Malzeme İhtiyaç Planlaması ve Üretim Kaynakları Planlamasının KOBİ’ler Üzerindeki Etkilerinin Araştırılması

Yıl 2009, Sayı: 22, 33 - 42, 01.08.2009

Enver Aydoğan Ömer Asal

Öz

Malzeme İhtiyaç Planlama-MİP Material Requirement Planning - MRP sistemi, stok yatırımlarınıminimize etmek, üretimi ve etkinliği arttırmak ve alıcıya yapılan hizmeti geliştirmek amacıyla kullanılan bir yönetim çizelgeleme ve kontrol tekniğidir. Üretim KaynaklarıPlanlaması–ÜKP, Manufacturing Resource Planning – MRP II uzun ve orta dönemde üretim faaliyetlerinin planlamasıve kontrolü için kullanılan bir bilişim sistemidir. Bu çalışmada; Malzeme İhtiyaç Planlamasıve Üretim KaynaklarıPlanlamasının üretim planlama ve kontrol faaliyetleri üzerindeki etkileri incelenmiştir. Yapılan çalışmada, imalat sektöründe faaliyet gösteren işletmelerin teknolojik yapısınıortaya koymak, rekabet güçlerini tespit etmek ve işletmeler üzerindeki etkilerini belirlemek amaçlanmıştır. Bu amaçla, MİP ve ÜKP’nin uygulandığı, sürekli üretim yapan ve özellikle montaj hatlarına sahip kuruluşlar üzerinde araştırmalar yapılmıştır. Araştırmaya Ankara bölgesinde yer alan farklısanayi bölgelerindeki toplam 93 işletme dahil edilmiştir. Araştırma çerçevesinde, belirlenen bu işletmelere, genel bilgiler, işletme özellikleri, organizasyon yapısı, genel yönetim ve üretim yönetimi ile ilgili toplam 39 sorudan oluşan bir anket uygulanmıştır. Anket çalışmalarından elde edilen sonuçlar, istatistiksel analizler yapan SPSS 15 paket programına aktarılmıştır. SPSS programından elde edilen verilere göre sonuçlar yorumlanmıştır.

Anahtar Kelimeler

Malzeme İhtiyaç Planlaması MİP, Üretim Kaynakları Planlaması ÜKP, KOBİ

Investigation of Impacts of Material Requirement Planning and Manufacturing Resource Planning on SMEs

