Session Seven – Detailed Capacity Management　　第七部分-详细的容量管理

--SessionSeven–DetailedCapacityManagement-CapacityRequirementsPlanning#Summarizethephasesofthecapacityrequirementsplanningprocess>CRPpreparestheoperationplanforexecutioninthejobandbatch(fordiscreteproducts)manufacturingenvironment.DetermineLoadonresourcesoveraperiodoftimeSimulationschedulingofloadatworkcenterbyperiodDetermineLoadonresourcesoveraperiodoftimeSimulationschedulingofloadatworkcenterbyperiodResolveload-capacityimbalancesReviseMPSifnotresolvedPrepareoperationplanforexecutionResolveload-capacityimbalancesReviseMPSifnotresolvedPrepareoperationplanforexecutionCreateworkcenterloadreportCapacityRequirementsPlanningCapacitymanagement–Thefunctionofestablishing,measuring,monitoring,andadjustinglimitsorlevelsofcapacity,inordertoexecuteallmanufacturingschedules…Capacitymanagementisabusinessprocessthatincludesthefollowing:Capacityplanning:Theprocessofdeterminingtheresourcesneededtoachievethepriorityplansandthemethodsrequiredtomakecapacityavailable.Capacitycontrol:Theprocessofmonitoringproductionoutput,comparingitwithcapacityplans,andtakingcorrectiveactionwhenneeded.Itoccursduringproductionactivitycontrol.>DeterminetheLoad>>SourcesofloadPlannedorderreleasesfromMRPOpenorderstatusinformationfromproductioncontrolProductreworkrequirementScrapthatexceedsexpectationQualityrecalls>>UnitsofMeasureWorkloadsandcapacitiesaremeasuredintermsofhours.Standardhourscanbeexpressedinmachineorlaborhours,dependingonwhetheraworkcenterismachine-pacedorlabor-paced.#ExplaintheroleofsimulationschedulingindeterminingworkcenterloadprofileThepurposeofthesimulation(alsocalledmodeling)istodetermineifadequateresourcesareavailableduringtheperiodwhentheyareactuallyneeded.Theschedulingmethodmostcommonlyusedforplannedorderordersisbackwardscheduling.Theresultsofthesimulatedschedulingareusedtocreateworkcenterloadreportsorprofilesthatcompareloadandavailablecapacity.#DescribethepurposeoftheworkcenterloadreportTheworkcenterloadreportiscommonlyrepresentedbyabarchart.Barchartsandlinegraphsareeasytointerpretandreadilyrevealwhetherunderloadoroverloadconditionsexistinparticulartimeperiods.#ListatleastfiveactionsthatcanbetakentoincreasecapacityduringCRP#ListatleastfiveactionsthatcanbetakentoredistributeloadduringCRPIna“planmaterialfirst”ormaterial-dominatedapproachtoplanning,plannersdependontheflexibilityofcapacity,whichenablesthemtomeettheduedatepriorities.Methodstobalancetheloadandcapacity:>IncreasecapacityShorttermMediumtermLongtermScheduleovertimeReassignpersonnel(temp.)Addequipment(rented)SubcontractAddextrashiftsAddpersonnelReducesetuptimeOutsourceworktooutsidemanufacturingfirms>ReduceloadShorttermRemarkReducelotsizeHoldordersinproductioncontrolChangeMPSNotedreducinglotsizewillreducetherun-timeload,butatexpenseofadditionalsetups.>ReducecapacityShorttermMediumtermReassignpersonnel(temp.)Eliminateshiftsorreducelengthofshiftsworked>IncreaseloadShorttermMediumtermReleaseorderearlier(temp.)IncreaselotsizesIncreaseMPS(leastoption)SubcontractworkforothersMakeitemsnormallypurchasedorsubcontracted>RedistributeloadforloadlevelingUsealternativeworkcentersUsealternativeroutinesModifyoperationprioritiesRunoverlappingoperationsoruselotsplitting#Describewhenitisappropriatetochangethemasterproductionscheduletoresolveimbalancesbetweenload-capacityimbalances>RevisingtheMPSisashort-termsolution.Chronicoverloadingofproductionisasignthattoachieverevenueandcustomerservicegoals,theplannerneedstoincreasecapacity.>Resourcecontention–ThesituationwherecapacityappearstobesufficientataCRPlevel,butisinfactnot,duetothetimingofproductsthroughthesameworkcenter.Itresultsindelaysandremainsundetectedinthecapacityplanunlessfinitecapacityplanningmethodsareemployed.>Secondaryconstraint–Thesituationwhereaworkcenterhasseveralmachinescapableofproducingacertainpart.Ifonlysomeofthemhavethetoolingforaspecificoperation,theresultiswhatiscalledsecondaryconstraint.Thesamethingcanhappenwithpersonnel.Apartialsolutionistoproduceadditionalloadreportsshowingcapacityrequirementsforthesecondaryconstraint.-CapacityManagementinProcessIndustriesProcessIndustry–Thegroupofmanufacturersthatproduceproductsbymixing,separating,forming,and/orbyperformingchemicalreactions.CapacityFirst–Forthemostpart,processindustriesaremorefocusedonplanningcapacityfirst,ratherthanmaterials.Theefficiencyandeffectivenessofplanningtheuseofcapacity-intensivecapacity,includinglongrunsandhighutilization,isthekeytoaddingvalueinprocessindustries.ContinuousFlowProduction–Aproductionsysteminwhichtheproductiveequipmentisorganizedandsequencedaccordingtothestepsinvolvedtoproducetheproduct…#ExplaintheroleofprocessstructureinprocessflowschedulingTheprocessFlowSchedulingSystem–suitableforcontinuousproductionandcapital-intensiverepetitiveproduction.ShipmentsTrainC1PlantCTrainA3TrainB2TrainB1TrainA2TrainA1PlantBPlantADivisionShipmentsTrainC1PlantCTrainA3TrainB2TrainB1TrainA2TrainA1PlantBPlantADivision>Thesystemisbasedontheproductionprocessstructureinsteadofamaterialsproductstructure(basedontheBOM).>Theprocessstructureconsistsofdivisions,plants,processtrains,andstages,andthisstructuredrivesplanningandscheduling.#DescribethebasicelementsofaprocesstrainProcessTrainsaretheproductionlinesinplants.Inreality,processtrainsaredividedintostagesconsistingofoneormoreprocessunits(piecesofequipment).Stagesaredecoupled(withintermediateinventory)fromotherstages.Decouplingallowsthestagestobescheduledasseparateentities,withdifferentlotsizesandproductionsequences,andtoberunindependentlyandmoreefficiently.#Differentiatebetweenprocessor-andmaterial-dominatedscheduling|finiteProcess-dominatedSchedulingMaterial-dominatedSchedulingCapacityisrelativelyexpensiveMaterialsarerelativelyexpensiveStageisabottleneckExcesscapacityexistsSetupcostsarehighSetupcostsarenotsignificantStageconsistsofsomejobshopoperation#DifferentiateamongthethreeflowschedulingtechniquesSchedulingMethodPlanningMethodReverseFlow3,2,1Supportsdemand-basedplanning(material-dominatedscheduling)ForwardFlow1,2,3Supportssupply-basedplanning(process-dominatedscheduling)MixedFlow2,1,3or2,3,1Supportsplanningwhenstage2isthelogicalfocusofattentionforschedulingbecauseofprocessingcapacityormaterialconstraints.-OtherCapacityManagementApproachesandPerformance#Explaintheroleoflinebalancinginrepetitive/leanproduction>Repetitivemanufacturingt