供应链规划与执行模组 ()

1、供應鏈規劃與執行模組世新大學資管系 鄒慶士 副教授1 中国最大的资料库下载AgendaOverview/Features of SCMSupply Chain Network DesignAdvanced Planning and SchedulingShop Floor ControlMES/MCS2 中国最大的资料库下载Enterprise functional silos with conflicting goalsPurchasingManufacturingDistributionCustomer Service/SalesFew change- oversStable schedu

2、lesLong run lengthsHigh inventoriesHigh service levelsRegional stocksSOURCEMAKEDELIVERSELL Low pur-chase priceMultiple vendorsLow invent-oriesLow trans-portationOverview of SCM - Issues3 中国最大的资料库下载Overview and targets of SCM Definition of Supply Chain Management: Supply Chain Management describes al

3、l kind of activities across multiplecompanies or locations to optimize the manufacturing of products. Herebyconcerning all interfaces on operational and strategic level for involvedassociates. Main focus Development of heterogeneous global production networks Increased integration of advanced techno

4、logies Minimzing costs for inventories and deliveries Long term relationships (customer / supplier binding) Customer satisfaction ByERP - BasisSCM - ToolsInternet4 中国最大的资料库下载Overview and targets of SCMBuys Ingredients and ComponentsMakes aProductMoves it to a DistributionCenterStores it atDistributi

5、onCentersStores it in aWarehouseMoves itto StoresStores it in the StoreSells it toConsumersMulti Enterprise Supply ChainsSource: I2-Technologies5 中国最大的资料库下载Overview and targets of SCM Integration of suppliers in planning in consideration of. Suppliers inventories Suppliers manufacturing capacities T

6、ransport times and capacitiesReduction of own inventories6 中国最大的资料库下载 Integrated planning of supply chains leads to Reduction of inventories Cost savings Capability to meet promised delivery datesIncreased customer satisfactionIntensified customer bindingPerspective to extend the sales marketOvervie

7、w and targets of SCM7 中国最大的资料库下载Prerequisites for success No management method guarantees itself for success Type of product leads to special type of supply chainPrimarily functional products Dont change much over time Long life cycles Predictable demand Stability invites competition Leads often to

8、low profit marginsPrimarily innovative products Enables higher profit margins Short life cycle (typically few month) Volatile demand Newness makes demand unpredictable Importance of early sales8 中国最大的资料库下载Prerequisites for successPrimarily functional products Supply at lowest costs to predictable de

9、mand High utilization rate of capacity Minimize inventories Short lead time as it doesnt increase costs Select suppliers primarily for costs and quality Physical efficiencyMinimize costs by Physical efficiencyPrimarily innovative products Respond quickly to unpredictable demand Deploy excess buffer

10、capacity Deploy significant buffer stocks Invest aggressively to reduce lead time Select suppliers primarily for speed, flexibility and quality Responsiveness to marketMinimize costs by Highest responsiveness to market Minimize risk of shortages or excess supply9 中国最大的资料库下载Prerequisites for successE

11、fficientResponsiveFunctionalInnovativematchmatchmismatchmismatchUse of SCM software tools like APO10 中国最大的资料库下载Prerequisites for success Share information with your suppliers Keep longer relationships with your suppliers Trust as foundation of relationships with suppliers Fundamentals of supply chai

12、n 中国最大的资料库下载11 中国最大的资料库下载SCM Business ProcessesTechnology helps enable a variety of SCM business processesPush to pullProcess orientationOptimizationPostponementMore frequent planningCollaboration12 中国最大的资料库下载Move from push to pull manufacturingManufacturersDistributors/ WholesalersConsumersSupplier

13、sRetailersManufacturersDistributors/ WholesalersConsumersSuppliersRetailers Make what we will sell, not sell what we will make! Features of SCM13 中国最大的资料库下载PurchasingManufacturingDistributionCustomer Service /SalesAvailable-to-Promise (ATP) Capable-to-Promise (CTP)Move from functional silos to proce

14、ss-oriented business processes (e.g., order-to-cash, cash-to-cash)Integrated Sales and Operations Planning (S&OP)SOURCEMAKEDELIVERSELLFeatures of SCM14 中国最大的资料库下载Optimization of all supply chain activitiesSupply Chain OptimizationSynchronized, Concurrent PlanningDemandPlanningDistributionPlanningMan

15、ufacturing PlanningProcurementPlanningIndependent, Sequential PlanningForecastingDistributionPlanningManufacturing PlanningProcurementPlanningFeatures of SCM15 中国最大的资料库下载PostponementMove to MTO,ATO and CTO from MTSFront-end APS suites support ATP/CTPProduct configurationBack-end integration to trans

16、action systemsInternationalTradeLogisticsWarehouseManagementAdvancedPlanning Scheduling CustomerRelationshipManagementLogisticsManufacturingMaterialsManagementAccounting Human Resources ERPEAIFeatures of SCMSCM16 中国最大的资料库下载More frequent planning means responsive to changing customer needs while decr

