供应链规划与执行模组知识讲解英文版).ppt

1,供應鏈規劃與執行模組,世新大學資管系鄒慶士副教授,2,Agenda,Overview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS,3,Enterprisefunctionalsiloswithconflictinggoals,Purchasing,Manufacturing,Distribution,CustomerService/Sales,Fewchange-oversStableschedulesLongrunlengths,HighinventoriesHighservicelevelsRegionalstocks,Lowpur-chasepriceMultiplevendors,Lowinvent-oriesLowtrans-portation,OverviewofSCM-Issues,4,OverviewandtargetsofSCM,DefinitionofSupplyChainManagement:SupplyChainManagementdescribesallkindofactivitiesacrossmultiplecompaniesorlocationstooptimizethemanufacturingofproducts.Herebyconcerningallinterfacesonoperationalandstrategiclevelforinvolvedassociates.,Mainfocus,DevelopmentofheterogeneousglobalproductionnetworksIncreasedintegrationofadvancedtechnologies,MinimzingcostsforinventoriesanddeliveriesLongtermrelationships(customer/supplierbinding)Customersatisfaction,By,ERP-BasisSCM-ToolsInternet,5,OverviewandtargetsofSCM,BuysIngredientsandComponents,MakesaProduct,MovesittoaDistributionCenter,StoresitatDistributionCenters,StoresitinaWarehouse,MovesittoStores,StoresitintheStore,SellsittoConsumers,MultiEnterpriseSupplyChains,Source:I2-Technologies,6,OverviewandtargetsofSCM,Integrationofsuppliersinplanninginconsiderationof.,SuppliersinventoriesSuppliersmanufacturingcapacitiesTransporttimesandcapacities,Reductionofowninventories,7,IntegratedplanningofsupplychainsleadstoReductionofinventoriesCostsavingsCapabilitytomeetpromiseddeliverydatesIncreasedcustomersatisfactionIntensifiedcustomerbindingPerspectivetoextendthesalesmarket,OverviewandtargetsofSCM,8,Prerequisitesforsuccess,NomanagementmethodguaranteesitselfforsuccessTypeofproductleadstospecialtypeofsupplychain,PrimarilyfunctionalproductsDontchangemuchovertimeLonglifecyclesPredictabledemandStabilityinvitescompetitionLeadsoftentolowprofitmargins,PrimarilyinnovativeproductsEnableshigherprofitmarginsShortlifecycle(typicallyfewmonth)VolatiledemandNewnessmakesdemandunpredictableImportanceofearlysales,9,Prerequisitesforsuccess,PrimarilyfunctionalproductsSupplyatlowestcoststopredictabledemandHighutilizationrateofcapacityMinimizeinventoriesShortleadtimeasitdoesntincreasecostsSelectsuppliersprimarilyforcostsandqualityPhysicalefficiencyMinimizecostsbyPhysicalefficiency,PrimarilyinnovativeproductsRespondquicklytounpredictabledemandDeployexcessbuffercapacityDeploysignificantbufferstocksInvestaggressivelytoreduceleadtimeSelectsuppliersprimarilyforspeed,flexibilityandqualityResponsivenesstomarketMinimizecostsbyHighestresponsivenesstomarketMinimizeriskofshortagesorexcesssupply,10,Prerequisitesforsuccess,UseofSCMsoftwaretoolslikeAPO,11,Prerequisitesforsuccess,ShareinformationwithyoursuppliersKeeplongerrelationshipswithyoursuppliersTrustasfoundationofrelationshipswithsuppliersFundamentalsofsupplychainplanningwww.ZQZL.cn中国最大的资料库下载,12,SCMBusinessProcesses,TechnologyhelpsenableavarietyofSCMbusinessprocessesPushtopullProcessorientationOptimizationPostponementMorefrequentplanningCollaboration,13,Movefrompushtopullmanufacturing,Manufacturers,Distributors/Wholesalers,Consumers,Suppliers,Retailers,Makewhatwewillsell,notsellwhatwewillmake!,FeaturesofSCM,14,Movefromfunctionalsilostoprocess-orientedbusinessprocesses(e.g.,order-to-cash,cash-to-cash),FeaturesofSCM,15,Optimizationofallsupplychainactivities,Independent,SequentialPlanning,FeaturesofSCM,16,PostponementMovetoMTO,ATOandCTOfromMTSFront-endAPSsuitessupportATP/CTPProductconfigurationBack-endintegrationtotransactionsystems,InternationalTradeLogistics,WarehouseManagement,AdvancedPlanningScheduling,CustomerRelationshipManagement,Logistics,Manufacturing,MaterialsManagement,Accounting,HumanResources,ERP,FeaturesofSCM,SCM,17,Morefrequentplanningmeansresponsivetochangingcustomerneedswhiledecreasinginventories,Time,Time,AverageSupply,AverageSupply,PlanningCycle,PlanningCycle,FeaturesofSCM,18,e-Businesswillenablesupplychaincollaborationamongtradingpartners,Manufacturer,Distributors/Wholesalers,Suppliers,Retailers,FeaturesofSCM,LogisticsProviders,19,ComponentsofE-SupplyChain,Supply-chainreplenishmentE-procurementCollaborativeplanningCollaborativeproductdevelopmentE-logisticsSupplywebs,20,EvolutionofIT,AR,AP,GL,Payroll,MRP,FMIS,HR,MRPII,Scheduling,planning,Distribution,ERP,APS/SCM,EIS,EDI,E-Commerce,BI,CRM,E-Business,21,Agenda,Overview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCSwww.ZQZL.cn中国最大的资料库下载,22,Manufacturers,WholesaleDistributors,Suppliers,Customers,InformationFlows,GoodsFlow,SupplyChainNetworkDesign,Retailers,LocationdecisionCapacitydecisionAssignmentdecision,23,StrategicPlanningProblems,Whichproductsshallbeproducedatwhichlocations?Howarecustomersassignedtodistributioncenters?Whereshallnewlocationsbeopened?Whichlocationsshallbeclosed?Whatarecapacityrequirementsforplants/distributioncenters?Whatisthecostsituationwithinthesupplychain?,24,PlanningMethod,PlanningoflocationassignmentandtransportationlanesLocationassignmentbasedongeographicaldistanceCostoptimallocationassignmentStructuralNetworkChangesPlacementofagivennumberoflocationsbasedongeographicaldistanceandcostsCostoptimalselectionoflocations,25,PlanningParameters,CostTransportationcostsProductioncostsStoragecostsHandlingcostsProcurementcostsLocationcosts/LocationproceedsFixmaintenancecostsCostsforopeningandclosureoflocationsPublicsubsidiesPenaltycostsfordelayedornon-fulfilleddemand,26,PlanningParameters,CapacitiesHandlingcapacitiesforplantsanddistributioncentersProductioncapacitiesofplantsDemandCalculationofdemandviaDemandPlanningSupportedbyforecastmethodsSimulationofdemandscenariosVariationofdemand,27,PlanningResults,SupplyChainNetworkAssignmentoflocationsTransportationlanesAllocationofproductstolocationsNewlocationswithgeographicpositionSelected/notselectedlocationsProposalforopeningorclosureoflocations,28,PlanningResults,QuantitiesProduction,transport,handling,storageandprocurementCostsProduction,transport,handling,storageandprocurementLocationcostsOpeningcosts,maintenancecosts,subsidies,etc.CapacityRequirementsProduction,transport,handlingundstorage,29,Outlook,Profit-orientedplanningConsiderationofpiece-wiselinearcostsfortransportandproductionConsiderationofstoragecapacitiesIntegrationofGISapplicationsautomaticcalculationoftransportationdurationandtransportationcostsexpandedgeographicdisplay,30,Agenda,Overview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS,31,ProductionLogistics,Forecast,Customerorderadministration,Primaryrequirementsplanning,Requirementsplanning,Purchasing,Capacityscheduling,Capacityadjustment,Orderrelease,Reservation,Sequencing,Detailedscheduling,Execution,Factorydataentry,Shopfloorcontrol,Planning,Planning/scheduling,Initiationofimplementationfunctions,32,TypicalPlanningProcess,Supply/DemandMeeting,MRP/ERP,ManualAdjustment,ReleasePO,Receiving/Receipt,ChangeProductionPlan,CannotdeliverontimeLongpromisetimeDeaditems&shortageCustomerunsatisfied,33,MRPIIPlanningProcess,Top-downprocessIterativeprocess,MasterPlanning,RCCP,MRP,CRP,SFC,34,ProbleminIndustry,SalesSOconfirm時間太長PC無法如期交貨Hub會造成投資風險PC/MC插單Cancel訂單訂單交期變更頻繁Yield和Rework造成交期Delay無法確認真正的產能與瓶頸作業替代料無法掌控ECN頻繁，易產生呆料,35,ProbleminIndustry,ShopFloor開製令前無法確認料是否備齊臨時缺料Yield和Rework造成大量未結案工單ShopFloor催MC，MC催Buyer，Buyer催Supplier產能規劃不合理，無法執行Buyer無法確認到底欠哪些料追料頻繁OrderCancel頻繁未考慮LeadTime,36,DrawbacksinTraditionalProductionPlanning,SequentialplanningProbleminschedulinglogicIndependentdemandandsupplyplanningLackofintegrationBatchprocessSinglepointplanningLackofsimulationcapability,37,SCMInformationSystem,38,DefinitionofAPS,theresnoprecisedefinitionofAPSsystems,butitisquiteintuitivetosaythattheAPSsystemsresolvetheshortcomingsoftheERPsystemsasaplanningtool.APSsystemsconsidermaterialrequirementsandplantcapacitytogeneratenewplans,andsomeofthemcreateadetailedproductionschedulethatsequencestheproductionoptimally,toachievetheorganizationgoalsaswellascustomersduedate.