OVERVIEW

Up to this point, information collected has identified the processes, their associated demand, and the effective minutes available to do work. With this information, Takt time can be calculated. Takt time defines the rate at which the line must run to achieve the desired daily output. The sequence of events (SOEs) have been developed. These SOEs document the individual tasks in sequential order, the time required to complete the identified tasks, and the quality criteria at the individual task level. The next consideration is how many resources will be required to achieve the capacity of the line.

What is a resource? Resources can be any of the following:

• People

• Workstations

• Machines

• Inventory

The Lean manufacturing methodology proceeds with the assignment of resources differently than does the MRP order launch methodology. MRP assumes infinite capacity is available in the manufacturing processes or in the "departments." Orders are periodically issued to meet demand based on the explosion of demand by the master schedule. Once MRP performs the time-phasing routines, the "load" in each of these departments is determined. Priority of the released orders is assigned according to the due dates and the available capacity in the department. As long as the order load does not exceed the stated capacity during the assigned time period, the plan is good.

To establish the correct start and due date for these orders, which in turn establishes the load in each department based on the net requirements, an indented bill of material (BOM) is required.