17、easing inventoriesTimeTimeAverageSupplyAverageSupplyPlanning CyclePlanning CycleFeatures of SCM17 中国最大的资料库下载e-Business will enable supply chain collaboration among trading partnersManufacturerDistributors/WholesalersSuppliersRetailersCollaborative Demand PlanningCollaborative Logistics PlanningTrans

18、portation servicesDistribution center servicesSynchronized Production SchedulingCollaborative Product DevelopmentFeatures of SCMLogistics Providers18 中国最大的资料库下载Components of E-Supply ChainSupply-chain replenishmentE-procurementCollaborative planningCollaborative product developmentE-logisticsSupply

19、webs19 中国最大的资料库下载Evolution of ITARAPGLPayrollMRPFMISHRMRPIISchedulingplanningDistributionERPAPS/SCMEISEDIE-CommerceBICRME-Business20 中国最大的资料库下载AgendaOverview/Features of SCMSupply Chain Network DesignAdvanced Planning and SchedulingShop Floor ControlMES/MCS 中国最大的资料库下载21 中国最大的资料库下载ManufacturersWholes

20、ale DistributorsSuppliersCustomers Information FlowsGoods FlowSupply Chain Network DesignSupplier ExchangesCustomer ExchangesLogisticsExchangesContract ManufacturersLogistics ProvidersVirtual ManufacturersRetailersLocation decisionCapacity decisionAssignment decision22 中国最大的资料库下载Strategic Planning P

21、roblemsWhich products shall be produced at which locations?How are customers assigned to distribution centers?Where shall new locations be opened?Which locations shall be closed?What are capacity requirements for plants/distribution centers?What is the cost situation within the supply chain?23 中国最大的

22、资料库下载Planning MethodPlanning of location assignment and transportation lanesLocation assignment based on geographical distanceCost optimal location assignmentStructural Network ChangesPlacement of a given number of locations based on geographical distance and costsCost optimal selection of locations

23、24 中国最大的资料库下载Planning ParametersCostTransportation costsProduction costsStorage costsHandling costsProcurement costsLocation costs / Location proceedsFix maintenance costsCosts for opening and closure of locationsPublic subsidiesPenalty costs for delayed or non-fulfilled demand25 中国最大的资料库下载Planning

24、ParametersCapacitiesHandling capacities for plants and distribution centersProduction capacities of plantsDemandCalculation of demand via Demand PlanningSupported by forecast methodsSimulation of demand scenariosVariation of demand26 中国最大的资料库下载Planning ResultsSupply Chain NetworkAssignment of locati

25、onsTransportation lanesAllocation of products to locationsNew locations with geographic positionSelected / not selected locationsProposal for opening or closure of locations27 中国最大的资料库下载Planning ResultsQuantitiesProduction, transport, handling, storage and procurementCostsProduction, transport, hand

26、ling, storage and procurementLocation costsOpening costs, maintenance costs, subsidies, etc.Capacity RequirementsProduction, transport, handling und storage28 中国最大的资料库下载OutlookProfit-oriented planningConsideration of piece-wise linear costs for transport and productionConsideration of storage capaci

27、tiesIntegration of GIS applicationsautomatic calculation of transportation duration and transportation costsexpanded geographic display29 中国最大的资料库下载AgendaOverview/Features of SCMSupply Chain Network DesignAdvanced Planning and SchedulingShop Floor ControlMES/MCS30 中国最大的资料库下载Production LogisticsForec

28、astCustomer order administrationPrimary requirements planningRequirements planningPurchasingCapacity schedulingCapacity adjustmentOrder releaseReservationSequencingDetailed schedulingExecutionFactory data entryShop floor controlPlanningPlanning/schedulingInitiation of implementation functions31 中国最大

29、的资料库下载Typical Planning ProcessSupply/DemandMeetingMRP/ERPManual AdjustmentRelease POReceiving/ReceiptChange Production PlanCan not deliver on timeLong promise timeDead items & shortageCustomer unsatisfied32 中国最大的资料库下载MRP II Planning ProcessTop-down processIterative processMaster PlanningRCCPMRPCRPSF

30、C33 中国最大的资料库下载Problem in IndustrySalesSO confirm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34 中国最大的资料库下载Problem in IndustryShop Floor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Shop Floor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Order

31、 Cancel頻繁未考慮Lead Time35 中国最大的资料库下载Drawbacks in Traditional Production PlanningSequential planningProblem in scheduling logicIndependent demand and supply planningLack of integrationBatch processSingle point planningLack of simulation capability36 中国最大的资料库下载SCM Information System37 中国最大的资料库下载Definiti

32、on of APStheres no precise definition of APS systems, but it is quite intuitive to say that the APS systems resolve the shortcomings of the ERP systems as a planning tool.APS systems consider material requirements and plant capacity to generate new plans, and some of them create a detailed productio

33、n schedule that sequences the production optimally, to achieve the organization goals as well as customers due date. (AMR, 1998)APS systems apply profound advanced technologies to achieve improved plans that take into account most of the factors and constraints that limit the ability to deliver on t

