Browsing by Author "Tiainen, Teemu"
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- Hankinnan materiaalivirtojen ohjaaminen kappaletavaratuotannossa
Helsinki University of Technology | Master's thesis(2007) Tiainen, TeemuManufacturing companies often practice material purchasing based on material requirements planning (MRP). Requirements are identified according to production plans, and difficulties are likely to occur if the actual production does not follow the production plans. In those situations, materials can be either not available or excess inventories are built up. In the company, to whom the master's thesis was done, this problem was recognized and a solution was needed. In order to solve the problem, a research project was decided to be conducted concerning the possible ways to improve purchasing control. The business goal of the project was to eliminate material shortages with lowest possible inventory levels. In addition, another goal was set to examine how mass customization manufacturing, which is part of the company's future prospects, can be supported with material control. Based on literature study and analysis of the company's present state, a method for controlling the purchased materials was developed. Method follows the ideas of pull-based material control, where the calls for material replacements are done based on consumption information. In the method, consumption of materials is communicated to the suppliers real-time, and replenishments are delivered based on this information. The most significant advantage of pull-based control compared to MRP is its independence from the forecasts. Material replacements are always called based on actual consumption, and changes in production plans do not affect material availability. Pull-based material control requires accurate monitoring of material consumption. In order to arrange consumption monitoring, radio frequency identification system is recommended to be acquired. Consumption event is then translated into impulse, which is automatically sent to supplier's order handling system. Pull-based control for purchased materials is feasible to be used with standardized material items, and the benefits of the system are the highest with high-volume items. With pull-based control, inventory levels can be decreased and material shortages are reduced. Since pull-based material control is an essential part of mass customization manufacturing, the method that was developed during this project can be used to serve the company in the future as well.