(AMR,1998)APSsystemsapplyprofoundadvancedtechnologiestoachieveimprovedplansthattakeintoaccountmostofthefactorsandconstraintsthatlimittheabilitytodeliverontime.(ForrestResearch,1996),39,FeaturesofAPS,SynchronizedconcurrentplanningConstraint-basedplanningOptimizedplanningReal-timeplanningDecisionsupportcapabilityWhat-ifsimulationPeggingbetweendemandandsupplySpeedandperformance,40,SynchronizedPlanning,41,Constraint-basedPlanning,APS,Constraint,Supply,Demand,Output,Time:PurchaseLTMfg.LTTrasf.LTDueDate,Capacity:ResourceloadRouting,Material:AlternatePartsECNPartsSourcingRule,Demand:ForecastSalesOrder,SupplyData:On-handWIPPurchasingOrder,OptimalPlan,42,OptimizedTechnologiesinAPS,DemandPlanningExponentialSmoothingSystemDynamicsMultipleLinearRegressionProductionPlanning&SchedulingLinearProgramming/MixedIntegerLPGeneticAlgorithmsSimulationAnnealingHeuristicMethodsDistributionPlanning&DeploymentFlowAlgorithmsBranch-and-BoundAlgorithm,43,ScopeofAPS,SupplychainstrategicplanningSupplychainnetworkplanningDemandplanningandforecastingInventoryplanningSupplychainplanningSupplyplanningDistributionplanningTransportationplanningShopflooroperationschedulingShipmentscheduling,44,FunctionsofAPS,45,APS是使用現存Transaction系統(ERP)的資訊，以提供快速規劃及排程的智慧型決策支援系統。,Purchasing,OrderEntry,Manufacturing,Logistics/Shipping,ERP,CurrentSituation,FinalPlan,SupplyChainPlanner,InputDataDemandCapacityMaterials,OutputProductionPlanShippingPlanPromisePlan,APSandERP,46,Multi-SitePlanning,Complexmulti-sitemanufacturingreferstotheenvironmentwheretherearemultiplesitesthataredependentuponeachotherformaterialandassemblies.SupplyPlanningforacomplexmulti-sitemanufacturingenvironmentinvolvestheconsolidationofdatafromtheindividualsitesintoacorporateconsolidationdatabase.,47,Multi-SitePlanning,GlobalAPSEngine,DemandPlanningEngine,OrderPromisingEngine,APSEngine,APSEngine,APSEngine,MasterPlan,MasterPlan,MasterPlan,SupplyPlan,SupplyPlan,SupplyPlan,DemandPlan,SupplyPlan,48,*Source:AMR,1996,PerformanceResults,49,Agenda,Overview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS,50,PurposeofShopFloorControl,將生產規劃單位所規劃的生產訂單(PO)有效的轉變成實際成品的產出,51,ShopFloorControlSystem,52,FunctionsofShopFloorControl,Orderreview/releaseDetailedshopflooroperationsschedulingDatacollection/monitoringControl/feedbackOrderdisposition,53,OrderReviewandRelease,扮演一個過濾機制，控制訂單進入現場的流量,54,FocusofOR/R,AvailabilityofmaterialsRequiredcapacityRequiredmachinesandtoolingsReal-timeproductionstatusVerifyMRPplansConfirm/modifyBOMstructureConfirm/modifyroutingEvaluateproductionloadsinshopfloorCriteriaofperformanceevaluation,55,OperationsScheduling,WorkcenterorientedschedulingWorkorderorientedschedulingBackwardschedulingForwardschedulingFiniteschedulingDispatching,56,DataCollectionandMonitor,BarcodeOpticalcharacterrecognitionMagneticstripeVoicerecognitionRadiofrequencyidentificationMachinevisionsystemBluetooth,57,ControlandFeedback,Orderproblemsvs.ResourcesproblemsIsitsolvable?Whatisthesolution?AdjustandimproveInformationfeedback,58,OrderDisposition,OrdercompletionASplannedOrdercancellationMaterialsshortageReleasepreviouslyassignedresourcesEvaluateproductionperformanceDefineandexplainspecificunexpectedconditions/solutions,59,ShopFloorControlSystem-Anotherview,60,Agenda,Overview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS,61,RelationshipsofERP/APS/MES/MCS,ERP,APS,MCS,MES,62,InteractionsBetweenERP/APSandMES,63,DefinitionofMES,將加工現場中的原物料、半成品、成品、機器、時間、成本等資訊以動態且即時的方式來收集、匯整與表達，並追蹤與管制目前正在進行中的各項製造作業的一個資訊系統(APICS)。其上層銜接APS的生產規劃結果，以進行即時性的現場生產派工；下層則連結MCS，根據派工結果控制設備進行實際加工生產，並即時收