AMERICAN PRODUCTION & INVENTORY CONTROL SOCIETY, INC
AP\CS
Twenty-ninth Annual International Conference ProceedingsOctober 20-24,1986 • St. Louis, Missouri
Table of Contents
Manufacturing Resource Planning
Preventive Maintenance Planning with an MRP II SystemRoland H. Raeker, CFPIM 1
Handshake Versus Foxhole ManagementDavid W. Buker, CFPIM 4
Microcomputer Systems for Small Manufacturers
Scott Hamilton 7
Fifth Generation Manufacturing Resource Planning:The Coming Revolution in Manufacturing LogisticsJohn J. Kanet, CFPIM 10
Conference Room Pilot:A Powerful Implementation and Training Tool
William E. Pendleton, CFPIMJohn P. Balderson, CFPIM 13
Applying MRP II to Remanufacturing: A Case StudyDavid A. Bentley, CFPIM, CSP
Stanley R. Rothstein, CPIMR. L Witt 18
Why Don't We Call It Sales and Operations Planning,Not Production Planning?F. John Sari, CFPIM 22
MRP Implementation in a Cosmetics Company:A Case Study of Renee Laboratories
Ellis J. Camp, CPIM 25
MRP II Evaluation and Selection: A Case Study at VolkswagenJames C. UsherCarl L Huett, CPIM 29
Large System Benefits for the Small Manufacturing Environment
Steven M. Boeder, CPIM 32
Production Planning: Key to Manufacturing StabilityArnold E. Rowland, CFPIM 37
Maintenance Can Be Managed: A Practical RX
David G. Jahnig, PE, CPIM
Lawrence P. Ettkin, CFPIM 40
After MRP II, What Next?
George R. lemmolo, CFPIM 44
MRP II in the Aerospace/Defense Industry:Will It Survive the Next Five Years?
Ronald N. Sullivan, CFPIM 49
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A Manufacturing Planning and Control System Simulator
Using Spreadsheet ProgramsStephen A. De Lurgio, Ph.D., CFPIM
Jiguang Zhao 53
Is Your Inventory in Between Plants?
Paul Linthorst, CFPIM 57
MRP II Education and Training: A Case StudyEdward J. BishopEarle J. Craigie, CFPIM 60
Master Planning and Demand Management
Just-in-Time Demand
Richard C. Ling, CFPIM 64
The Multiplier Effect
Jack B.\Harrison, CFPIM 66
Why Not Include Service Parts When \bu Master Schedule?
William X Jones, CFPIM 69\
A Fresh Look at Linking Plans with Schedules:
Tying Master Scheduling to Production PlanningLloyd Andreas, CFPIM 72
A Step Beyond: Advanced Techniques for Master SchedulingA. J. Muegel, CFPIMR.M.Ryan 77
The Role of Sales and Marketing in Planning and SchedulingJohn R. Dougherty, CFPIM
Christopher Gray, CFPIM 80
Master Schedule: Key to Success
Robert H. Murphy, CFPIM 84
Forgotten Importance of Simpler Forecasting TechniquesVince K. Gulati, CPIMStephen H. Knowlton, CPA, CMC 88
Master Planning Simulation: Playing the "What If Game
Samuel S. Sulser, CPIM 91
Master Scheduling and Final Assembly Scheduling:Whafs the Difference?
Michael G. Tincher, CPIM 94
777e New APICS "Practical Forecasting" Training AidMartin R Edelman, CMC, CPIM 97
77?e Role of P&IC in Product Discontinuance
Andru M. Peters 99
A Day in the Life of the Master Scheduler
Frederick W. Formon, CPIM 103
How to Master Production Schedule in a JIT Environment
Jeff Moran, CPIM 106
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Materials Requirements Planning
Why Listen to a Class "B" Company?Bob Fiedler, CPIM
Ray Elwell, CPIM ,111
Creation of a Material Planning Function to Support MRPImplementation: A Case StudyWilliam R. Muns, CPIM 115
MRP for Smaller Businesses:
A Case Study of Successful ImplementationFrank W. Swanson, CPIM 118
MRP II and JIT Make a Tough, Competitive Combination
John J. Civerolo 120
Project Management: A Plan for Implementation Success
Edward V. Lieggi, Sr., CFPIM 125
