产能管理教学内容

產能管理

(CapacityManagement)1Outline生產環境演變與相關管理工具之關係製造環境分類製造規劃及控制系統架構產能管理相關概念粗估產能規劃(RCCP)產能需求規劃(CRP)投入/產出規劃及控制(I/OPlanning&Control)作業排程(OperationSequencing)結論2CompetitivePriority竞争力1950~1960---成本

Cost

1970~1980---质量

Quality

1990~2000---交期、柔性、服务

以及“全球化”Delivery、Flexibility、Service

Global-wise3CompetitivePriority竞争力4手工藝時代大量生產豐田生產系統及時生產系統零庫存生產系統世界級製造成本品質彈性交期1920195019601970198019902000服務、創新、全球化MRP-1960’sand70’sMaterialRequirementsPlanning----材料需求计划MasterProductionScheduling---主生产排程Unconstrained---？？？6Demand需求Supply供应MRPII-1980’sUnconstrained---？？？ManufacturingPlanningandControl,withmanualprocessesto“closetheloop”---制造计划和控制，人工密切跟进CapacityManagement---产能管理

FinancialIntegration---财务上的综合考虑7ERP-1990’sAnaccounting-orientedinformationsystemforidentifyingandplanningtheenterprise-wideresourcesneededtotake,make,ship,andaccountforcustomerorders.[APICSdictionary]---识别企业广义资源，并对其获得、使用、发货进行计划，以满足客户的订单需求89TheVision版本TheDelivery概括MRPMRPIIERPExtendedERPReducedinventorythrough

“infinite”manufacturingplanning---无限制造计划，减少库存Reducedinventory,fewerstock-outsandaccuratefinancialrecordsthrough“infinite”manufacturingplanningandperiodictransactionprocessing.---通过非限制性制造计划和周期性改善减少库存并降低存货成本Customerfocused,dynamicallybalancedenterprisethroughassetoptimizationandreal-timetransactionprocessing.---以客户为中心，通过总优化和实时改善来协调企业资源Customerfocused,dynamicallybalancedvaluenetworkthroughassetoptimizationandreal-timetransactionprocessing..---以客户为中心，通过总优化和实时改善来协调各个价值链上的资源MRPMRPIIMRPII(plus)SupplyChainThevisionofERPisEvolvingtoincludetheExtendedEnterprise不同版本ERP对企业资源范畴的扩展資訊系統之演進MRPI--1960~1980生產者導向大量生產產品以價格及功能取勝生產成本降低整合：MPS及BOMMRPII--1980~1990消費者導向少樣多量生產產品以多樣化及高品質取勝生產彈性及消除浪廢整合：製造、行銷、財務、人事、專案ERP/SCM

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1990~消費者導向大量客製化（大规模定制）快速反應市場需求跨地區、跨幣別的即時、整合資訊10資訊系統11資料來源:資策會MICITIS計畫12企業應用軟體演變趨勢E-Business(電子企業環境)ESCM(延伸型供應鏈管理)EERP(延伸型企業資源規畫)E-Commerce(電子商務)SFA(銷售自動化)CRM(客戶關係管理)SCM(供應鏈管理)ERP(企業資源規畫)MRP(物料需求規劃)Payroll(薪資系統)GL(總帳會計)AP(應收帳款系統)AR(應付帳款系統)197019902000EDI(電子資訊交換)Planning(計劃)Scheduling(排程)Distribution

(配銷)MRPII(製造需求規劃)HR(人力資源)FMIS(財務系統)1980資料來源：HP簡報13E-BusinessApplicationArchitecture=e-commerceE-business+ERP+SCM+MES/MCS+KM+CRMCustomerEmployeeSupplierE-ProcurementCustomerRelationshipManagementEnterpriseApplicationsIntegrationManufacturingExecutionManufacturingControlKnowledgeManagementSupplyChainManagementEnterpriseResourcePlanningSellingChainManagement製造環境分類以製造策略分類JobShop(零工型)Repetitive(重複型)Batch(批量型)FlowShop(流線型)以產品定位策略分類Engineering-to-orderMake-to-orderAssemble-to-orderMake-to-stock14製造環境15RepetitiveproductionProductJobshopFlow

shopCustomLowvolumedifferentiatedHighvolumedifferentiatedCommoditySpecialtychemicals

anddrugsAerospaceIndustrialmachineryMachinetoolsElectricalandelectronicsPaperContainersBrewersAutomobile

Tireandrubber

SteelproductsMajorchemicalsanddrugsOil

Steel

ForestproductsProcessSource:Tayloretal.,whytheProcessIndustriesAreDifferents,?

