9780131128743

For courses in Materials Management, Production and Inventory Control, and Logistics taught in business and industrial technology departments of community colleges and universities. This is the only text listed in the APICSThe Educational Society for Resource Management CPIM Exam Content Manual as the text reference for the Basics of Supply Chain Management (BSCM) CPIM certification examination. Written in a simple and user-friendly style, it covers all the basics of supply chain management and production and inventory control.

Introduction to Materials Management

1

(18)

Introduction

1

(1)

Operating Environment

2

(3)

The Supply Chain Concept

5

(5)

What Is Materials Management?

10

(4)

Supply Chain Metrics

14

(2)

Summary

16

(1)

Key Terms

16

(1)

Questions

17

(1)

Problems

17

(2)

Production Planning System

19

(29)

Introduction

19

(1)

Manufacturing Planning and Control System

20

(5)

Sales and Operations Planning (SOP)

25

(2)

Manufacturing Resource Planning (MRP II)

27

(1)

Enterprise Resource Planning (ERP)

28

(1)

Making the Production Plan

29

(12)

Summary

41

(1)

Key Terms

41

(1)

Questions

42

(1)

Problems

43

(5)

Master Scheduling

48

(26)

Introduction

48

(1)

Relationship to Production Plan

49

(3)

Developing a Master Production Schedule

52

(6)

Production Planning, Master Scheduling, and Sales

58

(8)

Summary

66

(1)

Key Terms

66

(1)

Questions

66

(1)

Problems

67

(7)

Material Requirements Planning

74

(46)

Introduction

74

(4)

Bills of Material

78

(8)

Material Requirements Planning Process

86

(13)

Using the Material Requirements Plan

99

(5)

Summary

104

(1)

Key Terms

104

(1)

Questions

105

(1)

Problems

106

(14)

Capacity Management

120

(24)

Introduction

120

(1)

Definition of Capacity

120

(2)

Capacity Planning

122

(1)

Capacity Requirements Planning (CRP)

123

(2)

Capacity Available

125

(5)

Capacity Required (Load)

130

(3)

Scheduling Orders

133

(3)

Making the Plan

136

(1)

Summary

137

(1)

Key Terms

138

(1)

Questions

139

(1)

Problems

139

(5)

Production Activity Control

144

(35)

Introduction

144

(4)

Data Requirements

148

(2)

Order Preparation

150

(1)

Scheduling

150

(7)

Load Leveling

157

(1)

Scheduling Bottlenecks

158

(3)

Theory of Constraints and Drum-Buffer-Rope

161

(2)

Implementation

163

(1)

Control

164

(7)

Production Reporting

171

(1)

Summary

171

(1)

Key Terms

172

(1)

Questions

172

(1)

Problems

173

(6)

Purchasing

179

(20)

Introduction

179

(4)

Establishing Specifications

183

(2)

Functional Specification Description

185

(3)

Selecting Suppliers

188

(3)

Price Determination

191

(2)

Impact of Material Requirements Planning on Purchasing

193

(2)

Some Organizational Implications of Supply Chain Management

195

(1)

Key Terms

196

(1)

Questions

197

(1)

Problems

197

(2)

Forecasting

199

(34)

Introduction

199

(1)

Demand Management

200

(1)

Demand Forecasting

201

(1)

Characteristics of Demand

201

(3)

Principles of Forecasting

204

(1)

Collection and Preparation of Data

204

(1)

Forecasting Techniques

205

(2)

Some Important Intrinsic Techniques

207

(4)

Seasonality

211

(5)

Tracking the Forecast

216

(7)

Summary

223

(1)

Key Terms

224

(1)

Questions

224

(1)

Problems

224

(9)

Inventory Fundamentals

233

(27)

Introduction

233

(1)

Aggregate Inventory Management

234

(1)

Item Inventory Management

234

(1)

Inventory and the Flow of Material

235

(1)

Supply and Demand Patterns

236

(1)

Functions of Inventories

236

(2)

Objectives of Inventory Management

238

(2)

Inventory Costs

240

(4)

Financial Statements and Inventory

244

(5)

ABC Inventory Control

249

(4)

Summary

253

(1)

Key Terms

254

(1)

Questions

254

(1)

Problems

255

(5)

Order Quantities

260

(20)

Introduction

260

(1)

Economic-Order Quantity (EOQ)

261

(6)

Variations of the EOQ Model

267

(1)

Quantity Discounts

268

(1)

Use of EOQ When Costs Are Not Known

269

(2)

Period-Order Quantity (POQ)

271

(2)

Summary

273

(1)

Key Terms

273

(1)

Questions

274

(1)

Problems

274

(6)

Independent Demand Ordering Systems

280

(31)

Introduction

280

(1)

Order Point System

281

(2)

Determining Safety Stock

283

(7)

Determining Service Levels

290

(2)

Different Forecast and Lead-Time Intervals

292

(2)

Determining When the Order Point Is Reached

294

(2)

Periodic Review System

296

(2)

Distribution Inventory

298

(4)

Key Terms

302

(1)

Questions

302

(1)

Problems

303

(8)

Physical Inventory and Warehouse Management

311

(21)

Introduction

311

(1)

Warehousing Management

311

(7)

Physical Control and Security

318

(1)

Inventory Record Accuracy

319

(8)

Key Terms

327

(1)

