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MRP Ltd Public Education Courses


Below you can see the courses that were offered by MRP Ltd (MD Mike Salmon from 1990 until 2004). The material on these courses has been condensed into the book "Business Excellence" which can be purchased from this site. Click here for more information.

The purpose of MRP Ltd's public Business Excellence education programme was to open people's minds to new ways of working, to make the most of commercial MRPII and ERP software packages and to weld the disparate company disciplines into a team that can use these integrated tools for competitive advantage. By attending public courses you are able to see all aspects of MRPII and also able to meet and socialise with people from other companies.

The tools of excellence are available to any company that will take the trouble to learn them. They are typically easier to learn than even the most mundane production processes.

Two of our most popular courses on Stock Record Accuracy and Master Production Scheduling are now available on CD for just 95 (about US $150).

Mike Salmon began his involvement with MRP as Financial Controller for British American Cosmetics. Mike founded MRP Ltd. in 1981 and since then has helped many companies to become class "A" MRPII users, the better known being BNFL, Chloride Industrial Batteries, Formica, ICI Agrochemicals, Knowles Electronics, ND Marston, Sara Lee and York International.

Phil Robinson joined Knowles Electronics as Production Manager and subsequently became the project leader for their 1985 class "A" MRPII implementation, only the second in the UK. In the 10 years since starting their Business Excellence programme, Knowles had achieved class "A" in MRPII, reduced lead times from 8 weeks to next day kanban deliveries, reduced inventories by one third, achieved a better than 99.5% on-time delivery record and reduced customer returns to less than 300 parts per million. Phil has been teaching and consulting in Business Excellence since 1994 when BPIC was set up. In 2000 BPIC started running in-house education modules to support MRP's public education courses.

Overview of courses:

Senior Management Course

Creating a vision of excellence

Summary - our Senior Management Course provides busy executives and their key colleagues with a practical insight into the costs and benefits of current best practice techniques in planning and control. It shows how the Business Excellence concept improves their control of the business.

Content - overview of current best practice in planning and control, we call this "Business Excellence", and the need to integrate financial business planning with operations through the application of sales and operations planning. The seminar also covers in overview the principles of master scheduling, material and capacity planning, achieving data accuracy and how to open up opportunities in production and purchasing. Finally, the timescale, costs and benefits and resources required for implementation are discussed.

Seminar objectives - by the end of the seminar delegates will be able to evaluate the costs and benefits of various degrees of change to their business and the strategy necessary to achieve them.

The seminar is designed for Managing Directors and key staff

Duration - 2 days starting at 8:00 on day 1 and finishing at 6:15 on day 2

Business Excellence - The Fundamentals

Summary -an outline of the current best practice techniques in business planning and control including practical and proven ways to make the changes happen.

Content - the basic concepts including enterprise / manufacturing resource planning, total quality and just in time, followed by details of sales and operations planning, master scheduling, material requirements planning, capacity requirements planning, data accuracy, shop floor control, performance measures, cost and benefit analysis and implementation strategies.

Course aims - to leave all delegates with not only a working understanding of current best practices, "Business Excellence", but the knowledge to sell the ideas to the business and implement them.

The course is designed for :

1) People investigating best practice, i.e. Business Excellence, in advance of a business improvement project.

2) Project team and task force members engaged in an improvement process.

3) Recruits to a company that have implemented a Business Excellence project in the past.

Duration - 5 days starting 8:30 on day 1 and finishing at 1:15 on day 5

Business Excellence Project Implementation - The Implementor's Course

Summary - the team whose job it is to lead the implementation of Business Excellence is faced with a daunting task. The project involves innumerable interactions between the various business elements with significant scope for error. This course is crammed with practical advice based on the knowledge gained from many successful implementations.

Content - project organisation, managing change, project planning, education and training needs.

Course aims - the delegates will take away a practical and detailed implementation methodology.

The course is designed for - principally project leaders and board level sponsors but also other full time project team members and key managers involved with the implementation.

Duration - 3 days beginning at 8:30 on day 1 and ending at 5:00 on day 3

Performance Measures - How to Measure Excellence

Summary - the achievement of successful cultural change is critically dependent on a change of performance measures; if you do not change performance measures you do not change performance. The establishment of an integrated set of new performance measures to stimulate and support cultural change is the objective of this course.

Content - each element of the change process is examined and a set of performance measures established to support the changes necessary. All Business Excellence Performance Measures link to the overall financial performance by which the company is ultimately judged in most cases.

Course aims - to provide a framework for the delegates to set up forward looking, integrated performance measures that encourage team working.

The course is designed for - line managers at all levels and, in particular, personnel and finance directors as guardians of the traditional performance measures.

Duration - 3 days starting at 8:30 on day 1 finishing at 5:00 on day 3.

Sales and Operations Planning - Managing the interface

Summary - this practical course is designed to foster a team spirit in companies and co-operation between manufacturing, quality control, engineering and/or development, finance, sales and marketing by showing them how to marry their respective plans.

Content - roles in the sales and operations planning process, business planning, rough cut capacity planning, forecasting and implementation.

Course objective - the delegates will be able to set up and become actively involved with their company's sales and operations planning process.

