供应链规划与执行模组(一)

供應鏈規劃與執行模組世新大學資管系鄒慶士副教授1AgendaOverview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS2EnterprisefunctionalsiloswithconflictinggoalsPurchasingManufacturingDistributionCustomerService/SalesFewchange-oversStableschedulesLongrunlengthsHighinventoriesHighservicelevelsRegionalstocksSOURCEMAKEDELIVERSELL

Lowpur-chasepriceMultiplevendorsLowinvent-oriesLowtrans-portationOverviewofSCM-Issues3OverviewandtargetsofSCM

DefinitionofSupplyChainManagement:SupplyChainManagementdescribesallkindofactivitiesacrossmultiplecompaniesorlocationstooptimizethemanufacturingofproducts.Herebyconcerningallinterfacesonoperationalandstrategiclevelforinvolvedassociates.

Mainfocus

DevelopmentofheterogeneousglobalproductionnetworksIncreasedintegrationofadvancedtechnologies

Minimzingcostsforinventoriesanddeliveries

Longterm

relationships(customer/supplierbinding)

Customersatisfaction

ByERP-BasisSCM-ToolsInternet4OverviewandtargetsofSCMBuysIngredientsandComponentsMakesa

ProductMovesittoa

Distribution

CenterStoresitat

DistributionCentersStoresitinaWarehouseMovesit

toStoresStoresitin

theStoreSellsittoConsumersMultiEnterpriseSupplyChainsSource:I2-Technologies5OverviewandtargetsofSCM

Integrationofsuppliersinplanninginconsiderationof...

SuppliersinventoriesSuppliersmanufacturingcapacitiesTransporttimesandcapacitiesReductionofowninventories6

IntegratedplanningofsupplychainsleadstoReductionofinventoriesCostsavingsCapabilitytomeetpromiseddeliverydates

Increasedcustomersatisfaction Intensifiedcustomerbinding PerspectivetoextendthesalesmarketOverviewandtargetsofSCM7Prerequisitesforsuccess

NomanagementmethodguaranteesitselfforsuccessTypeofproductleadstospecialtypeofsupplychainPrimarilyfunctionalproducts

Don’tchangemuchovertimeLonglifecyclesPredictabledemandStabilityinvitescompetitionLeadsoftentolowprofitmarginsPrimarilyinnovativeproducts

EnableshigherprofitmarginsShortlifecycle(typicallyfewmonth)VolatiledemandNewnessmakesdemandunpredictableImportanceofearlysales8PrerequisitesforsuccessPrimarilyfunctionalproductsSupplyatlowestcoststopredictabledemandHighutilizationrateofcapacityMinimizeinventoriesShortleadtimeasitdoesn’tincreasecostsSelectsuppliersprimarilyforcostsandqualityPhysicalefficiencyMinimizecostsby

PhysicalefficiencyPrimarilyinnovativeproductsRespondquicklytounpredictabledemandDeployexcessbuffercapacityDeploysignificantbufferstocksInvestaggressivelytoreduceleadtimeSelectsuppliersprimarilyforspeed,flexibilityandqualityResponsivenesstomarketMinimizecostsbyHighestresponsivenesstomarketMinimizeriskofshortagesorexcesssupply9PrerequisitesforsuccessEfficientResponsiveFunctionalInnovativematchmatchmismatchmismatchUseofSCMsoftwaretoolslikeAPO10Prerequisitesforsuccess11SCMBusinessProcessesTechnologyhelpsenableavarietyofSCMbusinessprocessesPushtopullProcessorientationOptimizationPostponementMorefrequentplanningCollaboration12MovefrompushtopullmanufacturingManufacturersDistributors/WholesalersConsumersSuppliersRetailersManufacturersDistributors/

