To reduce high manufacturing overhead, companies should look beyond their direct labor and materials costs to the costs of transactions. These transactions are the exchanges of materials and/or information that are necessary to move production along. They do not directly result in physical products but instead in a kind of "augmented product" that the customer buys--on-time delivery, quality, variety, and design improvement. Three approaches to managing the costs of these transactions are to analyze which transactions are necessary and improve the methods of carrying them out, to increase the stability of operations, and to rely on automation and systems integration.
Materials requirements planning (MRP) is a computer-based system of coordinating materials supply, demand, inventory, and production scheduling for manufacturing operations. In addition to the master production schedule 'drive file,' files are created for bill of materials, inventory status and the materials requirements planning package. The value of MRP depends on an operation's size and the efficiency of its current materials system. Its adaptability, however, promises new applications in other areas.
Requires an analysis of both the process flows and the production control system used in a cranberry receiving plant. A rewritten version of an earlier case.