The course is designed for - managing directors along with sales and marketing, materials, manufacturing and finance directors and all managers who will be involved in setting up or operating the sales and operations planning process.

Duration - 2 days beginning at 8:15 on day 1 and finishing at 6:00 p.m. on day 2.

Master Production Scheduling - A framework for action

Summary - a correctly implemented master production schedule balances the demand and supply sides of the business to meet the company's customer service objectives and, at the same time, drives the material and capacity plans. The course looks in detail at forecasting and demand management as well as the numerous master scheduling tools and techniques including distribution resource planning and configuration.

Content - the role of master production scheduling and its integration with sales and operations planning, rough cut capacity planning, master scheduling in different environments and process design.

Course objective - delegates will be able to take an active role in the design and development of the master scheduling function. Commercial people will understand the important role of demand management. Planners will come away with a framework within which to develop their master scheduling skills.

The course is designed for - key directors and managers from sales, marketing, customer service and planning roles as well as master production schedule task force members.

Duration - 4 days starting at 8:15 on day 1 and finishing at 5:00 on day 4.

Stock Record Accuracy - Target is 100%

Summary - Inaccurate stock records are a major cause of failure with planning systems. Everyone now recognises you cannot "inspect in" quality for a product yet too many companies still try to correct stock data quality by counting. This course shows how to design a stock management process that will result in the high level of data accuracy that is required to plan most effectively.

Content - designing the data management process, typical problems and problem solving tools, control of kanban and lineside stock, control groups, stock control and auditing techniques.

Course objective - to help both those involved in the setting up and those involved with managing stock of all kinds to design and operate a high quality stock control process.

The course is designed for - stores people, material managers and task force members. No previous training is required to attend this course.

Duration - 2 days starting at 8:15 on day 1 and finishing at 3:45 on day 2.

Bill of Material - Keystone of a successful strategy

Summary - how to achieve and maintain a high level of bill of material accuracy, structuring the bills to minimise inventory, maximise customer service, provide accurate cost data and simplified manufacturing and control processes.

Content - bill of material structure considerations, planning bills, structuring for Business Excellence, software and change control.

Course objective - delegates will be able to audit current bills and manage the changes necessary to structure and implement any changes necessary.

The course is designed for - all managers who have responsibility for producing or maintaining bill of material information and task force members.

Duration - 3 days starting at 8:15 on day 1 and ending at noon on day 3.

World Class Manufacturing - Making it happen in the factory

Summary - the focus of attention in manufacturing is to improve customer service levels and responsiveness by focusing on reducing lead times and cutting inventory. This practical, hands-on course looks at both the better use of the planning tools for on time delivery and control plus the use of ideas such as just-in-time, total quality, lean manufacturing, continuous improvement, kanban and set-up reduction to reduce costs and lead times.

Content - capacity planning, shop floor control and workshop; kanban, housekeeping, lineside inventory layout and factory simulation exercise; set-up time reduction and exercise; concluding with implementation ideas.

Course objective - to start all delegates on the road to continuous improvement.

The course is designed for - all managers and team leaders in the planning, production engineering and operational sides of the business.

Duration - 4 days starting at 8:15 on day 1 and finishing at 5:00 on day 4.

Purchasing Power - Supply side techniques that really work

Summary - with timely and accurate material requirement data, excessive inventory can be eliminated and reliable supplies, when you need them, at the desired quality, can be assured. When armed with realistic and dependable schedules, buying professionals can use their skills to forge long term partnerships with suppliers which will significantly improve both your and your supplier's bottom line performance.

Content - purchasing for Business Excellence, just in time deliveries using kanban and electronic data interchange, vendor management and measuring performance, with the ultimate objective of a smaller number of qualified vendors.

Course objective - to establish a framework for developing excellent suppliers to support your business excellence project.

The course is designed for - everyone in the company with purchasing responsibilities and purchasing task force members.

Duration - 3 days starting at 8:15 on day 1 and ending at 5:00 on day 3

Material Requirements Planning - The engine room

Summary - the course explains the basic underlying logic that drives the whole planning process in a practical way using exercises and workshops.

Content - the material requirements planning mechanics, the planning parameters of lead time, order quantity and safety stock, preparing and releasing the plan, managing change and the links to the rest of the planning processes.

Course objective - to give everyone directly involved with planning a practical insight into how to get the most from planning systems.

The course is designed for - planners and master schedulers who may not have attended the 5 day Business Excellence Fundamentals course.

Duration - 2 days starting at 8:15 on day 1 and ending at 6:00 on day 2

Private Courses and Workshops - Another string to our bow

Summary - There are circumstances where a company would prefer a private course, given locally and structured to focus on the particular needs of the company.

Content - private courses can either have the same content as any of the public courses but delivered locally to just one company or be a specially constructed course focused on particular needs.

In addition to the above courses we have now set up a suite of modular courses from one day in duration designed to be delivered locally and tailored for individual companies. Click on private education courses for more details.

Course objective - to deliver a specific focused messaged address to a company's particular needs.

The course is designed for - anyone and everyone.

Duration - 1 to 5 days, normally starting at 8:30 and ending at 6:00 each day