供应链管理规划与执行

1供應鏈規劃與執行模組世新大學資管系鄒慶士副教授2AgendaOverview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS3EnterprisefunctionalsiloswithconflictinggoalsPurchasingManufacturingDistributionCustomerService/SalesFewchange-oversStableschedulesLongrunlengthsHighinventoriesHighservicelevelsRegionalstocksSOURCEMAKEDELIVERSELL

Lowpur-chasepriceMultiplevendorsLowinvent-oriesLowtrans-portationOverviewofSCM-Issues4OverviewandtargetsofSCM

DefinitionofSupplyChainManagement:SupplyChainManagementdescribesallkindofactivitiesacrossmultiplecompaniesorlocationstooptimizethemanufacturingofproducts.Herebyconcerningallinterfacesonoperationalandstrategiclevelforinvolvedassociates.

Mainfocus

DevelopmentofheterogeneousglobalproductionnetworksIncreasedintegrationofadvancedtechnologies

Minimzingcostsforinventoriesanddeliveries

Longterm

relationships(customer/supplierbinding)

Customersatisfaction

ByERP-BasisSCM-ToolsInternet5OverviewandtargetsofSCMBuysIngredientsandComponentsMakesa

ProductMovesittoa

Distribution

CenterStoresitat

DistributionCentersStoresitinaWarehouseMovesit

toStoresStoresitin

theStoreSellsittoConsumersMultiEnterpriseSupplyChainsSource:I2-Technologies6OverviewandtargetsofSCM

Integrationofsuppliersinplanninginconsiderationof...

SuppliersinventoriesSuppliersmanufacturingcapacitiesTransporttimesandcapacitiesReductionofowninventories7

IntegratedplanningofsupplychainsleadstoReductionofinventoriesCostsavingsCapabilitytomeetpromiseddeliverydates

Increasedcustomersatisfaction Intensifiedcustomerbinding PerspectivetoextendthesalesmarketOverviewandtargetsofSCM8Prerequisitesforsuccess

NomanagementmethodguaranteesitselfforsuccessTypeofproductleadstospecialtypeofsupplychainPrimarilyfunctionalproducts

Don’tchangemuchovertimeLonglifecyclesPredictabledemandStabilityinvitescompetitionLeadsoftentolowprofitmarginsPrimarilyinnovativeproducts

EnableshigherprofitmarginsShortlifecycle(typicallyfewmonth)VolatiledemandNewnessmakesdemandunpredictableImportanceofearlysales9PrerequisitesforsuccessPrimarilyfunctionalproductsSupplyatlowestcoststopredictabledemandHighutilizationrateofcapacityMinimizeinventoriesShortleadtimeasitdoesn’tincreasecostsSelectsuppliersprimarilyforcostsandqualityPhysicalefficiencyMinimizecostsby

PhysicalefficiencyPrimarilyinnovativeproductsRespondquicklytounpredictabledemandDeployexcessbuffercapacityDeploysignificantbufferstocksInvestaggressivelytoreduceleadtimeSelectsuppliersprimarilyforspeed,flexibilityandqualityResponsivenesstomarketMinimizecostsbyHighestresponsivenesstomarketMinimizeriskofshortagesorexcesssupply10PrerequisitesforsuccessEfficientResponsiveFunctionalInnovativematchmatchmismatchmismatchUseofSCMsoftwaretoolslikeAPO11Prerequisitesforsuccess12SCMBusinessProcessesTechnologyhelpsenableavarietyofSCMbusinessprocessesPushtopullProcessorientationOptimizationPostponementMorefrequentplanningCollaboration13MovefrompushtopullmanufacturingManufacturersDistributors/WholesalersConsumersSuppliersRetailersManufacturersDistributors/

