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CONTENTS OF MATERIAL MANAGEMENT

1. Introduction to Materials Management.


Operating Environment. The Supply Chain Concept. What Is Materials Management? Supply
Chain Metrics.

2. Production Planning System.


Manufacturing Planning and Control System. Sales and Operations Planning (SOP).
Manufacturing Resource Planning (MRP II). Enterprise Resource Planning (ERP). Making the
Production Plan.

3. Master Scheduling.
Relationship to Production Plan. Developing a Master Production Schedule. Production
Planning, Master Scheduling, and Sales.

4. Material Requirements Planning.


Bills of Material. Material Requirements Planning Process. Using the Material Requirements
Plan.

5. Capacity Management.
Definition of Capacity. Capacity Planning. Capacity Requirements Planning (CRP). Capacity
Available. Capacity Required (Load). Schedule Orders. Making the Plan.

6. Production Activity Control.


Data Requirements. Order Preparation. Scheduling. Load Leveling. Scheduling Bottlenecks.
Theory of Constraints and Drum-Buffer-Rope. Implementation. Control. Production Reporting.

7. Purchasing.
Establishing Specifications. Functional Specification Description. Selecting Suppliers. Price
Determination. Impact of Material Requirements Planning on Purchasing, Vendor-Managed
Inventory, Organizational Implications of Supply Chain Management.

8. Forecasting.
Demand Management. Demand Forecasting. Characteristics of Demand. Principles of
Forecasting. Collection and Preparation of Data. Forecasting Techniques. Some Important
Intrinsic Techniques. Seasonality. Tracking the Forecast.

9. Inventory Fundamentals.
Aggregate Inventory Management. Item Inventory Management. Inventory and the Flow of
Material. Supply and Demand Patterns. Functions of Inventory Management. Inventory Costs.
Financial Statements and Inventory. Methods of Evaluating Inventory, ABC Inventory Control.

10. Order Quantities.


Economic-Order Quantity (EOQ). Variations of the EOQ Model. Quantity Discounts. Use of
EOQ When Costs are Not Known. Period-Order Quantity (POQ).

11. Independent Demand Ordering Systems.


Order Point System. Determining Safety Stock. Determining Service Levels. Different
Forecast and Lead-Time Intervals. Determining When the Order Point is Reached. Periodic
Review System. Distribution Inventory.

12. Physical Inventory and Warehouse Management.


Warehouse Management. Physical Control and Security. Inventory Record Accuracy.

13. Physical Distribution.


Physical Distribution System. Interfaces. Transportation. Legal Types of Carriage.
Transportation Cost Elements. Warehousing. Packaging. Materials Handling. Multi-
Warehouse Systems.

14. Products and Processes.


Need for New Products. Product Development Principles. Product Specification and Design.
Process Design. Factors Specification and Design. Processing Equipment. Process Systems.
Selecting the Process. Continuous Process Improvement (CPI).

15. Just-In-Time Manufacturing.


Just-In-Time Philosophy. Waste. Just-in-Time Environment. Manufacturing Planning and
Control in a JIT Environment. Lean Production. Which to Choose-MPR (ERP), Kanban, or
Theory of Constraints?

16. Total Quality Management.


What Is Quality? Total Quality Management (TQM). Quality Cost Concepts. Variation as a
Way of Life. Process Capability. Process Control. Sample Inspection. ISO 9000.
Benchmarking. JIT, TQM, and MRP II.