Overview

Introduction to Materials Management is 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, operations and supply chain management programs; and by those already in industry, whether or not they are working in materials management.

The text covers all the basics of supply chain management, manufacturing planning and control systems, purchasing, physical distribution, process, quality and its management using Lean, Six Sigma and Total Quality Management. The writing style is simple and lucid and the material, examples, questions and problems lead the student logically through the text.

Features:

  • All has been updated to reflect new techniques and technology
  • New case studies have been added
  • Several special topic boxes have been added relating to non-manufacturing settings such as service industries
  • End-of- problems have been revised and some new ones added throughout the text
  • Expansion of purpose and impact of strategic planning, including environmental and sustainability issues. This allows students to understand the importance of the field at a higher level, including impacts and benefits to society as a whole.
  • Additional information included on demand management.
  • Additional information included on lean production concepts and Theory of Constraints.

Table of Contents

Introduction to Materials Management - Introduction Operating Environment - The Supply Chain Concept - What Is Materials Management? - Supply Chain Metrics - Summary - Key Terms - Questions – Problems

Production Planning System - Introduction - Manufacturing Planning and Control System - Sales and Operations Planning - Manufacturing Resource Planning - Enterprise Resource Planning - Making the Production Plan - Summary - Key Terms - Questions – Problems

Master Scheduling - Introduction - Relationship to Production Plan - Developing a Master Production Schedule - Production Planning, Master Scheduling, and Sales - Summary - Key Terms - Questions - Problems - Case Study: Acme Water Pumps

Material Requirements Planning - Introduction - Bills of Material - Material Requirements Planning Process - Using the Material Requirements Plan - Summary - Key Terms - Questions – Problems

Capacity Management - Introduction - Definition of Capacity - Capacity Planning - Capacity Requirements Planning (CRP) - Capacity Available - Capacity Required (Load) - Scheduling Orders - Making the Plan - Summary - Key Terms - Questions - Problems - Case Study: Wescott Products

Production Activity Control - Introduction - Data Requirements - Order Preparation - Scheduling - Load Levelling - Scheduling Bottlenecks - Contents ix Theory of Constraints and Drum-Buffer-Rope - Implementation - Control - Production Reporting - Summary - Key Terms - Questions – Problems

Purchasing - Introduction - Establishing Specifications - Functional Specification Description - Selecting Suppliers - Price Determination - Impact of Material Requirements Planning on Purchasing - Expansion of Purchasing Into Supply Chain Management - Some Organizational Implications of Supply Chain Management - Key Terms - Questions - Problems - Forecasting - Introduction - 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 - Summary - Key Terms - Questions – Problems

Inventory Fundamentals - Introduction - Aggregate Inventory Management - Item Inventory Management - Inventory and the Flow of Material - Supply and Demand Patterns - Functions of Inventories - Objectives of Inventory Management - Inventory Costs - Financial Statements and Inventory - ABC Inventory Control - Summary - Key Terms - Questions – Problems

Order Quantities - Introduction - Economic-Order Quantity (EOQ) - Variations of the EOQ Model - Quantity Discounts - Order Quantities for Families of Product When Costs Are Not Known - Period-Order Quantity (POQ) - Summary - Key Terms - Questions - Problems - Case Study: Carl’s Computers

Independent Demand Ordering Systems - Introduction - 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 - Key Terms - Questions - Problems

Physical Inventory and Warehouse Management - Introduction - Warehousing Management - Physical Control and Security - Inventory Record Accuracy - Technology Applications - Key Terms - Questions - Problems 

Physical Distribution - Introduction - Physical Distribution System - Interfaces - Transportation - Legal Types of Carriage - Transportation Cost Elements - Warehousing - Packaging - Materials Handling - Multi-Warehouse Systems - Key Terms - Questions - Problems - Case Study: Metal Specialists, Inc.

Products and Processes - Introduction - Need for New Products - Product Development Principles - Product Specification and Design - Process Design - Factors Influencing Process Design - Processing Equipment - Process Systems - Selecting the Process - Continuous Process Improvement (CPI) - Key Terms - Questions – Problems

Just-in-Time Manufacturing and Lean Production - Introduction - Just-in-Time Philosophy - Waste - Just-in-Time Environment - Manufacturing Planning and Control in a JIT Environment - Lean Production - Which to Choose—MRP (ERP), Kanban, or Theory of Constraints? - Summary - Key Terms - Questions - Problems - Case Study: Murphy Manufacturing

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: - Benchmarking - Quality Function Deployment - JIT, TQM, and MRP II - Key Terms - Questions – Problems

Review from Venkadesh Narayanan, Principal Consultant, Fhyzics