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Final MRP Wilkins Case Study

Wilkins, A Zurn Company provides material requirements planning (MRP) for its products including backflow preventers and repair kits. It faces issues with inaccurate inventory levels due to production using incorrect part numbers and unreported component changes. This causes production shutdowns and excess inventory. Recommended solutions include updating MRP to include safety stock and lead times, resolving data discrepancies, using unique part numbers, and integrating production and materials planning for custom orders.

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Ninad Maske
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2K views10 pages

Final MRP Wilkins Case Study

Wilkins, A Zurn Company provides material requirements planning (MRP) for its products including backflow preventers and repair kits. It faces issues with inaccurate inventory levels due to production using incorrect part numbers and unreported component changes. This causes production shutdowns and excess inventory. Recommended solutions include updating MRP to include safety stock and lead times, resolving data discrepancies, using unique part numbers, and integrating production and materials planning for custom orders.

Uploaded by

Ninad Maske
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Wilkins, A Zurn

Company:
Material
Requirements
Planning
PRESENTED BY:
SPANDAN, NINAD, NAYYER, NISHANT,
NIRANJAN,
Introduction & Background

Wilkins
Regulator General
Plumbing

Company Commercial
Building

1998
1971 Merger with
Jacuzzi Agricultural Municipal
Acquired Irrigation Water Works
1906 Brands, Inc.
by Zurn
Started Industries
Operations
Product Brief
 720 Product:
 Backflow preventer. Belongs to pressure
vacuum breaker (PVB) valve family
 Protects the quality of water when
installed in potable water lines
 Available in 6 different models based on
dimension of in-feed pipes
 Model examples: 34-720 – PVB valve
with a ¾-inch diameter in-feed pipe

 720 Repair Kit:


 Sold directly to customers
 Consists of additional eight parts
Organization structure – Materials
Department
Chris
Connors
General Manager

Jim Bernie
Gerpheide Barge
Materials Manager Inventory Manager

Cyd lane
Purchasing Manager

Tammi Vivian
Keyes Matthews
Purchasing Agent Purchasing Agent
Problems faced by Wilkins in MRP
Repeated physical verification of
Production department mistakenly uses the
inventory leading loss of revenue due
wrong part number
to production shut down

Relieving inventory based on what is


Continuous new product designs and
perceived to be built, and not what is
customization is not aligned with system
actually produced (makeshift type of
adaptability and inventory management
production techniques used)

Current inventory system is not completely


Component changes not adequately
accurate and hinders correct working of
reported in the production reports
MRP system

Bill of material is not always correct. Rippling affect caused by the inventory
Inventory level is always high. inaccuracy
Stated Reasons for Inventory
discrepancy by Wilkins employees
Part commonality: Creates confusion in the
Timing of transactions; data is not
real quantity of parts needed by
entered in to the computer until that
production
night or next morning

Use of wrong components not recorded.


Product modifications; product was
Wrong components used as right ones
redesigned but the BOM was not
were not found.
updated

Custom product requested by


customer, but was not noted during
the production.
Product Tree Structure
Recommended Solutions

 MRP update – accommodate safety stock, proper lead times, and


proper product tree structure

 Safety stock streamlining

 Resolving discrepancies in Lead Time

 Providing unique part numbers for individual products and repair kits

 Proper change management during production of customized


product should be adopted i.e. integration between production
planning and materials planning
Analysis and MRP
Questions?

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