WholesalersConsumersSuppliersRetailersMakewhatwewillsell,notsellwhatwewillmake!!FeaturesofSCM13PurchasingManufacturingDistributionCustomerService/SalesAvailable-to-Promise(ATP)Capable-to-Promise(CTP)Movefromfunctionalsilostoprocess-orientedbusinessprocesses(e.g.,order-to-cash,cash-to-cash)IntegratedSalesandOperationsPlanning(S&OP)SOURCEMAKEDELIVERSELLFeaturesofSCM14OptimizationofallsupplychainactivitiesSupplyChainOptimizationSynchronized,ConcurrentPlanningDemandPlanningDistributionPlanningManufacturingPlanningProcurementPlanningIndependent,SequentialPlanningForecastingDistributionPlanningManufacturingPlanningProcurementPlanningFeaturesofSCM15PostponementMovetoMTO,ATOandCTOfromMTSFront-endAPSsuitessupportATP/CTPProductconfigurationBack-endintegrationtotransactionsystemsInternationalTradeLogisticsWarehouseManagementAdvancedPlanningSchedulingCustomerRelationshipManagementLogisticsManufacturingMaterialsManagementAccountingHumanResourcesERPEAIFeaturesofSCMSCM16MorefrequentplanningmeansresponsivetochangingcustomerneedswhiledecreasinginventoriesTimeTimeAverageSupplyAverageSupplyPlanningCyclePlanningCycleFeaturesofSCM17e-BusinesswillenablesupplychaincollaborationamongtradingpartnersManufacturerDistributors/WholesalersSuppliersRetailersCollaborativeDemandPlanningCollaborativeLogisticsPlanningTransportationservicesDistributioncenterservicesSynchronizedProductionSchedulingCollaborativeProductDevelopmentFeaturesofSCMLogisticsProviders18ComponentsofE-SupplyChainSupply-chainreplenishmentE-procurementCollaborativeplanningCollaborativeproductdevelopmentE-logisticsSupplywebs19EvolutionofITARAPGLPayrollMRPFMISHRMRPIISchedulingplanningDistributionERPAPS/SCMEISEDIE-CommerceBICRME-Business20Agenda21ManufacturersWholesaleDistributorsSuppliersCustomersInformationFlowsGoodsFlowSupplyChainNetworkDesignSupplierExchangesCustomerExchangesLogisticsExchangesContractManufacturersLogisticsProvidersVirtualManufacturersRetailersLocationdecisionCapacitydecisionAssignmentdecision22StrategicPlanningProblemsWhichproductsshallbeproducedatwhichlocations?Howarecustomersassignedtodistributioncenters?Whereshallnewlocationsbeopened?Whichlocationsshallbeclosed?Whatarecapacityrequirementsforplants/distributioncenters?Whatisthecostsituationwithinthesupplychain?23PlanningMethodPlanningoflocationassignmentandtransportationlanesLocationassignmentbasedongeographicaldistanceCostoptimallocationassignmentStructuralNetworkChangesPlacementofagivennumberoflocationsbasedongeographicaldistanceandcostsCostoptimalselectionoflocations24PlanningParametersCostTransportationcostsProductioncostsStoragecostsHandlingcostsProcurementcostsLocationcosts/LocationproceedsFixmaintenancecostsCostsforopeningandclosureoflocationsPublicsubsidiesPenaltycostsfordelayedornon-fulfilleddemand25PlanningParametersCapacitiesHandlingcapacitiesforplantsanddistributioncentersProductioncapacitiesofplantsDemandCalculationofdemandviaDemandPlanningSupportedbyforecastmethodsSimulationofdemandscenariosVariationofdemand26PlanningResultsSupplyChainNetworkAssignmentoflocationsTransportationlanesAllocationofproductstolocationsNewlocationswithgeographicpositionSelected/notselectedlocationsProposalforopeningorclosureoflocations27PlanningResultsQuantitiesProduction,transport,handling,storageandprocurementCostsProduction,transport,handling,storageandprocurementLocationcostsOpeningcosts,maintenancecosts,subsidies,etc.CapacityRequirementsProduction,transport,handlingundstorage28OutlookProfit-orientedplanningConsiderationofpiece-wiselinearcostsfortransportandproductionConsiderationofstoragecapacitiesIntegrationofGISapplicationsautomaticcalculationoftransportationdurationandtransportationcostsexpandedgeographicdisplay29AgendaOverview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS30ProductionLogisticsForecastCustomerorderadministrationPrimaryrequirementsplanningRequirementsplanningPurchasingCapacityschedulingCapacityadjustmentOrderreleaseReservationSequencingDetailedschedulingExecutionFactorydataentryShopfloorcontrolPlanningPlanning/schedulingInitiationofimplementationfunctions31TypicalPlanningProcessSupply/DemandMeetingMRP/ERPManualAdjustmentReleasePOReceiving/ReceiptChangeProductionPlanCannotdeliverontimeLongpromisetimeDeaditems&shortageCustomerunsatisfied32MRPIIPlanningProcessTop-downprocessIterativeprocessMasterPlanningRCCPMRPCRPSFC33ProbleminIndustrySalesSOconfirm時間太長長PC無法如期期交貨Hub會造成投投資風險險PC/MC插單Cancel訂單訂單交期期變更頻頻繁Yield和Rework造成交期期Delay無法確認認真正的的產