The Systems of the Future for the Factories of the Future
Thomsa H. Goodrich, CPIM
John R. Lischefska, CPIM 128
Increase Your Profits by Managing Your Constraints
Donald M. Birk, CFPIM 132
Organizing the Team: A Win or Lose PropositionJoseph La Monica 137
Why Is MRP So Difficult in Aerospace/Defense?Rob Pfunder, CFPIM 140
Push vs. Pull: Which is Best? Let's Eliminate the Confusion
Andre J. Martin 145
Two MRP Turnaround Case Studies
Kirk L. Prather, CFPIM 148
MRP/D: The Defense Industry's Key to Higher Production OutputCarleton F. Kilmer, CFPIMAlexander Lengyel, CPIM 151
"Micro" MRP l\ User Audit Results: Is It Working?HorstJ. Paul 156
MRP by Contract
Odell Richardson, CPIM 159
MRP II in a Custom Fabrication Environment
William E. Lamberty, CPIM 162
Material Requirements Planning; Aerospace/Job ShopChip Long 166
Capacity Management
The Major Issues of Capacity Requirements PlanningNeville P. May, FBPICS, FIPC 170
Capacity Planning and Execution:The Other Half of the EquationMel Nelson, CPIM 173
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Capacity Management: An Integrated ApproachStephen R Machon, Jr., CPIMEarl C. Young, CPIM 178
Capacity Management: Managing Today While
Planning for the Future
Frederick L Thome, CFPIM 182
Tooling: The Frontier of Capacity ManagementMark Kupferberg, CFPIM 186
Rough-Cut Capacity Planning Using SpreadsheetsJohn H. Blackstone, Jr., CFPIM 190
Operation Sequencing: Scheduling for On-Time DeliveryRichard J. Bruun, CPIM 192
Operations Sequencing: A Key to Shbp Floor Control
Harold E. Searl, CPIM 194
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Production Activity Control
Flat Bills of Material with Production Activity Control
Terry Lunn, CFPIM 197
Factory Focus Through Data Collection
Alphedor J. Perreault, CPIM 201
Beyond MRP: The Coming Revolution on Shop Floor Is CAM
Jonathan J. Golovin 206
Shop Floor Control: The Unfulfilled Promise
George J. Miller, CPIM 210
Production Activity Control Basics: The Key to PaybackPaul B. Lavallee, CFPIM 216
An Alternative to the Exact Determination of Queue Time
Randy Eisenbach, CFPIM 222
Identifying the Principles of Effective Production Activity Control
Steven A. Melnyk, Ph.D., CPIM
Phillip L. Carter, Ph.D., CFPIM 227
Bar Codes a Concept Whose Time Has Come:
Or Look Out the Japanese Have Discovered Bar Codes
Robert W. Brooks, CPIM 233
Inventory Management
How to Set Up an Effective Inventory Accuracy ProgramVinnie Chopra, CPIM 238
The Limits of Cycle CountingJan B. Young, CFPIM 241
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Synchronized Inventory: Survival Made Profitable
Donald J. Mayer, CFPIM ....244
AS/RS Implementation at a Large Defense Contractor
Richard L Umble 247
What Are the First Steps to 95% Inventory Accuracy?Chester N. Childers, CPIM 252
Microcomputer-Based Systems: They're for Big Companies Too
Philip L. Allor, CFPIM 255
Bar Code Applications in MRO Stores
Rick Handley, CPIM 258
Inventory: Asset or Liability?Mike Hunter, CFPIM 261
Reducing Inventories for a Company in a Depressed IndustryRichard W. White 266
Controlling Floor Stock: An Approach That Works
George E. Murdock, CFPIM 268
Meeting the Materials Management ChallengeWithin the Context of Government ContractingSusan Keim, CPIM 271
Determining Appropriate Inventory Levels
Jeff South, CFPIM 274
Up Your Accuracy: Using Control-Group Cycle CountingRandall J. Roman, CFPIM 278
The Buyer/Planner PartnershipGeorge N. Wells, CPIM 282
Cycle Count Your Work-in-Process:
Closing the Loop on Data IntegrityAl Eckerdt, CPIM ...