WholesalersConsumersSuppliersRetailersMakewhatwewillsell,notsellwhatwewillmake!!FeaturesofSCM14PurchasingManufacturingDistributionCustomerService/SalesAvailable-to-Promise(ATP)Capable-to-Promise(CTP)Movefromfunctionalsilostoprocess-orientedbusinessprocesses(e.g.,order-to-cash,cash-to-cash)IntegratedSalesandOperationsPlanning(S&OP)SOURCEMAKEDELIVERSELLFeaturesofSCM15OptimizationofallsupplychainactivitiesSupplyChainOptimizationSynchronized,ConcurrentPlanningDemandPlanningDistributionPlanningManufacturingPlanningProcurementPlanningIndependent,SequentialPlanningForecastingDistributionPlanningManufacturingPlanningProcurementPlanningFeaturesofSCM16PostponementMovetoMTO,ATOandCTOfromMTSFront-endAPSsuitessupportATP/CTPProductconfigurationBack-endintegrationtotransactionsystemsInternationalTradeLogisticsWarehouseManagementAdvancedPlanningSchedulingCustomerRelationshipManagementLogisticsManufacturingMaterialsManagementAccountingHumanResourcesERPEAIFeaturesofSCMSCM17MorefrequentplanningmeansresponsivetochangingcustomerneedswhiledecreasinginventoriesTimeTimeAverageSupplyAverageSupplyPlanningCyclePlanningCycleFeaturesofSCM18e-BusinesswillenablesupplychaincollaborationamongtradingpartnersManufacturerDistributors/WholesalersSuppliersRetailersCollaborativeDemandPlanningCollaborativeLogisticsPlanningTransportationservicesDistributioncenterservicesSynchronizedProductionSchedulingCollaborativeProductDevelopmentFeaturesofSCMLogisticsProviders19ComponentsofE-SupplyChainSupply-chainreplenishmentE-procurementCollaborativeplanningCollaborativeproductdevelopmentE-logisticsSupplywebs20EvolutionofITARAPGLPayrollMRPFMISHRMRPIISchedulingplanningDistributionERPAPS/SCMEISEDIE-CommerceBICRME-Business21Agenda22ManufacturersWholesaleDistributorsSuppliersCustomersInformationFlowsGoodsFlowSupplyChainNetworkDesignSupplierExchangesCustomerExchangesLogisticsExchangesContractManufacturersLogisticsProvidersVirtualManufacturersRetailersLocationdecisionCapacitydecisionAssignmentdecision23StrategicPlanningProblemsWhichproductsshallbeproducedatwhichlocations?Howarecustomersassignedtodistributioncenters?Whereshallnewlocationsbeopened?Whichlocationsshallbeclosed?Whatarecapacityrequirementsforplants/distributioncenters?Whatisthecostsituationwithinthesupplychain?24PlanningMethodPlanningoflocationassignmentandtransportationlanesLocationassignmentbasedongeographicaldistanceCostoptimallocationassignmentStructuralNetworkChangesPlacementofagivennumberoflocationsbasedongeographicaldistanceandcostsCostoptimalselectionoflocations25PlanningParametersCostTransportationcostsProductioncostsStoragecostsHandlingcostsProcurementcostsLocationcosts/LocationproceedsFixmaintenancecostsCostsforopeningandclosureoflocationsPublicsubsidiesPenaltycostsfordelayedornon-fulfilleddemand26PlanningParametersCapacitiesHandlingcapacitiesforplantsanddistributioncentersProductioncapacitiesofplantsDemandCalculationofdemandviaDemandPlanningSupportedbyforecastmethodsSimulationofdemandscenariosVariationofdemand27PlanningResultsSupplyChainNetworkAssignmentoflocationsTransportationlanesAllocationofproductstolocationsNewlocationswithgeographicpositionSelected/notselectedlocationsProposalforopeningorclosureoflocations28PlanningResultsQuantitiesProduction,transport,handling,storageandprocurementCostsProduction,transport,handling,storageandprocurementLocationcostsOpeningcosts,maintenancecosts,subsidies,etc.CapacityRequirementsProduction,transport,handlingundstorage29OutlookProfit-orientedplanningConsiderationofpiece-wiselinearcostsfortransportandproductionConsiderationofstoragecapacitiesIntegrationofGISapplicationsautomaticcalculationoftransportationdurationandtransportationcostsexpandedgeographicdisplay30AgendaOverview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS31ProductionLogisticsForecastCustomerorderadministrationPrimaryrequirementsplanningRequirementsplanningPurchasingCapacityschedulingCapacityadjustmentOrderreleaseReservationSequencingDetailedschedulingExecutionFactorydataentryShopfloorcontrolPlanningPlanning/schedulingInitiationofimplementationfunctions32TypicalPlanningProcessSupply/DemandMeetingMRP/ERPManualAdjustmentReleasePOReceiving/ReceiptChangeProductionPlanCannotdeliverontimeLongpromisetimeDeaditems&shortageCustomerunsatisfied33MRPIIPlanningProcessTop-downprocessIterativeprocessMasterPlanningRCCPMRPCRPSFC34ProbleminIndustrySalesSOconfirm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35ProbleminIndustryShopFloor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LeadTime36DrawbacksinTraditionalProductionPlanningSequentialplanningProbleminschedulinglogicIndependentdemandandsupplyplanningLackofintegrationBatchprocessSinglepointplanningLackofsimulationcapability37SCMInformationSystem38DefinitionofAPS…there’snoprecisedefinitionofAPSsystems,butitisquiteintuitivetosaythattheAPSsystemsresolvetheshortcomingsoftheERPsystemsasaplanningtool….APSsystemsconsidermaterialrequirementsandplantcapacitytogeneratenewplans,andsomeofthemcreateadetailedproductionschedulethatsequencestheproductionoptimally,toachievetheorganizationgoalsaswellascustomer’sduedate.(AMR,1998)…APSsystemsapplyprofoundadvancedtechnologiestoachieveimprovedplansthattakeintoaccountmostofthefactorsandconstraintsthatlimittheabilitytodeliverontime.(ForrestResearch,1996)39FeaturesofAPSSynchronizedconcurrentplanningConstraint-basedplanningOptimizedplanningReal-timeplanningDecisionsupportcapabilityWhat-ifsimulationPeggingbetweendemandandsupplySpeedandperformance40SynchronizedPlanning41Constraint-basedPlanningAPSConstraintSupplyDemandOutputTime:PurchaseLTMfg.LTTrasf.LTDueDateCapacity:ResourceloadRoutingMaterial:AlternatePartsECNPartsSourcingRuleDemand:ForecastSalesOrderSupplyData:On-handWIPPurchasingOrderOptimalPlan42OptimizedTechnologiesinAPSDemandPlanningExponentialSmoothingSystemDynamicsMultipleLinearRegressionProductionPlanning&SchedulingLinearProgramming/MixedIntegerLPGeneticAlgorithmsSimulationAnnealingHeuristicMethodsDistributionPlanning&DeploymentFlowAlgorithmsBranch-and-BoundAlgorithm43ScopeofAPSSupplychainstrategicplanningSupplychainnetworkplanningDemandplanningandforecastingInventoryplanningSupplychainplanningSupplyplanningDistributionplanningTransportationplanningShopflooroperationschedulingShipmentscheduling44FunctionsofAPS45APS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/ShippingERPCurrentSituationFinalPlanSupplyChainPlannerInputDataDemandCapacityMaterialsOutputProductionPlanShippingPlanPromisePlanAPSandERP46Multi-SitePlanningComplexmulti-sitemanufacturingreferstotheenvironmentwheretherearemultiplesitesthataredependentuponeachotherformaterialandassemblies.SupplyPlanningforacomplexmulti-sitemanufacturingenvironmentinvolvestheconsolidationofdatafromtheindividualsitesintoacorporateconsolidationdatabase.47Multi-SitePlanningGlobalAPSEngineDemandPlanningEngineOrderPromisingEngineAPSEngineAPSEngineAPSEngineMasterPlanMasterPlanMasterPlanSupplyPlanSupplyPlanSupplyPlanDemandPlanSupplyPlan48*Source:AMR,1996PerformanceResultsLateOrder25-50%ImprovementOrderLeadTime10-40%ImprovementPlanningCycle95%ImprovementProductionLeadTime10-50%ImprovementInventory10-60%ImprovementOperatingExpense10-50%ImprovementThroughput2-5%Improvement49AgendaOverview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS50PurposeofShopFloorControl將生產規劃單單位所規劃的的生產訂單(PO)有效的轉變成成實際成品的的產出51ShopFloorControlSystem52FunctionsofShopFloorControlOrderreview/releaseDetailedshopflooroperationsschedulingDatacollection/monitoringControl/feedbackOrderdisposition53OrderReviewandRelease扮演一個過濾濾機制，控制制訂單進入現現場的流量54FocusofOR/RAvailabilityofmaterialsRequiredcapacityRequiredmachinesandtoolingsReal-timeproductionstatusVerifyMRPplansConfirm/modifyBOMstructureConfirm/modifyroutingEvaluateproductionloadsinshopfloorCriteriaofperformanceevaluation55OperationsSchedulingWorkcenterorientedschedulingWorkorderorientedschedulingBackwardschedulingForwardschedulingFiniteschedulingDispatching56DataCollectionandMonitorBarcodeOpticalcharacterrecognitionMagneticstripeVoicerecognitionRadiofrequencyidentificationMachinevisionsystemBluetooth57ControlandFeedbackOrderproblemsvs.ResourcesproblemsIsitsolvable?Whatisthesolution?AdjustandimproveInformationfeedback58OrderDispositionOrdercompletionASplannedOrdercancellationMaterialsshortageReleasepreviouslyassignedresourcesEvaluateproductionperformanceDefineandexplainspecificunexpectedconditions/solutions59ShopFloorControlSystem-Anotherview60AgendaOverview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS61RelationshipsofERP/APS/MES/MCSERPAPSMCSMES62InteractionsBetweenERP/APSandMES63DefinitionofMES將加工現場中中的原物料、、半成品、成成品、機器、、時間、成本本等資訊以動動態且即時的的方式來收集集、匯整與表表達，並追蹤蹤與管制目前前正在進行中中的各項製造造作業的一個個資訊系統(APICS)。其上層銜接APS的生產規劃結結果，以進行行即時性