ProductionandInventoryManagementJournal,1981.One-of-a-kindPERT/CPMMRP;CRPMRP;LineBalancingJITManufacturingSystemModel

制造系统模块BusinessPlanning商业计划SalesPlanning销售计划ProductionPlanning生产计划MPS主生产计划MRP物料需求计划DemandManagement需求管理FinancePlanning财政计划ResourceRequirementsPlanning资源需求计划Rough-CutCapacityPlanning粗略的产能计划CapacityRequirementsPlanning产能需求计划Purchasing采购ProductionActivityControl生产调度MidTerm中期Long-Term长期Short-Term短期InventoryManagement库存管理Input/OutputControl投入/产出控制CapacityManagementinMPSSystem

MPS系统中的产能管理17Resource

requirements

planningRough-cut

capacity

planningCapacity

requirements

planningPurchasing采购Material

requirements

planning材料需求计划Messageto

BUYorMAKEProductionactivitycontrol生产调度Master

production

scheduling主生产计划Production

Planning生产计划Input/OutputanalysisOperationSequencingCapacityPlanningandControl

产能计划和控制18Priority优先级Capacity产能Planning计划Control控制PP生产计划MPS主生产计划MRP材料需求计划RRP资源需求计划RCCP粗略产能计划CRP产能需求计划Input/OutputControl投入/产出控制OperationSequencing作业顺序CapacityDefinition产能定义Therateatwhichworkiswithdrawfromthesystem.Thehighestreasonableoutputratewhichcanbeachievedwiththecurrentproductspecifications,productmix,workforce,plant,andequipment.[APICSdictionary]19CapacityManagementThefunctionofestablishing,measuring,monitoring,andadjustinglimitsorlevelsofcapacityinordertoexecuteallmanufacturingschedules.[APICSdictionary]Includecapacityplanningcapacitycontrol20WorkCenterandLoadWorkCenterAspecificproductionfacility,consistingofoneormorepeopleand/ormachines,whichcanbeconsideredasonunitforpurposesofcapacityrequirementsplanninganddetailedscheduling.[APICSdictionary]LoadTheamountofscheduledworkaheadofamanufacturingfacility,usuallyexpressedintermsofhoursofworkorunitsofproduction.[APICSdictionary]21Wight’sFunnel22CAPACITYLOADOUTPUTCapacityandLoad[APICS]23CapacityLoad(每一作業之Setup及runtimes)工程研發工單PM重工工單計劃工單已發放工單加班及外包考慮人員,設施,之availablehours及TimeEfficiencyRate減項

Breaks,Downtime,ReworkAbsenteeism,Daily,Maintenance,OtherCapacityPlanningTermsLoadAvailableWeekHoursperresourceCapacityUtilizationScenariosLoadAvailableLoadAvailableLoadAvailableBalancedUnderloadedOverloadedDeterminingCapacityAvailableDemonstrated(Measured)Capacity产能示例theaveragerecentoutputactuallyachieved,isfiguredfromhistoricaldata最近一段时间的实际平均产量isdefinedasaverageoutput,notmaxoutput平均产量而非最大产量Rated(Calculated)Capacity产能率availablehours×utilization×efficiency

可用小时数×利用率×效率26Utilization利用率276%6%62%13%13%BreaksR.MaintenanceRunTimeUn-utilizedbutscheduledtimeSetupTimeActualtimeused(runandsetup)实际运行时间

Scheduledtimeintendedforproduction计划运行时间Utilization利用率=Ameasureofhowintensivelyaresourceisbeingused….Utilization28Example:

Breaks:20minutespershift Routinemaintenance:10minutespershift Runtimecharged:6hours Setuptime:0.5hour Utilization=6*60/（20+10+6*60+0.5*60）=85.71%

Efficiency效率Ameasureofhowcloselypredeterminedstandardsareachieved.29Actualoutput(standardhoursearned)实际产出Standardoutputexpected(scheduled)理论产出Efficiency=Efficiency30Example:

Workcenter:3machines,two8-hrsshifts,fivedaysaweek Breakdown:12hrsperweekUtilization=（5*8*2*3-12）/（5*8*2*3）=95%

recordsindicatethattheworkcenterproducedanaverageof250.8sta.Hoursofoutput.Efficiency=250.8/（5*8*2*3-12）=110%Capacity=250.8

