Kurumsal kaynakların planlaması (ERP) ve çağdaş üretim-yönetim sistemleri ile ilişkileri

Abstract

Rekabet ortamında işletmeler, müşteri ihtiyaç ve beklentilerini etkin şekilde karşılamak için daha verimli sistemler kurmaya yönelmişlerdir. 21. yy da daha da hızlı gelişen bilgi teknolojisini takip etmek ve sürekli değişen, gelişen koşullara uyum sağlamak için işletmeler, çağdaş üretim-yönetim sistemlerine ve aralarındaki entegrasyona önem vermektedir. Bu sistemlerden biri olan ERP sistemi, işletmelere maliyetleri düşürmek, işlemleri hızlandırmak, stok düzeyini azaltmak, işgücü verimliliğini arttırmak, dünyanın çeşitli yerlerindeki tedarik-imalat-dağıtım merkezleri arasında malzeme ve bilgi akışını sağlamak gibi pek çok alanda fayda sağlamaktadır. Yüksek Lisans Tezi kapsamında hazırlanan bu çalışmada bilgisayar destekli üretim planlama ve kontrol tekniklerinden ERP (Kurumsal Kaynakların Planlaması) ve modülleri ile bilgisayar destekli sistemler arasındaki ilişkiler üzerinde durulmuştur. Tedarik, üretim, ulaşım, dağıtım, depolama, malzeme taşıma ve stok yönetimi ile satış ve pazarlama faaliyetlerini kapsayan ve ürün bazında, talep ile kaynak ve stok dengesini sağlayarak, zamanında ve düşük maliyette müşteri ihtiyaçlarının karşılanması için sistemdeki stok faaliyetlerinin nasıl olması gerektiğini belirleyen günümüzde işletmeler için önemli konulardan biri olan Tedarik Zinciri Yönetimi ve ERP ile ilişkisi de ele alınmıştır. Tez çalışmamın Giriş Bölümünden sonraki ikinci bölümde üretim sistemleri, üretim tipleri, üretim yönetimi, üretim planlama ve kontrol faaliyetleri ele alınmıştır. Üçüncü Bölümde Tedarik Zinciri Yönetimi, Lojistik Yönetimi, Tedarik Zinciri Yönetimi için üç önemli etmen ve örnek stratejiler ve ERP sistemi ile ilişkileri ele alınmaktadır. Dördüncü Bölümde Satış ve Üretim Planı, Ana Üretim Planı, Malzeme İhtiyaç Planlaması yaklaşımı, ilkeleri, Kapasite İhtiyaç Planlaması, Üretim Kaynaklan Planlamasına geçiş, ilkeleri, çalışma sistematiği, Dağıtım Kaynaklan Planlaması, Kurumsal Kaynakların Planlaması, çalışma sistematiği ve sistemin kurulması için gerekli koşullar ele alınmıştır. Beşinci Bölüm, uygulama bölümüdür. MTE A.Ş.'nde ERP modülleri, sistemin kurulması sırasında gerçekleştirilen çalışmalar, firma yapısı, sistemin kurulması için gerekli veriler açıklanmıştır. Altıncı Bölümde global rekabet dünyasında sadece üretim planlama faaliyetlerinde gelişime uymak yeterli değildir, kurum içinde ve kurumlar arasında gerçekleşen tüm faaliyetlerin entegrasyonu için ERP dışında diğer bilgisayar destekli sistemlere önem verilmeli ve aralarında etkin veri -malzeme alışverişi sağlanmalıdır. Bu bölümde ERP sistemlerinin diğer çağdaş üretim-yönetim sistemleri ile ilişkileri açıklanmaktadır

