Use this material requirements planning record to explain how kanbans and MRP can be used together
This plant operates on a 40-hour week, and uses a 10% safety factor on a container size of 20 units with a half-day turnaround time on a container. What features of each system should be used and for what purposes?
Week 1 2 3
Gross Requirement 900 1000 1100
Scheduled Receipts 0 0 0
Projected Ending Inventory 0 0 0
Net Requirements 900 1000 1100
Planned Receipts 900 1000 1100
Planned Orders 900 1000 1100
What will be an ideal response?
Answer: Companies that use both MRP and kanbans use the planning features of MRP and the control features of kanbans. This plant is adhering to the lean philosophy by making exactly what it needs each week with no anticipated ending inventory. As net requirements increase from week to week, the plant manager will have to increase the number of kanbans in the system according to the following calculations:
y =
y1 = = 4.95 → 5 containers
y2 = = 5.5 → 6 containers
y3 = = 6.05 → 7 containers
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