CapacityDetermination31ShiftperDay

MachinesorWorkStations

HoursperShift

DaysperWeek

Utilization

Efficiency=StandardHoursperWeekEx:

Shifts=3ShiftLength=8hrs5DaysperWeekNumberofMachines=6MachineUtilization=.8Efficiency=.9518.4Rough-CutCapacityPlanningTheneedforlongplanninghorizonsandthelackofspecific,accuratedataformanyimportantfactorsmakeRCCPtechniquesmorepracticalthandetailedcalculationsAcapacityplanshouldnotbedeferred;rough-cutapproachesareverypractical粗略产能计划是必需的，在长期的预测性计划以及一些精确数据缺乏时也是非常实用的产能计划不能拖延，并且非常的重要

32BillofResource(BillofLabor)資源清單(BOR;BOL)乃針對製造料件或零件群時，所需之主要關鍵資源的產能需求條列。不是為了作為途程(Routing)用途。只是一種估計特定料項所需產能的方法。33RCCPProcedureConvertingunitsofproductintheMPStostandardhoursofworkinindividualcenters

----主生产计划中单批产品在每个加工步骤的标准时间ToaccumulateineachperiodintheMPSthetotalhoursofworkrequiredtoproduceallproductsscheduledinthatperiod

----根据MPS计算所有产品总计在每个时间段的工作时间需求noLToffsetting

---不考虑生产周期的相互影响nolot-sizing

---不考虑批量大小变化的影响nosignificantchangesininventoriesofitems

---不考虑后续库存变化带来的影响34RoutingforProductX35ProductXSEQ

WorkCenter

UsageOP11 0.1hrs/pcOP22 0.5hrs/pc12438765PERIODSPlannedOrderReleasedProductX1005080100406090RoutingforAssy-0136Assy-0112438765PERIODSPlannedOrderReleasedAssy-01SEQ