284
Material Control and the Small Repetitive Manufacturer
C. Burt Caldwell, CPIM 287
JUST-IN-TlME I
The Direct Route to JIT
Ed Heard, CFPIM 290
Low Volume/High Mix JIT
William A. Sandras, Jr., CFPIM 295
Just-inTime Manufacturing: An Update on Japan 1986
Kenneth J. McGuire, CFPIM 300
Management Policy Changes: Musts for JIT
Julie A. Heard 304
Measuring Labor Effectiveness in a Just-in-Time Environment
Ken Wantuck, CFPIM 310
Toyota Versus Nissan: '
Two Approaches to Resource Planning and SchedulingWalter E. Goddard 313
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Implementing Just-in-Time (JIT):Opportunities, Concerns, and a Strategy for Success
Preston W. Blevins, FBPICS, CPIM 318
Lessons From the JIT Journey: A Case StudyMichael S. Spencer, CPIM 326
Supplying Just-in-Time to NUMMI: A Case StudyJohn W. Kinsey, CFPIM 331
How to Gain a Competitive Edge That Is Second to None
R. Dave Garwood
Darryl Landvater 335
Demand-Pull Principles and Practice
Roger B. Brooks, CFPIMCharlene Adair 338
The Factory in 1990: Will It Be Dark and Empty?John F. Proud, CFPIM 344
JIT Applications in the Job Shop Environment
James P. Kelleher, CFPIM 348
One Day at a Time:
Implementing JIT in a High Tech Company, A Case StudyV. G. Lippa, CFPIM 352
The JIT Starter Kit for Design EngineeringDavid A. Waliszewski, CPIM 358
JUST-IN-TlME II
From Traditional Manufacturing to JIT
Nicholas M. Testa, Jr., CFPIM 361
JIT: Just in Time or Just Inviting Trouble
David L. Baer, CPIM 366
JIT: Not Just for the Factory!Randall J. Benson, CFPIM 370
Material Handling and bead Time Reduction:
Common Threads Through MRP II, JIT, and CIM
Tom Bechtel, CPIM 375
Vendors as Just-in-Time Partners
Kenneth J. Howser, PE, CPIM 378
SMED Equals Higher ProductivityMichael J. Stickler, CPIM 381
Performance Measurements:The Key to Continuous ImprovementsMichael P. Novitsky, CPIM 386
Overcoming Cultural Barriers to JIT
Ernest C. Huge, CFPIM
Jeffrey W. Sipes, CPIM 389
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Distribution/Logistics and Warehousing
Distribution Management in the 1980s
Alan Dunn, CPIM 394
Installing a "Push" Distribution SystemPeter A. Sawchuck, CFPIM 399
MRP/DRP: Who Is driving Whom?Paul C. Hanson, CPIM 402
How DRP Fits with MPS and MRP -
Lloyd A. Buchholz, CPIM 404
Warehouse Consolidation: A Positive ExperienceJohn A. Gibert, CPIMFrank I. Epps 407
The Path of Flow Dynamics of Network Distribution
Robert L. VanDeMark 412
Stockroom Productivity Using a Manual SystemRoger R Buckley, CPIM 416
Inventory Accuracy: A People PerspectiveMichael P. Clark, CPIM - 418
Computer Integrated Manufacturing
Long-Range Systems Planning for CIM
Jim Mottern, CPIM 421
Technological Options for Computer Integrated ManufacturingWilliam a Lee, Ph.D., CFPIM 424
CIM: APICS' New Frontier?
Woodrow W. Chamberlain,...
429
The Role of Expert System Technology in P&IC
Larry Mannis, CFPIMJohn Morris, CPIM 433
Synchronized Manufacturing: The CAM of the CIM FlywheelRobert B. Vollum, CFPIM 438
Ifs Interfacing, Not Integrating!Joseph L Aiello, CPIM 443
Managing Integrated Manufacturing TechnologiesGus Berger, CPIM 446
FMS/CIM and Work Force ManagementCharles G. Andrew, CFPIM 451
CIM: Alchemy or Chemistry?James A. Jacobs, CPIM 457
Operational Strategy IntegrationOwen R. Burger 459
! Schedule Execution in the Factory of the Future:
Simple or Complex?James W. Branam, CPIM 462
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Move Over Mainframe: Make Way for the Micro
Lester S. ShindelmanCarter C. Utzig 467
GAD Systems for Small Design DepartmentsC. H. "Pete" Link
.472
The Design and Implementation of Flexible
Manufacturing SystemsDonald J. Agostino, CPIM 475
MRP Megatrends: Is CIM Creating a Need for MRP II?
Wilford E. Dunn
Eugene V. Lemberger 478
New Guidelines for Selecting and JustifyingFactory Automation ProjectsLawrence T. Michaels, CPIM 483
Operations Management
Integratedvurchasing Systems: A Realitya J. Bastow, CPM, CPIM 486
PDQ: Purchasing to Support Manufacturing, or"Where's the Req?"John R Flavin, CPIMThomas H. Fuller, Jr., CFPIM
....490
MRP II Won't Schedule the Factory of the Future
Hal Mather, CFPIM.... 495
The New Ballgame: JIT PurchasingBob Parmelee, CPIM 498
"For Sale": The Plant That Did Not Work Together^'
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Patrick J. Delaney, CPIM 504
Dealing with Management Styles:From Recognition to Task AccomplishmentDennis Fisher, CPIM 508
Controlling Overhead: The Hidden Cost
William G. Savage, CFPIM 512
Improvement Through Performance Measurement