Questions

327

(1)

Problems

328

(4)

Physical Distribution

332

(31)

Introduction

332

(3)

Physical Distribution System

335

(2)

Interfaces

337

(1)

Transportation

338

(3)

Legal Types of Carriage

341

(1)

Transportation Cost Elements

342

(4)

Warehousing

346

(7)

Packaging

353

(1)

Materials Handling

354

(2)

Multi-Warehouse Systems

356

(3)

Key Terms

359

(1)

Questions

359

(1)

Problems

360

(3)

Products and Processes

363

(34)

Introduction

363

(1)

Need for New Products

363

(2)

Product Development Principles

365

(2)

Product Specification and Design

367

(2)

Process Design

369

(1)

Factors Influencing Process Design

370

(2)

Processing Equipment

372

(1)

Process Systems

373

(2)

Selecting the Process

375

(4)

Continuous Process Improvement (CPI)

379

(12)

Key Terms

391

(1)

Questions

391

(2)

Problems

393

(4)

Just-in-Time Manufacturing

397

(32)

Introduction

397

(1)

Just-in-Time Philosophy

398

(1)

Waste

399

(3)

Just-in-Time Environment

402

(9)

Manufacturing Planning and Control in a JIT Environment

411

(11)

Lean Production

422

(1)

Which to Choose---MRP (ERP), Kanban, or Theory of Constraints?

423

(2)

Summary

425

(1)

Key Terms

426

(1)

Questions

426

(1)

Problems

427

(2)

Total Quality Management

429

(29)

What Is Quality?

429

(2)

Total Quality Management (TQM)

431

(4)

Quality Cost Concepts

435

(1)

Variation as a Way of Life

436

(4)

Process Capability

440

(4)

Process Control

444

(3)

Sample Inspection

447

(2)

ISO 9000

449

(2)

Benchmarking

451

(3)

JIT, TQM, and MRP II

454

(1)

Key Terms

455

(1)

Questions

455

(1)

Problems

456

(2)

Readings

458

(5)

Index

463

What is included with this book?

The New copy of this book will include any supplemental materials advertised. Please check the title of the book to determine if it should include any access cards, study guides, lab manuals, CDs, etc.

The Used, Rental and eBook copies of this book are not guaranteed to include any supplemental materials. Typically, only the book itself is included. This is true even if the title states it includes any access cards, study guides, lab manuals, CDs, etc.

Introduction to Materials Managementis an introductory text written for students in community colleges and universities. It is used in technical programs, such as industrial engineering and manufacturing engineering; in business programs; and by those already in industry, whether or not they are working in materials management. This text has been widely adopted by colleges and universities not only in North America, but also in other parts of the world. APICS--The Educational Society for Resource Management recommends this text as the reference for certification preparation for various CPIM examinations. In addition, the text is used by production and inventory control societies in other countries, including South Africa, Australia, New Zealand, Germany, France, and Brazil, and by consultants in presenting in-house courses to their customers. Introduction to Materials Managementcovers all the basics of supply chain management, manufacturing planning and control systems, purchasing, and physical distribution. The material, examples, questions, and problems lead the student logically through the text. The writing style is simple and user-friendly--both instructors and students who have used the book attest to this. In the fifth edition, we have added content in the following areas: Supply chain metrics coverage in Chapter 1, Introduction to Materials Management. New ERP coverage in Chapter 2, Production Planning System. New "Vendor-managed inventory" and "Organizational implications of supply chain management" sections in Chapter 7, Purchasing. Production lead time/demand lead time ratio in Chapter 8, Forecasting. New "Methods of evaluating inventory" section in Chapter 9, Inventory Fundamentals. Performance metrics, Lean production, and Poke-yoke in Chapter 15, Just-in-Time Manufacturing. New "Other quality control tools" section in Chapter 16, Total Quality Management. Coverage of first in, first out (FIFO); last in, first out (LIFO); average cost; and standard cost added to Chapter 9, Inventory Fundamentals. In addition, we have modified figures in many of the end-of-chapter problems to provide adopters with a new set of problems. Also, the index has been updated to include all key terms. Features carried over from the fourth edition include: Margin icons note key concepts. Key terms listed at the end of each chapter with chapter page cross-references. Example problems within the chapters. Chapter summaries. Questions and problems at the end of each chapter. Chapter references to case studies inIntroduction to Materials Management Casebook. THE CASEBOOK For the fifth edition, we developed theIntroduction to Materials Management Casebook,authored by Arnold, Chapman, and Lloyd M. Clive. The casebook takes the student beyond the textbook problems by presenting a situation followed by related analysis questions. Most text chapters have cases associated with them, as noted in the table that follows the Table of Contents, and some cases bridge several chapters. Cases vary in level of difficulty, with the more challenging cases requiring students to think about the management issues involved in their decisions on the job. Reviewers noted that the casebook has added overall rigor to this text. APPROACH AND ORGANIZATION Materials management means different things to different people. In this textbook, materials management includes all activities in the flow of materials from the supplier to the consumer. Such activities include physical supply, operations planning and control, and physical distribution. Other terms sometimes used arebusiness logisticsandsupply chain management.Often, the emphasis in business logistics is on transportation and distribution systems with little concern for what occu

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Introduction to Materials Management

Introduction to Materials Management

0131128744

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