Material Requirement Planning at a-Cat Corp

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Brief Summary of the Case-Study This case analyses how Sunita Menon's adoption of an MRP system at A-CAT Corp. (A-CAT) has improved the production-planning process. To make one unit of A-CAT's main product, P0110, requires two P0X units and two P0Y units; in addition, each P0X unit needs two types of subparts: four P1X1 units and three P1X2 units. The case examines the intricacies of procurement, warehousing and processing costs of various material components by critically evaluating different techniques in practice. Using situational scenarios, the case presents lot-sizing techniques - including lot for lot, economic order quantity, least total cost and least unit cost - for balancing costs such as set-up costs, ordering costs and inventory-holding costs. Introduction to MRP Material requirements planning (MRP) is a production planning and inventory control system used to manage manufacturing processes. Most MRP systems are software-based, while it is possible to conduct MRP by hand as well. Objectives of MRP An MRP system is intended to simultaneously meet three objectives: • Ensure materials are available for production and products are available for delivery to customers. • Maintain the lowest possible material and product levels in store • Plan manufacturing activities, delivery schedules and purchasing activities. MRP is a tool to deal with these problems. It provides answers for several questions: • What items are required? • How many are required? • When are they required? The basic function of MRP system includes inventory control, bill of material processing and elementary scheduling. MRP helps organizations to maintain low inventory levels. It is used to plan manufacturing, purchasing and delivering

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