Manufacturing in nineties has changed in variety of ways and the goal has become to automate and integrate the activities at all levels of a production system. This would brings strategic advantages such as reduced lead time, faster responses to constantly changing customer demands, flexibility to quickly adapt to dynamic market conditions, instantaneous and accurate communication with customers and suppliers. These advantages have become increasingly vital to manufacturing enterprises in the area of global competition. As the international competition increases, finding global markets and producing globally accepted products gain importance. This globalization process brings the requirement to consider the concepts of strategic design, resources management, financial management and information technology within the same framework. Any future development concerning these should be foreseen in advantage. Today modern companies are competing for what customers want, they trying to offer them their goods by reduced prices while keeping their profit margin. To do this they try to make factories work more efficient. Improved Inventory Management, Production Planning, Material Requirements Planning, Manufacturing Resources Planning and Enterprise Resources Planning reduces investment and operational costs. Shift global competition, lack of effective planning capability and more demanding customers are just a few of many challenges that all firms face. To meet challenges ahead and remain competitive, all firms have to plan their resources effectively and maintain the rapid flow of any integration of information within the firm and also for all overall subsidiaries. Until I960' s all production planning and control activities were managed by classic and manual methods. By development of massive data handling capabilities of computers, in I960' s Material Requirements Planning (MRP) system, was developed as an inventory control system, is the scheduling logic used to manage the flow of material in manufacturing operations. Successful companies realize that it is of primary importance for people using this tool to understand both the technique and their role in its execution. There is a real need for today's businesses, across all functional lines, understand the workings a material requirements planning system. XI Once business professionals understand the simple concepts of MRP technique and how its parts work together, they can effectively apply this tool to make their lives easier tomorrow. Material Requirements Planning is typically used to schedule the flow of materials to and through a manufacturing process. When these plans are accurate and we used them for execution, we are then able to use the materials flow as a base for planning all the company's resources. All company's resources planning is called MRP n or Manufacturing Resources Planning. MRP system gives the answers of : what we will produce and how much? What are the requirements? What is the inventory level data of products or materials? How and when we will supply the material requirements? In 1970's, other production planning and control functions have been added to MRP systems like purchasing, realizing work orders, shop floor control, capacity planning, shipments and this system was called "Closed-loop MRP". In 1979 simulation and financial issues were added to closed-loop MRP systems and Manufacturing Resources Planning (MRP II) was emerged. MRP II is a tool for managing, predicting and controlling a company's resources and their operating investments. The advantages of the MRP II systems are explained as follows : Development in customer satisfaction Reduced work-in-process level. Decrease in inventory stocks. Fast data access. Reduced purchasing costs. Decrease in organizational costs. Reduced lead times. Improvement in cash flow and financial plans. Increased communication ability of the organization. Low shrinkage rate. Increased utilization of resources. Uncovered "hidden" capacity. Better cost identification. More efficient use of warehouse space. Improved inventory accuracy. Improved operating flexibility. Increased efficiency. In other words, MRP II implementation results in reduction in inventory levels, reduction in cost and it assures timely delivery which is very important from the customer satisfaction point of view. The most typical features of manufacturing resources planning can be listed as follows :. It operates on a common database in a top-down system.. The database system is integrated with the islands of automation such as robots, CNC workstations and flexible cells. xu . Financial functions form an umbrella over all other MRP II functions.. The logic of the system is transparent to all users.. The relational integration of all functional groups is provided.. It is a simultor which is intended to answer "what if' questions. The technology which builds up MRP II system has grown increasingly and information systems were fully integrating manufacturing functions with marketing and financial data containing sufficient information to run an entire company. At the end of the nineties global competition increased growly and managed all resources in the different geographic areas of the world was very difficult for the international companies and Enterprise Resources Planning was developed for this. The companies, have distribution centers, plants, suppliers and customers in the different areas of the world, manage all resources effectively with ERP system. In addition Supply Chain Management is very important approach for the postponement, marketing, production, distribution and inventory control activities and providing balance between demand and resource. In addition ERP systems integrate the other computer aided systems and management information systems effectively. The materials and information flow are important for system implementation and the prosesses, software-hardware structure, network infrastructure, the company's organization and management structure etc. must be determined for implementing ERP system. This thesis which is called "Enterprise Resources Planning and the relationship among computer aided systems and information systems "aims to explain Production Planning and Inventory Control Systems, Material Requirements Planning (MRP), Manufacturing Resources Planning (MRP D), Enterprise Resources Planning (ERP) and Supply Chain Management. After explaining these concepts, this study shows the relationship between supply chain management and ERP and steps of the implementation process for ERP systems and integration for the other computer aided systems. In the second section that is named as "Production Management", a general production system, production management and planning concept, production control logic, inventory control systems are described. In the third section supply chain management (SCM) system is analyzed detaily. Three principles of SCM and Logistic Management and sample logistic strategies are explained. In the fourth section Enterprise Resources Planning system is analyzed detaily. First, Sales and Operation Planning and Master Production Planning are explained by basic logic, requirements and assumption, aims. Then MRP system, inputs of it such as bill of materials, inventory data are mentioned detaily. Also the issues of the system, such as releasing planned purchasing and work orders, rescheduling orders explained. MRP uses the ordering policies, lead times and product structure information established in the bill of materials system, the orders and maintained in the material control system and the schedule coming from master production planning, MRP creates the time phased projection of the firm's component part xni requirements in relation to available inventory. MRP determines when manufacturing, purchase and subcontract orders should be adjusted, rescheduled or canceled and makes necessary recommendations to ensure that the firm have the right materials on hand when it needs them. Then manufacturing resources planning, its description, basic principles, Capacity Requirements Planning, Rough Cut Capacity Planning, Distribution Resources Planning, Enterprise Resources Planning and their principles and processes are described. Essential tasks and the steps for implementing ERP system are analyzed. Each company must create its own implementation plan, based on its particular needs and resources. There are three phases for implementing ERP project: pre-implementation, implementation, post-implementation. "Pre-implementation " means that defined clear vision, mission and strategies of the company and characteristics of a system which will be required. Selecting the right people for core project team, especially the project manager and give them the time and resources to do job and preparing project plan. In implementation step, procedures are documented for users and starting traning. Educating everyone in the company and using the business redesign methodology to initiate specific implementation tasks and managing data transaction. In post-implementation step, measuring progress and taking corrective action when necessary and solving problems. Top managers must become more involved and must learn to run their business through ERP. Implementing ERP is most difficult in undisciplined and divided organizations but for them the potential benefits are greatest. In fifth section an application is defined. ERP project in Makina Takım Endüstrisi A. Ş. (MTE A. Ş.). The aim of the study is the steps of ERP project. What must be done for it? The modules of Symix Syteline ERP Program are analyzed and the processes and structure of MTE A. Ş. are defined. In the end section the computer aided systems and information systems are analyzed. The relationships among ERP and the other technologic systems are examined for integration them. The companies must get platforms, interfaces between these systems and design network structure as well. Database and integrated information are essential part of maintaining and improving competitiveness.