34、ime. (Forrest Research, 1996)38 中国最大的资料库下载Features of APSSynchronized concurrent planningConstraint-based planningOptimized planningReal-time planningDecision support capabilityWhat-if simulationPegging between demand and supplySpeed and performance39 中国最大的资料库下载Synchronized Planning40 中国最大的资料库下载Cons

35、traint-based PlanningAPSConstraintSupplyDemandOutputTime:Purchase LTMfg.LTTrasf.LTDue DateCapacity:Resource loadRoutingMaterial:Alternate PartsECN PartsSourcing RuleDemand:ForecastSales OrderSupply Data:On-handWIPPurchasing OrderOptimal Plan41 中国最大的资料库下载Optimized Technologies in APSDemand PlanningEx

36、ponential SmoothingSystem DynamicsMultiple Linear RegressionProduction Planning & SchedulingLinear Programming/Mixed Integer LPGenetic AlgorithmsSimulation AnnealingHeuristic MethodsDistribution Planning & DeploymentFlow AlgorithmsBranch-and-Bound Algorithm42 中国最大的资料库下载Scope of APSSupply chain strat

37、egic planningSupply chain network planningDemand planning and forecastingInventory planningSupply chain planningSupply planningDistribution planningTransportation planningShop floor operation schedulingShipment scheduling43 中国最大的资料库下载Functions of APS44 中国最大的资料库下载APS是使用現存Transaction系統(ERP)的資訊，以提供快速規劃

38、及排程的智慧型決策支援系統。PurchasingOrder EntryManufacturingLogistics/ShippingERPCurrent SituationFinalPlanSupply Chain PlannerInput DataDemandCapacityMaterialsOutputProduction PlanShipping PlanPromise PlanAPS and ERP45 中国最大的资料库下载Multi-Site PlanningComplex multi-site manufacturing refers to the environment wher

39、e there are multiple sites that are dependent upon each other for material and assemblies.Supply Planning for a complex multi-site manufacturing environment involves the consolidation of data from the individual sites into a corporate consolidation database.46 中国最大的资料库下载Multi-Site PlanningGlobal APS

40、 EngineDemand Planning EngineOrder Promising EngineAPSEngineAPSEngineAPSEngineMaster PlanMaster PlanMaster PlanSupply PlanSupply PlanSupply PlanDemand PlanSupply Plan47 中国最大的资料库下载*Source: AMR, 1996Performance ResultsLate Order25-50% ImprovementOrder Lead Time10-40% ImprovementPlanning Cycle95% Impro

41、vementProduction Lead Time10-50% ImprovementInventory10-60% ImprovementOperating Expense10-50% ImprovementThroughput2-5% Improvement48 中国最大的资料库下载AgendaOverview/Features of SCMSupply Chain Network DesignAdvanced Planning and SchedulingShop Floor ControlMES/MCS49 中国最大的资料库下载Purpose of Shop Floor Contro

42、l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50 中国最大的资料库下载Shop Floor Control System51 中国最大的资料库下载Functions of Shop Floor ControlOrder review/releaseDetailed shop floor operations schedulingData collection/monitoringControl/feedbackOrder disposition52 中国最大的资料库下载Order Review and Release扮演一個過濾機制，控制訂單進入現場的流量53 中国最大的

43、资料库下载Focus of OR/RAvailability of materialsRequired capacityRequired machines and toolingsReal-time production statusVerify MRP plansConfirm/modify BOM structureConfirm/modify routingEvaluate production loads in shop floorCriteria of performance evaluation54 中国最大的资料库下载Operations SchedulingWork cente

44、r oriented schedulingWork order oriented schedulingBackward schedulingForward schedulingFinite schedulingDispatching55 中国最大的资料库下载Data Collection and MonitorBarcodeOptical character recognitionMagnetic stripeVoice recognitionRadio frequency identificationMachine vision systemBlue tooth56 中国最大的资料库下载Co

45、ntrol and FeedbackOrder problems vs. Resources problemsIs it solvable? What is the solution?Adjust and improveInformation feedback 57 中国最大的资料库下载Order DispositionOrder completionAS plannedOrder cancellationMaterials shortageRelease previously assigned resourcesEvaluate production performanceDefine an

46、d explain specific unexpected conditions/solutions58 中国最大的资料库下载Shop Floor Control System-Another view59 中国最大的资料库下载AgendaOverview/Features of SCMSupply Chain Network DesignAdvanced Planning and SchedulingShop Floor ControlMES/MCS60 中国最大的资料库下载Relationships of ERP/APS/MES/MCSERPAPSMCSMES61 中国最大的资料库下载In

47、teractions Between ERP/APS and MES62 中国最大的资料库下载Definition of MES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，並即時收集與回饋現場生產資訊。63 中国最大的资料库下载Functions of MES64 中国最大的资料库下载Order & Operations ManagementSelect orderAssign routingDispatchingTrace WIPOrder progress65 中国最大的资料库下载Material & Resource ManagementMonitor materials supplyDeplo