The optimisation of Daimlerchrysler's SAP-MRP system through systems analysis, design, and simulation

Kirby, Hugh Christopher (2004-12)

Thesis (MSc)--University of Stellenbosch, 2004.

Thesis

ENGLISH ABSTRACT: This report presents the findings of a study that started as an evaluation of the possible implementation of the Options Inventory Management Model (OIMM), developed by van Wijck and Bekker [4], at DaimlerChrysler South Africa (DCSA). The OIMM System was developed as a possible alternative to the SAP-MRP System to ensure a high Customer Service Level, with the lowest possible inventory level, under the 10 Day Option Freeze Environment. DCSA indicated that although the OIMM System may be an ideal solution, in terms of optimising Plant Inventory levels whilst maximising Customer Service Levels, the practical problems associated with the possible implementation of this system would outweigh the associated benefits. This being the case, a directive was given to investigate the SAP-MRP System’s ability to provide a high Customer Service Level under the 10 Day Option Freeze Environment and not to pursue the OIMM implementation option. The objectives of this directive were to evaluate and establish the performance capabilities of the SAPMRP System under the 10 Day Option Freeze Environment as well as develop a system to aid in the customisation of the system. Design of Experiments (DOE) was utilised to plan the evaluation procedure and to ensure that a consistent approach was followed. The DOE generated huge amounts of output data that represented the Usage Category Behaviour Characteristics of the SAP-MRP System. Regression Analysis was utilised to investigate this data. A part-by-part analysis was avoided and the analysis approach followed presented results that could be applied to almost the entire range of parts, excluding bulk parts, at DCSA. The results showed that Coverage Profile alone could be used as a proactive inventory management tool to ensure maximum Customer Service Level. The Regression Analysis revealed that various combinations of Safety Time, Minimum, and Target Coverage resulted in similar or equal Avg. Plant Inventories, Avg. Number of Orders, and Avg. Order Sizes. These findings were used to develop a Decision Support Tool that could be used by DCSA when evaluating the resultant changes caused by the proposed changes in the aforementioned Input Parameters.

AFRIKAANSE OPSOMMING: Hierdie verslag stel die bevindinge van ‘n studie voor wat begin het met die evaluering van die moontlike implementering van die “Options Inventory Management Model” (OIMM), ontwikkel vir DaimlerChrysler (DCSA) deur van Wijck en Bekker [4]. Die OIMM sisteem was ontwikkel as ‘n moontlike alternatief vir die SAP-MRP sisteem om ‘n hoë verbruikersdiensvlak tesame met die laagste moontlike voorraadvlak in ‘n 10-dag opsie-vries omgewing te verseker. DCSA het aangedui dat, hoewel die OIMM sisteem ‘n ideale oplossing bleik te wees in terme van die optimisering van fabriek-voorraadvlakke tesame met die verbruikersdiensvlakke, die praktiese probleme wat met die moontlike implimentering daarvan geassosieer word, die geassosieerde voordele oorskry. Daar is dus opdrag gegee om die SAP-MRP sisteem se vermoë om hoë verbruikersdiensvlakke in die 10-dag opsie-vries omgewing te lewer te ondersoek en sodoende nie die implimentering van die OIMM sisteem te vervolg nie. Die doelwitte van hierdie opdrag was die evaluering en vestiging van die prestasievermoëns van die SAP-MRP sisteem in die 10-dag opsie-vries omgewing, asook om ‘n sisteem te ontwikkel wat as hulpmiddel kan dien in die geïndividualiseerde aanpassingsoptimisering daarvan. ‘n Eksperimentele Ontwerp (DOE) is gebruik in die beplanning van die evalueringsprosedure en ook om te verseker dat ‘n konstante benadering gevolg is. Die DOE het ‘n groot hoeveelheid uitsetdata genereer wat die prestasie van die SAP-MRP sisteem se gedragseienskappe voorgestel het. Regressie-analise is uitgevoer om die data te ondersoek. Onderdeel-by-onderdeel analise is vermy en die analise-benadering wat gevolg is het resultate gelewer wat toegepas kon word vir omtrent die hele reeks onderdele by DCSA, uitsluitende onderdele wat in grootmaat aangekoop word. Die resultate het gewys dat die “Coverage Profile” alleen gebruik kan word as ‘n pro-aktiewe voorraadbestuur hulpmiddel om maksimum verbruikersdiensvlakke te verseker. Die regressie-analise het getoon dat verskeie kombinasies van “Safety Time,” “Minimum” en “Target Coverage” gelei het tot dieselfde hoeveelheid fabrieks-voorraad, bestellingsvrystellings en bestellingsgroottes. Hierdie tendense is toegepas in die ontwikkeling van ‘n ondersteunende besluitnemingshulpmiddel wat deur DCSA gebruik sou kon word in die evaluering van die veranderinge wat onstaan vanweë die voorgestelde verandering in die voorafgenoemde insetparameters.

Please refer to this item in SUNScholar by using the following persistent URL: http://hdl.handle.net/10019.1/16364
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