Teknik Lot for Lot pada Lot Sizing (Penentuan Ukuran Lot) dalam Sistem MRP

Summary

This video explains the 'Lot-for-Lot' technique in Material Requirements Planning (MRP) within ERP systems. It covers the process of calculating material orders based on production requirements for each period. The script provides a week-by-week breakdown of stock levels, demand forecasting, and necessary orders, illustrating how to manage inventory effectively. The speaker also walks through the cost calculations, including ordering, holding, and setup costs, arriving at a total of $737,000. The session concludes with a brief mention of other MRP techniques to explore in future lessons.

Takeaways

• 😀 The topic of the lecture is about lossing measurement techniques in the Material Requirement Planning (MRP) system within ERP.
• 😀 There are three main techniques for measuring one lot or calculating the production size in MRP systems, one of which is the 'Lot-for-Lot' method.
• 😀 In the 'Lot-for-Lot' technique, the quantity to be produced is calculated based on the weekly scheduled needs, and production happens weekly.
• 😀 The process begins by knowing the demand for production, which is scheduled to be produced weekly (e.g., 10 weeks with a certain number of units).
• 😀 Stock from the previous period is taken into account, which will be used to meet the current week's demand, with an initial stock of 35 units.
• 😀 In the case of insufficient stock, material orders need to be placed. For example, if 30 units are needed in week 2, 30 units will be ordered in week 1 to meet the demand.
• 😀 Lead time for orders is considered, which in this case is 1 week, so materials ordered in one week will arrive the following week.
• 😀 For weeks where the required material quantity exceeds the available stock, more orders are placed. For instance, 40 units need to be ordered in week 3.
• 😀 By week 4, there is an excess of material, which leads to a situation where orders may be reduced or adjusted to maintain optimal stock levels.
• 😀 After applying the 'Lot-for-Lot' technique, total costs, including storage and setup costs, are calculated. The cost of ordering is also included in the total cost assessment.

Q & A

What is the Lot-for-Lot technique in Material Requirement Planning (MRP)?

The Lot-for-Lot technique is a method used to determine the exact amount of materials needed for production in each period, without building up excess inventory. It involves ordering materials based on the production schedule for each week, ensuring that the exact quantity is available when required.

How does the speaker calculate material requirements using the Lot-for-Lot method?

The speaker calculates material requirements by assessing the production schedule for each week. If, for example, 35 units are needed in week 1, and no prior stock is available, a material order for 35 units will be placed. This approach ensures no excess stock is carried forward from previous periods.

What role does stock availability play in this method?

Stock availability directly influences the ordering process. If there is no stock from previous periods, new orders must be placed. The system calculates exactly what is needed based on the production schedule, adjusting the required quantity accordingly.

How is lead time factored into the Lot-for-Lot technique?

Lead time is crucial in the Lot-for-Lot method. For example, if the lead time is one week, an order must be placed by the end of week 1 to receive the materials in time for week 2’s production. This ensures that the required materials are available exactly when needed.

What costs are associated with the Lot-for-Lot method?

The costs include storage and setup fees for each lot of material ordered. However, storage costs are not included if they are part of previous period’s overheads. The key cost here is the cost per order, which is multiplied by the number of orders placed throughout the production schedule.

How are inventory levels managed using the Lot-for-Lot technique?

Inventory levels are managed by ensuring that materials are ordered only for the exact amount needed in each period. If there is no stock available, orders are placed to match the production demand for that week, thereby avoiding excess inventory and reducing storage costs.

Why is the Lot-for-Lot technique useful in Material Requirement Planning?

The Lot-for-Lot technique is useful because it minimizes inventory costs and ensures that only the necessary materials are ordered. This method optimizes the supply chain by aligning material orders precisely with production needs, which helps in reducing wastage and unnecessary stock.

What is the significance of the production schedule in the Lot-for-Lot technique?

The production schedule is critical as it drives the material ordering process. The exact quantity of materials required each week is determined based on the production schedule, and material orders are placed to fulfill those exact needs. This approach ensures efficient material handling and production planning.

What happens if stock runs out during the production period?

If stock runs out, the system ensures that an order is placed for the required quantity of materials to meet production needs. In the script, the example shows that if the stock is exhausted, a new order will be placed for the required amount based on the production schedule, accounting for lead time.

How does the speaker calculate the total cost of production using the Lot-for-Lot method?

The total cost of production is calculated by multiplying the number of orders placed by the cost per order. The speaker mentioned that each order incurs a setup and storage cost, which is added to the overall production cost to determine the total cost for the period.