James K. Wiggins, CPIM 514
How to Get Started with Quality ManagementJeffrey H. Cooper, CPIM 517
Total Quality Control:Key Ingredient in the Successful JIT RecipeRobert E. Olsen, CPIM 519
The Role Total Quality Control Plays in Our Business
Michael W. Gozzo, CPIM 522
How to Really Create and Maintain Accurate Bills of MaterialsDonald N. Frank, CPIM .. 524
American Production & Inventory Control Society
On Target: Overhead Cost
Raymond L Martin, Ph.D., CPM, CPIM 527
Just-in-Time: A Boon or Boondoggle in PurchasingRobert A. Stahl, CPIM 530
Productivity: Not Only the Responsibility of the Production Une
Donald J. Green, CFPIM 533
Planning Ain't the Same as Doing: Doing Is What Pays the Bills
Barry E. Blood, CPIM 538
Functional Interfaces,
Classification Coding for Group Technologyand Standardization
John N. Petroff, CPIM 540
Closed Loop Engineering Change Control
Craig Phillips, CFPIM 545
Product Designs Initiate Excess and Obsolete InventoryTom Little 549
Management's Role (Responsibility) in ForecastingThomas C. Detscher 552
Forecasting Fundamentals
Dolores A. Brosky, CPIM 554
MRP II and Sales Order ManagementMary Kay Wells, CPIM 559
Customer Service by Objectives: The Road to Excellence
Larry "Jake" Wolfe, CPIM 563
Implementing a Cost Management System in a
Japanese Automotive SupplierJames A. Jonas, CFPIM 565
Financial and Manufacturing Management:Partners in ProfitabilityAllan R. Kauth, CPIM 570
Computer Integrated Cost Accounting:New Concepts, New Methods
Robert A. Bonsack, CPIM 572
Incorporating Customer Service in the Corporate Culture
Carolyn Farr, CPIMSarah Wenzel, CPIM 576
Building and Maintaining a Good Client/Vendor RelationshipJack O'Connor, CDP, CPIMRick Schwieter 580
Sales and Materials: Natural Enemies or Allies
Wilson B. Grab 583
Manufacturing Accounting System for the Factory of the Future
Mehran Sepehri, Ph.D., CPIM 588
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uosr Accounting: Flexibility Required to Support Just-in-Time
Laymond Harrier, CRM ..59,
The Cost Accountant's Role in an MRP II ImplementationRobert J. Sellani, CPIM .
596
Executive Management Issues
What I Learned to Use in Materials Management from
Teaching Quality Improvement Courses
Peter W. Langford, CFPIM 599
Manufacturing: A Team Sport . » .
Richard W. Malko, CFPIM 602
Management—Art or Science: The TheoryEliyahu iyi. Goldratt 604
Managerrient—Art or Science: A Case StudyRobert E,W CFPIM 605
Manufacturing Strategy: A Full Partner in Business PlanningLewis J. Soloway, CPIM 606
Why We Let the Users Select the System: A Case StudyPaul N. Funk, CPIM 610
An Executive Perspective: Planning Today for the
.Information Needs of the Future
Larry J. ShunAlton C. Todd, CFPIM 616
MRP, JIT, CIM: Choosing the "Right" StrategyTerry R. Schultz, CFPIM 620
Manufacturing Strategy: The Next Frontier
Thomas F. Wallace 623
Case Study: Application of JIT to Total Business
S. S. Cherukuri, CPIMR. A. Judd 627
Change Performance Measures First
Steven A. Souza, CFPIM 631
New Horizons for Production and Inventory Control
Henry H. Jordan, CMC, CFPIM 634
Manufacturing Excellence: Pulling the Pieces TogetherAnn Marucheck, Ph.D.Ronald Pannesi, Ph.D., CPIMSarah Wenzel, CPIM 637
MRP for Competitive AdvantageThomas H. Slaight, CPIM 64.1
Productivity Through PeopleRickTitone 643
American Production & Inventory Control Society
Professional Development
How to Develop and Implement a SuccessfulEducation/Training ProgramDale A. Smith, CPIM 645
Training for the 90s: JIT, TQC, CIM
Peter L. Grieco, Jr. 648
ChangemastersE. M. "Mac" Barnett, CFPIM 651
innovation in Education
Scott A. Levin, CPIM 654
How to GeUthe Most Out of Video Education
Paul M. Elliott, CPIM 658
Dealing with Organizational Conflict
Gary A. Landis, CPIM . 663
Professional Development: A Bi-Directional ApproachE J. Russo 667
Educating for MRP II Systems Installation
Larry Gildea, CPIM 670
Special Presentations
Making the Stripes Earn Their Way:How to Implement Integrated Bar CodingEugene E Baker, CMC 673
New Developments in Forecasting:A Live Video Demonstration
Richard P., Artes, CPIM
Leroy D. Reinhart, CFPIM 686
Is a Computer Necessary?Gerhard Plenert, CPIM 690
Special Presentations
JIT Update: A Japan Study Mission ReportJ. Thomas Brown, CFPIM 694
Professional Logistics Education and Training in an
Electronics/Appliances Multinational
Hans E. van Goor, CPIM 697
The "P' in Productivity is PeopleL 0. Smith, CPIM 701
Lead Time: The Root of All Evils
Warwick R. Johnson, CFPIM 704
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