Öz

Manufacturing Resource Planning MRP is a technics of management schudeling and control which is use for minimize the stock envestismans, to increase production and activity and to develop the service for buyer. Manufacturing Resource Planning MRP II is a informatics system which is use for planning of production activities at the long and middle period. In this study, effects of Material Requirement Planning and Manufacturing Resource Planning on the control activities were examined. In the studies, it is aimed that designation technological structure of the companies, establishing the rivalry force and designation effects on the companies. For this aim, researchs were carried out on the companies that have MRP or MRP II, continual production and especially have a assembly line. Total 93 companies that in the Ankara region and different industry areas have been added in this study. In this study, a questionnaire that existenced 39 questions have been applicated about general informations, company properties, structure of the organization, general management and production management. The results which have been obtained the questionnaire have been transferred SPSS 15 Software. The results have been commented on the outcome of the SPSS programme. While the production activities have been maintained at present industry, date of production and deliveries, cost of production, defining the capasity of production, commodity procurement and acquiring quality are quite important. On account of this, enterprises have to make production planning before commencing the production for achieving analysis of when, by whom, where, in which way, on which products, in which duration and steps the production will be implemented. All the activities of enterprise functions start with what their obectives are and how to attain them. However, this is the beginning of planning process; so production acivities start with production planning initially as production is an enterprise function. Production planning should be defined as planning activity of optimal quantity usage of resources for preset requirements of production. The plans which purvey production requirements to attain enterprise’s objectives are production plannings. All of the production activities that will be implemented in enterprise are realized according to production plans. Production plans lead managers and employees who are dealing with production activities. The importance of production planning has improved rapidly in parallel with the improvement of production systems. The reasons that production planning must take place in a manufacturing enterprise inevitably may be summarized as follows: • Activity density and complexity of production systems • Coordination difficulty of activities in enterprises • Dependence among enterprices and improvement of relationships • Enlargement of consumer mass and diverse array of their demands • Multidivision of procuration and distribution activities • Increase of maintanence, quality and price rivalry • The necessity of minimizing the loss of material, mechanical time and labour with the aim of making the enterprise work economically MRP is a planning method in production basically. The basic aim of MRP is furnishing that the material which are produced or bought may be ready before the next production step. This operation is achieved by predefining and considering each production activity, abrogating spare times and backward calculation from the beginning. In MRP; it is supposed that charts are dependent on spare times. MRP facilitates employers to define fixed spare times. Hence, MRP is used for organizing complex activities occured in production process. MRP is a production planning system and it is not used for production tabulating. The developments in MRP II are capasity requirements planning and shop control system in addition to MRP in terms of production planning. So many MRP II software firms use their special versions for shop control systems. Operating the real timed MRP system in its actual mode with consumer orders instead of estimated main pruduction plans has advantages as follows: • Operating the system is eased up by processing consumer orders one by one and more secured production charts are prepared with the data in decreasing number • It is immediately decided that the delivery dates are acceptable thanks to system’s operating consumer orders in real timed mode. • System gives short delivery date by meeting consumers’ needs immediately. Because of these determined reasons, inclusion of the computer technologies to the enterprise planning activities has become an inevitable consequence. Material Requirement Planning MRP , Manufacturing Resource Planning MRP II , Computer Aided Manufacturing CAM and Enterprise Resources Planning ERP systems have arisen through wide ranges of methods developed by especially advanced countries all around the world. MRP system has been a system that aims at not only ensuring the material at the right time and place but also working effectively of the planning departments within the enterprise and most importantly, meeting the client demands on time and completely by performing an effective stock planning and order system on the enterprise level. Material Requirement Planning accepts the final product oriented demand that is determined by the main manufacturing plan as input and makes the planning acoording to this input. Dependance of the part demands on the product demand and mass production of them form a discontinous demand and make stock control methods that use economical order quantity inadequate. Material Requirement Planning system that is developed for these deficiencies secures the desired material to be ready at the desired time and place. MRP is an interrelated operations group, decision rules and records that tranform the main manufacturing programme to the well-timed, clear requirements for the interdependent stock elements that form this programme and is arranged for meeting of these requirements as planned. MRP II is not a developed version of MRP but a second generation planning approach consisting of MRP as well. In other words, MRP II aims at developing all the activities as manufacturing, purchase, production planning, stock management, accounting and financial affairs within the organization in a harmony in accordance with a plan. It is a production management approach that consolidate closed cycle material requirement planning, production capacity and cash flow for meeting clients’ needs and is integrated with computer programmes fulfilling basic operational functions in accordance with MRP II enterprise policy. The most important characteristic of ERP is its simulator charecteristic in addition to its being a financial and operational system. Thanks to this, the management can decide how different strategies will produce an effect on the whole enterprise. In this study, the effects of material requirement planning and manufacturing resources planning on manufacturing planning and control activities are determined as a result of the overall surveys on Small and Medium Sized Enterprises in Ankara region. For this purpose, a survey sheet comprising of 39 questions and the general data of the enterprises, their characteristics and manufacturing methods is prepared. It is noted that the content of the survey sheets are enclosed by questions that have not privacy extent and an objection to answer in terms of enterprises. The companies that will be applied the survey are determined as a result of getting information from Ankara Chamber of Industry ACI , National Productivity Center NPM , Organisation of The Ankara Dressing Manufacturer OADM and Ostim Organized Industrial Region OOIR about SMEs which use high technology. These survey sheets are applied to 93 different companies that are determined in Ostim, İvedik, Sincan, Siteler and Balgat industrial zones. So as to be a high reliability and accuracy of the answers that are given to the surveys, names of the enterprises are kept private. Analysis and assesments of the tables are made through assuring data coding to the answered survey sheets by SPSS Statistical Package for Social Sciences 15.0 for Windows Programme

Anahtar Kelimeler

Material Requirement Planning MRP, Manufacturing Resource Planning MPRII, Small and Medium

