Order Promising and the Master Production Schedule*

Previous research on material requirements planning (MRP) systems has rarely considered the impact of the master production scheduling method used to promise customer orders and to allocate production capacity. Based on a simulation study of an MRP environment, we show that the correct selection of a master production schedule (MPS) method depends on the variance of end-item demand. In addition, we find evidence that the effectiveness of a particular MPS method can be enhanced by holding buffer inventory at the same level in the product structure as in the MPS.     

A Model for Master Production Scheduling in Uncertain Environments

In uncertain environments, the master production schedule (MPS) is usually developed using a rolling schedule. When utilizing a rolling schedule, the MPS is replanned periodically and a portion of the MPS is frozen in each planning cycle. The cost performance of a rolling schedule depends on three decisions: the choice of the replanning interval (R), which determines how often the MPS should be replanned; the choice of the frozen interval (F), which determines how many periods the MPS should be frozen in each planning cycle; and the choice of the forecast window (T), which is the time interval over which the MPS is determined using newly updated forecast data. This paper uses an analytical approach to study the master production scheduling process in uncertain environments without capacity constraints, where the MPS is developed using a rolling schedule. It focuses on the choices of F, R, and T for the MPS. A conceptual framework that includes all important MPS time intervals is described. The effects of F, R, and T on system costs, which include the forecast error, MPS change, setup, and inventory holding costs, are also explored. Finally, a mathematical model for the MPS is presented. This model approximates the average system cost as a function of F, R, T, and several environmental factors. It can be used to estimate the associated system costs for any combination of F, R, and T.     

An Integrative,Experiential Approach to Production Management Education

This paper addresses the important relationship between production and operations management (POM) and information technology. An approach to POM education is presented in which information technology is used to create an experiential learning environment that integrates the topics taught in POM courses. Results of an implementation of the proposed approach are presented and implications are discussed for POM education.     

The Performance of MRP Purchase Lot-Size Procedures Under Actual Multiple Purchase Discount Conditions

Several heuristic procedures for purchase lot sizing in material requirements planning (MRP) systems were tested with actual data from manufacturing companies. Information provided by the companies for each purchased item included the estimated requirements and costs, the price discount structure from the vendor, and the actual company ordering policy. Simulation tests for each purchased item involved comparisons of several purchase lot-size procedures from the research literature along with the actual procedure used by the company providing the data. Results indicate that one of the heuristic lot-size procedures from the literature consistently outperformed the company policies as well as all other models tested. Another noteworthy result is that, in some cases, the actual company order policy was more cost-effective than some of the models from the research literature.     

Freezing the Master Production Schedule: Implications for Fill Rate*

Previous research examining alternative ways of dealing with schedule instability has shown that freezing a portion of the master production schedule (MPS) is a cost effective way to reduce instability. While it is often argued that MPS freezing limits the firm's ability to react to changing customer needs, the impact of freezing on customer service is not well understood. We examined the impact of freezing a specified portion of the MPS on the average fill rate under a wide variety of conditions using controlled simulation experiments. The results show that freezing can be implemented without causing a severe reduction in customer service.     

A Comparative Analysis of Master Production Scheduling Techniques for Assemble-To-Order Products

This paper studies the master production scheduling (MPS) activity of manufacturing firms that produce assemble-to-order (ATO) products. It describes four techniques for master scheduling ATO products: end-product bills, modular bills, super bills, and percentage bills. These procedures are compared in terms of the percentage of customer orders delivered late, the mean tardiness of customer order deliveries, and the total cost of inventory using simulation analysis. The results indicate that the performance of an MPS technique is affected by the level of uncertainty of the end products' demands and the degree of component commonality in the product structure. In particular, modular bills produce the highest customer service level and super bills produce the lowest total inventory cost under most operating conditions. The conclusions also suggest that the choice of a particular MPS technique is often a compromise between the benefits of improved MPS performance and the costs of implementing and executing the MPS system.     

Vendor Performance and Alternative Manufacturing Environments*

Today, many American firms are demanding a high level of performance from their major suppliers while at the same time reducing the number of them. Vendor performance is an important aspect of maintaining low production costs and high product quality. In this study, we examine the effects of poor vendor quality and vendor lead time uncertainty in a variety of manufacturing environments using a comprehensive simulation model. The results indicate that the effect of poor vendor performance on various manufacturing firms depends on the number of stocking points and the degree of component commonality. Moreover, disruption of the manufacturing system caused by poor vendor performance can be manifested in higher levels of inventory and order backlogs. We introduce the concept of supplyside uncertainty, as it relates to component-part commonality, to demonstrate that in certain environments commonality reduces order backlogs but increases total inventories and creates an environment that is very sensitive to vendor quality problems. Finally, several conjectures are posited for future research.     

