the MRP.
Time unit: daily or multiple of takts Time unit: weekly and beyond
Moves material and informations Moves only informations
It’s useful for the daily control of the production and It’s useful for random orders and for the weekly
for the supplier of parts with a constant usage. and monthly control of the production.
MRP+ JIT: MRP can provide a control about the constancy of the requiremetns of the items
required through JIT systems.

JIT &
World Class Manufacturing
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Bibliographic

• Kanban Made Simple

• J.M.Gross, K.R. Mcinnis - Amacom
• Making Material Flow
• P.Harris – Lean ent. institute
• ERP in logistics
• G.Levy – Franco Angeli
• Spirit Toyota
• T.Ohno – Einaudi
• The Management of Industrial Production
• A.Brandolese - Hoepli
• Master Scheduling
• J.F.Proud – Wiley

JIT &
World Class Manufacturing
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