Kaynakça

• Adam, E., Elbert, R., (1992), “Production and Operations Management Concepts, Models and Behavior”, McGraw-Hill Company, New York, 15-89.
• Alfieri, A., Brandimarte, P. ve Orazio, S., (2002), “LP based heuristics for the capacitated lot-sizing problem: the interaction of model formulation and solution algorithm”, International Journal of Production Research,40:441-458.
• Arslancan, A., Ercan, S., (1995), “MRP II’nin Türkiye’deki Firmalarda Uygulanmasının İncelenmesi”, TMMOB Makine Mühendisleri Odası, Endüstri Mühendisliği, 6 (6): 10-15.
• Aydoğan, E., Altuğ, M., (2006), “Küçük Ve Orta Ölçekli İşletmelerin (KOBİ) Rekabet Gücünün Artırılmasında İleri Yönetim Teknolojilerinin Rolü, Makine İmalat Sektörüne Yönelik Bir Uygulama”, Selçuk Üniversitesi, Sosyal Bilimler Enstitüsü Dergisi, 16:87-110.
• Bayar, B., (2004), “Malzeme İhtiyaç Planlaması Ve Stok Yönetiminde Bir İşletme Uygulaması”, Marmara Üniversitesi, Sosyal Bilimler Enstitüsü, Yüksek Lisans Tezi, 1-5.
• Gardner, A.J., (1990), “Common Sense Manufacturing Becoming a Top Value Competitor”, Illinois Homewood, 315.
• Göksu, N., Öz, B., (2008), “Etkin Ücret Yönetiminin İşletmeye Sağlayacağı Yararlar Konusunda İşgören Algılamaları: Bir Alan Çalışması”,Selçuk Üniversitesi, Sosyal Bilimler Enstitüsü Dergisi, 20: 419-436.
• Ho, C.J., (2002), “Evaluating dampening effect of alternative lot-sizing rules to reduce MPR system nervousness”, International Journal of Production Research, 40: 2633-2652.
• Ho, C.J., Law, W.K. ve Rampal, R., (1995), “Uncertainty-dampening methods for reduce MPR system nervousness”, International Journal of Production Research, 33: 483-496.
• İlyasoğlu, E., Barbarosoğlu, G., Tanyaş, M. ve Duruiz L., (1994), “MRP II Üretim Kaynak Planlaması Seminer Notları”, Trio Çözüm Evi, İstanbul, 28.
• İprişoğlu, E., (2006), “Malzeme Gereksinim Planlama Sistemindeki Gelişmelerin Üretim Planlama ve Kontrol Faaliyetlerine Etkisi ve Otomotiv Sektöründe Bir Uygulama”, Dumlupınar Üniversitesi, Sosyal Bilimler Enstitüsü, Yüksek Lisans Tezi, 1-3.
• Murthy, D.N., Ma, L., (1991), “MRP with uncertainty: a review and some extensions”, International Journal of Production Economics, 25:51-64.
• Orlicky, J. A.,. (1975), “Material Requirements Planning”, McGraw-Hill Company, New York, 33-98,188.
• Özgen, D., (2001), “Üretim Planlama ve Kontrol Sisteminin Temel Girdilerine Bağlı Olarak Toplu Üretim Planlamasının Bilgisayar Destekli Optimizasyonu”, Yıldız Teknik Üniversitesi, Fen Bilimleri Enstitüsü, Yüksek Lisans Tezi,1-2.
• Parıltı, N., Aydoğan, E. ve Koçak, A., (2007), “Üretim Yönetimi”, Nobel Yayıncılık, Ankara, 45-98.
• Ram, B., Pour, M.R. ve Yu, X., (2006), “Material Requirements planning with flexible bill-of-material”, International Journal of Production Research,44 (2): 399-415.
• Sarıca, M., (1998), “Seri İmalat Yapan Bir İşletmede Üretim Planlama ve Kontrolü”, İTÜ, Fen Bilimleri Enstitüsü, Yüksek Lisans Tezi,1-5.
• Şenyiğit, E., (2001), “MRP Sistemleri İçin Parti Büyüklüğü Belirlenmesinde Yeni Bir Sezgisel Algoritma ve Analizi”, Çukurova Üniversitesi, Fen Bilimleri Enstitüsü, Yüksek Lisans Tezi,1-2.
• Tanyaş, M, (1988), “Üretim Planlama ve Kontrol II”, Mess Yayını, İstanbul, 117.
• Wight, O. W., (1984), “MRP II”, Wight Pablications, Vermont, 20-45.