Notes and Communications REPLANNING FREQUENCIES FOR MASTER PRODUCTION SCHEDULES

Updating production plans typically is achieved by rolling the planning horizon forward one period at a time, each time including the latest information in order to determine the best course of action to pursue in the present period. Theoretical planning-horizon studies have identified the conditions by which the production decisions in the current and some specified number of future periods remain optimal given some set of future demands. Motivated by these findings, this study addresses the replanning frequency in a hierarchical production planning problem where no planning-horizon theorems are available. In this problem the aggregate production plan and the master production schedule are linked by a rolling-horizon practice. Empirical experimentation indicates that under certain cost and demand conditions the master production schedule need not be updated every period. If a schedule does not need to be updated for several periods, the schedule for these periods can be frozen to provide stability for planning components at lower levels in the bill of material of the products. The results of this study thus provide some reference for the determination of the frozen portion of the master production schedule.     

Efficient Heuristics for MRP Lot Sizing with Variable Production/Purchasing Costs*

Two heuristics based on branch and bound (B&B) are developed to solve closed-loop material requirements planning (MRP) lot-sizing problems that have general product structures and variable costs. A “look ahead method'’(LAM) heuristic allows for variable production/purchasing costs and uses a single-level B&B procedure to rapidly improve lower bound values; thus, LAM efficiently uses computer-storage capacity and allows solution of larger problems. The “total average modification'’(TAM) heuristic uses B&B, applied level by level, and modified setup and carrying costs to solve the variable production/purchasing costs MRP lot-sizing problem. LAM and TAM are tested on problems and compared to heuristics in the literature. TAM may be used to solve large MRP lot-sizing problems encountered in practice.     

SOME COMMENTS ON “A SYSTEMS PERSPECTIVE ON MATERIALS REQUIREMENTS PLANNING”*

We believe there are some serious deficiencies in the Morecroft article on MRP problems which appeared in a recent issue of this journal. The article, at the most, shows that MRP, inappropriately imposed on an existing production system, can result in undesirable system performance. This does not represent a new or startling conclusion. Four problem areas in the article are discussed, and suggested alternative approaches are offered.     

Location of Inventories in an MRP Environment

Previous research on MRP systems has rarely considered at what level in a modular sub-assembly product structure to hold inventories. Based on a simulation study of an MRP environment, we show that the correct decision concerning where to hold inventory depends on the variance in end-item demand, the amount of inventory investment, and concomitantly, the desired level of customer service. In particular, for small investment in inventories and moderate end-item demand variance, it is equally effective to hold inventories at the subassembly level or the end-item level. But when end-item demand variance is high, subassembly level inventories are better. As inventory investment grows, however, it is best to use a diversified approach of holding both subassembly and end-item inventories, irrespective of end-item demand variance. The robustness of these conclusions is validated by simulating a hypothetical firm that also uses safety time to hedge against uncertainties.     

Resource Flexibility Issues in Multistage Manufacturing

We test the situational impact of two types of resource flexibility, machine flexibility and labor flexibility, in a material requirements planning (MRP)-driven production system. Machine flexibility has not been treated in prior multistage research, only labor flexibility. Machine flexibility is closely related to a plant's positioning strategy. A process-focused plant opts for considerable machine flexibility by choosing general-purpose equipment. Resource flexibility, if effective, can be an attractive alternative to two other types of buffers, inflated inventories and costly capacity cushions. Our simulation results, using factor settings established earlier by a panel of managers, show that resource flexibility is indeed an effective buffer against uncertainties such as end-item demand variability, capacity bottlenecks, equipment failures, and yield losses. Machine flexibility is especially helpful in environments characterized by high uncertainties, tight capacities, and large lot sizes. Worker flexibility has a similar, but less dramatic, impact. Benefits are most striking with customer service, rather than with inventory or labor productivity. Finally, we show that simultaneous introduction of both machine and labor flexibility yields only marginal improvements over either kind of flexibility alone.     

