Description
This is a presentation describes the resource planning at cement manufacturing company limited.
RESOURCE PLANNING
Cement Manufacturing Company Limited
What is Resource Planning?
A systematic planning and control methodology for production and inventory
A procedure for planning and controlling the raw materials and WIP inventories
It answers three questions
What is needed?
How much is needed?
When is it needed?
Largest cement manufacturer in North East India Located at Meghalaya with 60 acres of plant and 450 hectares of limestone mines Brand name of “Star Cement”
Customers comprise of • • • • Larsen & Tourbo, National Hydro Power Corporation, Public Works Department, Indian Railways and Ministry of Defense.
The Cement Manufacturing Process
V. Packing and dispatch IV. Storage
III. Burning
II. Raw Grinding
2. Transporting
I. Quarry
Components of MRP
MRP inputs
Bills of Materials Inventory Records Master Production Schedule
Bills of Materials
It is a list of the raw materials, sub-assemblies, intermediate assemblies, sub-components, components, parts and the quantities of each needed to manufacture the final product. It provides with a product structure tree
Ordinary Portland Cement (OPC 53 and 43-Grade)
Portland Pozzolana Cement
Products manufactured under Star Cement
Product Structure Tree for OPC
OPC (1 tonn)
Clinker (0.95 tonn)
Secondary additives -Gypsum (0.05 tonn)
Limestone (1.35 tonn)
Shale (0.18 tonn)
Iron and mill scale (0.02 tonn)
Coal (2.26 tonn)
Product Structure Tree for PPC
PPC (1 tonn)
Clinker (0.60 tonn)
Fly Ash (0.35)
Secondary Additives Gypsum (0.05)
Limestone (1.35 tonn)
Shale (0.18 tonn)
Iron and mill scale (0.02 tonn)
Coal (2.26 tonn)
The production ratio for PPC:OPC is 4:1
The production process till clinkerization is same in both cases
Limestone requirement is constant
80% limestone PPC 20 % limestone OPC
Amount of clinker formed is different in both the cases
Inventory Records File
It keeps a record of the inventory held by an organization. It includes a description of the part, the quantity held, and the location of all the holdings.
Fly ash consumption % @ Coal consumption % @ Raw Meal consumption Coal UHV Sp. Heat Consumption Fly ash Stock Closing Stock OPC-43 Closing Stock OPC-53 Closing Stock PPC Closing Stock Raw Coal Closing Stock Mill Scale
35.00 15.37 2850.00 5580.41 857.71 4398.85 0.00 262.90 580.10 46536.05 940.45
Stock Position Closing
Lime stone Raw Meal SILO-1(PPC) SILO-2(opc43) SILO-3(53 ) Total Cem.
3255.000 4874.500 580.100 0.000 262.900 843.000
Master Production Schedule
A master production schedule (MPS) is a plan for production, staffing, inventory etc.
MPS provided as an input to the ERP by the company
Product PPC Day Required Order Placement OPC Required Order Placement Clinker Required Order Placement Limestone Required Order Placement 3240 430 430 50 50 120 120 1100 1100 5424 5424 2400 3240 1 2 3 4 5 3200 3200 500 500 2400
Raw Materials Limestone Clinker Shale
Lead Time 1 day 1 day 1 day
Iron and Mill Scale
Gypsum Fly Ash Coal
3 day
3 day 2 days 2 days
Shale
Required Order Placement
Iron and Mill Scale
Required Order Placement
Gypsum
Required Order Placement
Fly Ash
Required Order Placement
Coal
Required Order Placement
MRP Outputs
MRP Sheet
MRP Sheet
Item: Limestone Lot Size: Gross Requirements Scheduled Receipts Projected on Hand Net Requirements Planned Order Receipts Planned Order Releases 3240 3240 3240 Low-Level Code: Lead Time: 1 day 3240 1 2 3 4 5
Item: Gypsum Lot Size: Gross Requirements Scheduled Receipts Projected on Hand Net Requirements
Low-Level Code: Lead Time: 3 days
1
2
3
4
5
120
120 120 120
Planned Order Receipts Planned Order Releases
Enterprise resource planning
The ERP integrated all the 3 locations through WAN using VSAT’s
Star Cement decided to deploy Microsoft Windows Server 2003 as the network foundation, which is based on the implementation of Active Directory® directory service.
Matrix Infosystems was used to:
• Prevent integration issues with Windows • work with a local company that could provide a world class solution with skills available in the cities and locations where Star Cement was present
Prevent integration issues with Windows
work with a local company that could provide a world class solution with skills available in the cities and locations where Star Cement was present
Improved security
Reduced total cost of ownership
Ease of administration Matrix Infosystems Easy to learn and use
Distinctive Features of Matrix Infosystems
doc_160599705.pptx
This is a presentation describes the resource planning at cement manufacturing company limited.