能與與瓶頸作作業替代料無無法掌控控ECN頻繁，易易產生呆呆料34ProbleminIndustryShopFloor開製令前前無法確確認料是是否備齊齊臨時缺料料Yield和Rework造成大量量未結案案工單ShopFloor催MC，MC催Buyer，Buyer催Supplier產能規劃劃不合理理，無法法執行Buyer無法確認認到底欠欠哪些料料追料頻繁繁OrderCancel頻繁未考慮LeadTime35DrawbacksinTraditionalProductionPlanningSequentialplanningProbleminschedulinglogicIndependentdemandandsupplyplanningLackofintegrationBatchprocessSinglepointplanningLackofsimulationcapability36SCMInformationSystem37DefinitionofAPS…there’snoprecisedefinitionofAPSsystems,butitisquiteintuitivetosaythattheAPSsystemsresolvetheshortcomingsoftheERPsystemsasaplanningtool….APSsystemsconsidermaterialrequirementsandplantcapacitytogeneratenewplans,andsomeofthemcreateadetailedproductionschedulethatsequencestheproductionoptimally,toachievetheorganizationgoalsaswellascustomer’sduedate.(AMR,1998)…APSsystemsapplyprofoundadvancedtechnologiestoachieveimprovedplansthattakeintoaccountmostofthefactorsandconstraintsthatlimittheabilitytodeliverontime.(ForrestResearch,1996)38FeaturesofAPSSynchronizedconcurrentplanningConstraint-basedplanningOptimizedplanningReal-timeplanningDecisionsupportcapabilityWhat-ifsimulationPeggingbetweendemandandsupplySpeedandperformance39SynchronizedPlanning40Constraint-basedPlanningAPSConstraintSupplyDemandOutputTime:PurchaseLTMfg.LTTrasf.LTDueDateCapacity:ResourceloadRoutingMaterial:AlternatePartsECNPartsSourcingRuleDemand:ForecastSalesOrderSupplyData:On-handWIPPurchasingOrderOptimalPlan41OptimizedTechnologiesinAPSDemandPlanningExponentialSmoothingSystemDynamicsMultipleLinearRegressionProductionPlanning&SchedulingLinearProgramming/MixedIntegerLPGeneticAlgorithmsSimulationAnnealingHeuristicMethodsDistributionPlanning&DeploymentFlowAlgorithmsBranch-and-BoundAlgorithm42ScopeofAPSSupplychainstrategicplanningSupplychainnetworkplanningDemandplanningandforecastingInventoryplanningSupplychainplanningSupplyplanningDistributionplanningTransportationplanningShopflooroperationschedulingShipmentscheduling43FunctionsofAPS44APS是使用用現存存Transaction系統(ERP)的資訊訊，以以提供供快速速規劃劃及排排程的的智慧慧型決決策支支援系系統。PurchasingOrderEntryManufacturingLogistics/ShippingERPCurrentSituationFinalPlanSupplyChainPlannerInputDataDemandCapacityMaterialsOutputProductionPlanShippingPlanPromisePlanAPSandERP45Multi-SitePlanningComplexmulti-sitemanufacturingreferstotheenvironmentwheretherearemultiplesitesthataredependentuponeachotherformaterialandassemblies.SupplyPlanningforacomplexmulti-sitemanufacturingenvironmentinvolvestheconsolidationofdatafromtheindividualsitesintoacorporateconsolidationdatabase.46Multi-SitePlanningGlobalAPSEngineDemandPlanningEngineOrderPromisingEngineAPSEngineAPSEngineAPSEngineMasterPlanMasterPlanMasterPlanSupplyPlanSupplyPlanSupplyPlanDemandPlanSupplyPlan47*Source:AMR,1996PerformanceResultsLateOrder25-50%ImprovementOrderLeadTime10-40%ImprovementPlanningCycle95%ImprovementProductionLeadTime10-50%ImprovementInventory10-60%ImprovementOperatingExpense10-50%ImprovementThroughput2-5%Improvement48AgendaOverview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS49PurposeofShopFloorControl將生產產規劃劃單位位所規規劃的的生產產訂單單(PO)有效效的轉轉變成成實際際成品品的產產出50ShopFloorControlSystem51FunctionsofShopFloorControlOrderreview/releaseDetailedshopflooroperationsschedulingDatacollection/monitoringControl/feedbackOrderdisposition52OrderReviewandRelease扮演演一一個個過過濾濾機機制制，，控控制制訂訂單單進進入入現現場場的的流流量量53FocusofOR/RAvailabilityofmaterialsRequiredcapacityRequiredmachinesandtoolingsReal-timeproductionstatusVerifyMRPplansConfirm/modifyBOMstructureConfirm/modifyroutingEvaluateproductionloadsinshopfloorCriteriaofperformanceevaluation54OperationsSchedulingWorkcenterorientedschedulingWorkorderorientedschedulingBackwardschedulingForwardschedulingFiniteschedulingDispatching55DataCollectionandMonitorBarcodeOpticalcharacterrecognitionMagneticstripeVoicerecognitionRadiofrequencyidentificationMachinevisionsystemBluetooth56ControlandFeedbackOrderproblemsvs.ResourcesproblemsIsitsolvable?Whatisthesolution?AdjustandimproveInformationfeedback57OrderDispositionOrdercompletionASplannedOrdercancellationMaterialsshortageReleasepreviouslyassignedresourcesEvaluateproductionperformanceDefineandexplainspecificunexpectedconditions/solutions58ShopFloorControlSystem-Anotherview59AgendaOverview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS60RelationshipsofERP/APS/MES/MCSERPAPSMCSMES61InteractionsBetweenERP/APSandMES62DefinitionofMES將加工現現場中的的原物料料、半成成品、成成品、機機器、時時間、成成本等資資訊以動動態且即即時的方方式來收收集、匯匯整與表表達，並並追蹤與與管制目目前正在在進行中中的各項項製造作作業的一一個資訊訊系統(APICS)。。其上層銜銜接APS的生產規規劃結果果