供应链规划与执行模组知识讲解英文

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PC無法如期交交貨Hub會造成投資資風險PC/MC插單Cancel訂單訂單交期變變更頻繁Yield和Rework造成交期Delay無法確認真真正的產能能與瓶頸作作業替代料無法法掌控ECN頻繁，易產產生呆料34ProbleminIndustryShopFloor開製令前無無法確認料料是否備齊齊臨時缺料Yield和Rework造成大量未未結案工單單ShopFloor催MC，MC催Buyer，Buyer催Supplier產能規劃不不合理，無無法執行Buyer無法確認到到底欠哪些些料追料頻繁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是使用現存Transaction系統(ERP)的資訊，以提提供快速規劃劃及排程的智智慧型決策支支援系統。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將生產規劃單單位所規劃的的生產訂單(PO)有效效的轉變成實實際成品的產產出50ShopFloorControlSystem51FunctionsofShopFloorControlOrderreview/releaseDetailedshopflooroperationsschedulingDatacollection/monitoringControl/feedbackOrderdisposition52OrderReviewandRelease扮演一個過濾濾機制，控制制訂單進入現現場的流量53FocusofOR/RAvailabilityofmaterialsRequiredcapacityRequiredmachinesandtoolingsReal-timeproductionstatusVerifyMRPplansConfirm/modifyBOMstructureConfirm/modifyroutingEvaluateproductionloadsinshopfloorCriteriaofperformanceevaluation54OperationsSchedulingWorkcenterorientedschedulingWorkorderorientedschedulingBackwardschedulingForwardschedulingFiniteschedulingDispatching55DataCollectionandMonitorBarcodeOpticalcharacterrecognitionMagneticstripeVoicerecognitionRadiofrequencyidentificationMachinevisionsystemBluetooth56ControlandFeedbackOrderproblemsvs.ResourcesproblemsIsitsolvable?Whatisthesolution?AdjustandimproveInformationfeedback57OrderDispositionOrdercompletionASplannedOrdercancellationMaterialsshortageReleasepreviouslyassignedresourcesEvaluateproductionperformanceDefineandexplainspecificunexpectedconditions/solutions58ShopFloorControlSystem-Anotherview59AgendaOverview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS60RelationshipsofERP/APS/MES/MCSERPAPSMCSMES61InteractionsBetweenERP/APSandMES62DefinitionofMES將加工現場場中的原物物料、半成成品、成品品、機器、、時間、成成本等資訊訊以動態且且即時的方方式來收集集、匯整與與表達，並並追蹤與管管制目前正正在進行中中的各項製製造作業的的一個資訊訊系統(APICS)。其上層銜接接APS的生產規劃劃結果，