WorkCenter

UsageOP12 0.2hrs/pcOP23 0.8hrs/pc100508020018040609037ResourceLoadProfileWorkCenter205010015020025012345678PeriodLoadOthersAssy-01ProXCapacityBOMforFG38ItemMasterFilesforFG39RoutingFilesforFG40WorkCenterMasterFiles41MPSforPart10042RCCP-ProcessTimeComputation43RCCP-BORComputation44RoughCutCapacityRequirements45RCCP46RCCP47A11A12A22A21WC1WC2P1P2B11B12B22B21P1P2M1M2C11C12C22C21WC1WC2M1M2RCCPMPSBORBackwardandForwardScheduling48OPNOPN-1OP1………ForwardschedulingBackwardschedulingOrderDueDateOrderStartDateOPN-1InfiniteandFiniteLoading49InfiniteFiniteCapacityCapacityCRPDefinitionThefunctionofestablishing,measuring,andadjustinglimitsorlevelofcapacityTheprocessofdeterminingindetailtheamountoflaborandmachineresourcesrequiredtoaccomplishthetasksofproduction[APICSDictionary]50CapacityRequirementsPlanning51CapacityRequirementsPlanningPlannedordersReleasedordersRoutingWorkcenterWorkcenterloadreportRevisedscheduleManufacturingOrderandRoutingManufacturingOrder(WorkOrder)Adocument,groupofdocuments,orscheduleidentityconveyingauthorityforthemanufactureofspecifiedpartsorproductsinspecifiedquantities.[APICSdictionary]RoutingAsetofinformationdetailingthemethodofmanufactureofaparticularitem.Itincludestheoperationstobeperformed,theirsequence,thevariousworkcenterstobeinvolved,andthestandardsforsetupandrun(times).[APICSdictionary]52InputsNeededforCRPOpenOrderFilePlannedOrderReleasesRoutingFileoperationstobeperformedsequenceofoperationsworkcenterstobeusedpossiblealternateworkcenterstoolingneededateachoperationstandardtimes:setuptimes,runtimesWorkCenterFilemovetime,waittime,queuetimeShopCalendar53LeadTimeManufacturingLTqueue,setup,process,wait,moveAverageQ(SU+RT)1+(SU+RT)2+…+(SU+RT)n54queuesetupprocesswaitmove12nW/C……..WIPExpectedQueueingTime55ActivationQueueingTime0.80.840.880.920.961.00Assumption:M/M/1queueingsystemE(Q)=a/[s(a-s)];a:ave.arrivalrate;s:ave.servicerateActivation=a/sARevisedDefinitionofCapacityAvailableCapacityavailable=TimeavailableEfficiencyAvailabilityActivationAvailability1-thefractionoftimedownduetomachinebreakdownand/orabsenteeismActivation1-thefractionofdownduetolackofwork56UTILIZATIONHowLoadIsDetermined?TheproductionplanlongrangerateofproductionTheMPSdriveMRPMRPgenerateplannedordersreleased(open)ordersCRP(capacityrequirementsplanning)calculatesstdhoursrequired,byW/C,bytimeperiod,basedonplannedandopenorders57LoadDeterminationOpenOrders(fromorderfilestatusfilemaintainedbyproductioncontrol)orderduedateorderquantityoperationscompletedoperationremainingMRP-plannedOrderReleases(fromMRP’soutput)plannedorderreleasedateplannedorderreceiptdateplannedquantity58DataRequirementsforCRPValidduedatesonallreleasedandplannedordersUp-to-dateroutingsandprocessinginformationAccuratestandardsforsetupandprocessingtimeAschedulingprogramtohandlealloperationsAloadingprogramtoassignworktotimeperiodsStandardqueueallowancesforallworkcentersEstimatesofloadduetounplannedoccurrences59MRPforFG60CRPComputationSetuptimecomputationforplannedorderRuntimecomputationforplannedorderSetuptimecomputationforopenorderRuntimecomputationforopenorderCRPloadreport61PlannedOrderReleases62SetupTimeMatricesforFG63RunTimeMatricesforFG64CapacityReq.ofPlannedReleases65CapacityReq.byReleasedOrders66CapacityRequirementsPlanforFG67CRP68W/CCapacityvs.AverageLoadTheformalplandoesnotincludealltheloaditwillbenecessarytohandlenewproductsnotinthecurrentMPSuseofalternateroutingsandprocessingscrapreplenishmentandreworkoperationsadditionalprocessingneededforanyreasonrecorderrorsresultinginadditionalmaterialrequirementsSomeoftheloadmustremaininthecentertoprovidetheplannedstandardqueue69Input/OutputControl70InputRateControlOutputRateControlQueue(WIP,Load)Input/OutputControlInput/Outputcontrolisamethodtomanagequeuesandwork-in-processleadtimesInput/OutputControlReport71WeekEnding:06/0606/1306/2006/2707/0307/1007/17InputPlanned182203172178193205208Actual197180168191189CumDeviation15-8-121-3OutputPlanned207207207207207207207Actual213202206210212CumDeviation61038QueueBegging:300hrsPlanned275271236207193191192Actual284262224205182DefinitionPlannedInputWorkexpectedtoarrivebytimeperiodbasedonCRPconstraintsexpressedinstandardhoursorothercommonunitofmeasurePlannedOutputWorktobereducedbytimeperiodtoreducequeue,planoutputgreaterthaninputmakecapacityavailable72DefinitionPlannedQueueBeginningqueue+plannedinput-plannedoutputweekending06/06:300+182-207=275weekending06/13:275+203-207=271continuingforeachsucceedingweekActualInputWorkarrivingatworkcenterbytimeperiod,sameunitofmeasureobtainedfromreportingsystemsormanuallogsaffectedbyreleasestoshop,flowfromprioroperations73DefinitionActualInputWorkarrivingatworkcenterbytimeperiod,sameunitofmeasureobtainedfromreportingsystemsormanuallogsaffectedbyreleasestoshop,flowfromprioroperationsActualOutputStandardhoursproducedduringeachperiodfromreportingsystemsormanuallogsaffectedbyresources,efficiency,workload74DefinitionActualQueueBegging(orpriorperiod)queue+actualinput-actualoutputweekending06/06:300+197-213=284verifiedperiodicallytoconfirmaccuracyofinputandoutputdataControlmeasureactualtoplanactualoutputvs.plannedoutputactualoutputvs.actualinputactualinputvs.plannedinput75Input/OutputComparisonsActualoutputplannedoutputQueues,LTnotenoughinput?Insufficientcapacity?Actualoutputplannedoutputmayrunoutofwork,excesscapacityActualinputplannedinputmayrunoutofworkfeedingw/cbehind