COMMENTS ON “COST INCREASES DUE TO DEMAND UNCERTAINTY IN MRP LOT SIZING”: A VERIFICATION OF ORDERING PROBABILITIES

In a recent article in this journal, De Bodt and Van Wassenhove [1] presented analytic derivations related to lot-sizing behavior under uncertainty. Although their models appear to have been verified in the aggregate by simulation experiments, detailed justifications for several of the derivations are missing. The present paper looks at De Bodt and Van Wassenhove's analysis and provides verifications of (and corrections to) the ordering probabilities and order cycles used by the authors to estimate the cost effects of forecast errors in the particular operating environment studied. The probabilities simulated in this study also generate additional insight into the “system nervousness” caused by lot-sizing and forecast errors.     

THE PERFORMANCE OF A SIMPLE INCREMENTAL LOT-SIZING RULE IN A MULTILEVEL INVENTORY ENVIRONMENT

A simple incremental cost approach to lot sizing was tested in a multilevel inventory environment. The incremental approach has not previously been tested in a large-scale study involving multiple product-structure levels. Using the Wagner-Whitin (WW) algorithm as a benchmark, the simple incremental rule (IPPA) was compared to three heuristic procedures (LFL, EOQ, and POQ) frequently used in material requirements planning (MRP) lot-sizing research. The incremental rule consistently generated lower total order/setup and carrying costs than the three heuristics across the 3,200 multilevel test situations examined. In many of the test situations, the incremental rule also outperformed the WW benchmark.     

MEASURING MASTER PRODUCTION SCHEDULE STABILITY UNDER ROLLING PLANNING HORIZONS

Maintaining a stable master production schedule (MPS) is difficult for many firms, especially when material requirements planning is used to manage production operations. This paper is concerned with the problem of measuring MPS stability, and the impact on stability of three important decision variables in managing the MPS within a rolling-horizon framework in a make-to-stock environment: the method used to freeze the MPS, the proportion of the MPS frozen, and the length of the planning horizon for the MPS. Simulation experiments conducted to determine the impact of these decision variables, as well as other important product demand and cost characteristics, on MPS stability are reported. The results indicate MPS stability can be influenced by managerial action directed toward management of the MPS as well as changes in important product cost and requirements characteristics.     

A NOTE ON DYNAMIC LOT SIZING IN A ROLLING-HORIZON ENVIRONMENT

This paper presents a modification of the dynamic lot-size algorithm of Wagner and Whitin for rolling horizon environments. The computational results show that the modified algorithm gives better cost performance than the Wagner-Whitin algorithm and the Silver-Meal heuristic. The improvements over the Wagner-Whitin algorithm require very few additional computations.     

COST INCREASES DUE TO DEMAND UNCERTAINTY IN MRP LOT SIZING

This paper analyzes the cost increases due to demand uncertainty in single-level MRP lot sizing on a rolling horizon. It is shown that forecast errors have a tremendous effect on the cost effectiveness of lot-sizing techniques even when these forecast errors are small. Moreover, the cost differences between different techniques become rather insignificant in the presence of forecast errors. Since most industrial firms face demand uncertainty to some extent, our findings may have important managerial implications. Various simulation experiments give insight into both the nature and the magnitude of the cost increases for different heuristics. Analytical results are developed for the constant-demand case with random noise and forecasting by exponential smoothing. It is also shown how optimal buffers can be obtained by use of a simple model. Although the analysis in this paper is restricted to simplified cases, the results merit further consideration and study. This paper is one of the first to inject forecast errors into MRP lot-sizing research. As such it attempts to deal with one of the major objections against the practical relevance of previous research in this area.     

Open Order Rescheduling in Job Shops with Demand Uncertainty: A Simulation Study

This paper addresses the problem of open order rescheduling in a job shop. Results are reported of experiments conducted in a simulation model of an 8-machine job shop. Four different order updating policies are examined. The due-date process is modeled to include several realistic features about the pattern of due-date variability. These features are parameterized and tested at several levels. Tardiness results indicate that open order rescheduling is beneficial only when allowances are loosely set. The results indicate that inventory performance is improved by order rescheduling, particularly in cases when due dates are revised to earlier times than originally forecast.     

An Efficient Zero-One Formulation of the Multilevel Lot-Sizing Problem

This paper presents a zero-one linear formulation of the multilevel lot-sizing problem for materials requirement planning systems without capacity constraints. The model is an efficient statement of the problem and has a structure that is particularly convenient for research work. In addition, it is demonstrated that the relaxed linear programming solution to this formulation will always be integer. The results of a rather large computational history are reported along with a variable reduction methodology that allows for the solution of reasonably sized research problems.