RESOURCE PLANNING
Cement Manufacturing Company Limited
What is Resource Planning?
A systematic planning and control methodology for production and inventory
A procedure for planning and controlling the raw materials and WIP inventories
It answers three questions
What is needed?
How much is needed?
When is it needed?
Largest cement manufacturer in North East India Located at Meghalaya with 60 acres of plant and 450 hectares of limestone mines Brand name of “Star Cement”
Customers comprise of • • • • Larsen & Tourbo, National Hydro Power Corporation, Public Works Department, Indian Railways and Ministry of Defense.
The Cement Manufacturing Process
V. Packing and dispatch IV. Storage
III. Burning
II. Raw Grinding
2. Transporting
I. Quarry
Components of MRP
MRP inputs
Bills of Materials Inventory Records Master Production Schedule
Bills of Materials
It is a list of the raw materials, sub-assemblies, intermediate assemblies, sub-components, components, parts and the quantities of each needed to manufacture the final product. It provides with a product structure tree
Ordinary Portland Cement (OPC 53 and 43-Grade)
Portland Pozzolana Cement
Products manufactured under Star Cement
Product Structure Tree for OPC
OPC (1 tonn)
Clinker (0.95 tonn)
Secondary additives -Gypsum (0.05 tonn)
Limestone (1.35 tonn)
Shale (0.18 tonn)
Iron and mill scale (0.02 tonn)
Coal (2.26 tonn)
Product Structure Tree for PPC
PPC (1 tonn)
Clinker (0.60 tonn)
Fly Ash (0.35)
Secondary Additives Gypsum (0.05)
Limestone (1.35 tonn)
Shale (0.18 tonn)
Iron and mill scale (0.02 tonn)
Coal (2.26 tonn)
The production ratio for PPC:OPC is 4:1
The production process till clinkerization is same in both cases
Limestone requirement is constant
80% limestone PPC 20 % limestone OPC
Amount of clinker formed is different in both the cases
Inventory Records File
It keeps a record of the inventory held by an organization. It includes a description of the part, the quantity held, and the location of all the holdings.
Fly ash consumption % @ Coal consumption % @ Raw Meal consumption Coal UHV Sp. Heat Consumption Fly ash Stock Closing Stock OPC-43 Closing Stock OPC-53 Closing Stock PPC Closing Stock Raw Coal Closing Stock Mill Scale
35.00 15.37 2850.00 5580.41 857.71 4398.85 0.00 262.90 580.10 46536.05 940.45
Stock Position Closing
Lime stone Raw Meal SILO-1(PPC) SILO-2(opc43) SILO-3(53 ) Total Cem.
3255.000 4874.500 580.100 0.000 262.900 843.000
Master Production Schedule
A master production schedule (MPS) is a plan for production, staffing, inventory etc.
MPS provided as an input to the ERP by the company
Product PPC Day Required Order Placement OPC Required Order Placement Clinker Required Order Placement Limestone Required Order Placement 3240 430 430 50 50 120 120 1100 1100 5424 5424 2400 3240 1 2 3 4 5 3200 3200 500 500 2400
Raw Materials Limestone Clinker Shale
Lead Time 1 day 1 day 1 day
Iron and Mill Scale
Gypsum Fly Ash Coal
3 day
3 day 2 days 2 days
Shale
Required Order Placement
Iron and Mill Scale
Required Order Placement
Gypsum
Required Order Placement
Fly Ash
Required Order Placement
Coal
Required Order Placement
MRP Outputs
MRP Sheet
MRP Sheet
Item: Limestone Lot Size: Gross Requirements Scheduled Receipts Projected on Hand Net Requirements Planned Order Receipts Planned Order Releases 3240 3240 3240 Low-Level Code: Lead Time: 1 day 3240 1 2 3 4 5
Item: Gypsum Lot Size: Gross Requirements Scheduled Receipts Projected on Hand Net Requirements
Low-Level Code: Lead Time: 3 days
1
2
3
4
5
120
120 120 120
Planned Order Receipts Planned Order Releases
Enterprise resource planning
The ERP integrated all the 3 locations through WAN using VSAT’s
Star Cement decided to deploy Microsoft Windows Server 2003 as the network foundation, which is based on the implementation of Active Directory® directory service.
Matrix Infosystems was used to:
• Prevent integration issues with Windows • work with a local company that could provide a world class solution with skills available in the cities and locations where Star Cement was present
Prevent integration issues with Windows
work with a local company that could provide a world class solution with skills available in the cities and locations where Star Cement was present
Improved security
Reduced total cost of ownership
Ease of administration Matrix Infosystems Easy to learn and use
Distinctive Features of Matrix Infosystems
doc_160599705.pptx