生产计划与排程(英文)(ppt 44页).ppt

1、Introduction to Rhythm Factory Planner,Kwok Poon May 17, 2000,Agenda,What Is Rhythm Factory Planner (FP) Rhythm FP Architecture Rhythm Factory Planner (FP) Planning Concept Rhythm FP features,What Is Rhythm Factory Planner (FP) ?,What Is Rhythm Factory Planner (FP),Factory Planner uses the informati

2、on from the existing transaction system (ERP) to provide intelligent decision support capability in Planning and Scheduling Factory Planner provides a global integrated view,What Can Rhythm FP Do?,Factory Planner provides a systematic and constraint-based planning concept Factory Planner can help to

3、 minimize the current ad-hoc planning process Factory Planner can quickly reveal the production constraint, which is almost impossible for traditional planning process,Rhythm FP Architecture,Rhythm FP Architecture,Client-Server Architecture Both server and client processes can run on Windows NT mach

4、ines May run server and client on separate machines Use existing data (from Triton and SFCS) Memory Resident Multi-User capability,Rhythm FP Architecture (cont.),Production Planner,Material Planner,Report Reader,Production Server,What-if Server,Rhythm FP Framework (Input & Output),Rhythm FP Server,D

5、emand,Product Structure: Part number BOM Routings,Factory Model: Resources Resource Calendar,Material Availability: Unassigned Inventory P.O./ Vendor Info. WIP,Other Information: Tools .,Production Plan: Capacity Material,Rhythm FP Framework (cont.),FP requires ACCURATE and SUFFICIENT data input (ga

6、rbage in & garbage out) Open loop planning process in the first phase Planners execute the production plan based on FPs suggestion,Basic FP Data Objects,BOM data Demand order data Part number data Unassigned inventory data Supplier part data Resource data Routing data,More FP Data Objects,Wip data O

7、peration resource data Resource calendar data Vendor calendar data Variable capacity bucket size data,FP Output Files,Critical delivery data Purchase order EDC recommendations Manufacturing order data Planned start times Procurement data Procurement by part data etc.,FP Data Objects Relationship,Rhy

8、thm FP Planning Concept,FP Planning Concept,BTO (Build-to-order) engine: use Demands as the driver to create plan Consider both material and capacity constraints at the same time Consider both Sales Orders and Forecasts as the demand input with different priorities Start as an Infinite Capacity Plan

9、 and progress to a Finite Capacity Plan,FP Planning Concept (cont.),Materials are assigned according to the BOM explosion from the finish good level also consider Time factors Raw Materials (Procured Parts) are supplied by on-hand inventory or P.O. from vendors. Manufactured parts (finish goods and

10、intermediate parts) are supplied by WIP or manufacturing orders (work orders).,Process Flow in FP,Infinite Capacity Planning,Finite Capacity Planning CAO (constraint anchor optimization),Detail Scheduling,Identify Material and Capacity Problems Fix Material Problems,Attempt to fix Capacity Problems,

11、Create detailed schedules,FP Infinite Capacity Planning (ICP),Build factory model phase Inventory Assignment phase Planned start time phase Capacity utilization phase Presents plan through user interface (client),ICP - Build Factory Model,Read files into memory and create resident memory model File

12、formats in Spec Files Do consistency checking,ICP - Inventory Assignment,Explore Bill of Materials Determines BOM configuration and routing assignments Creates manufacturing orders to satisfy demands Net requirements for raw materials and sub-assemblies against on-hand inventory and WIP (Work-In-Pro

13、cess) Creates material requirements,ICP - Inventory Assignment (cont.),Backward Schedule Definition: Latest Possible Start Time (LPST) - the latest date a manufacturing task can begin and still complete on time LPST = Task Due Date - Task Processing time Calculates the LPST for each manufacturing ta

14、sk Each manufacturing task will have a LPST Soft constraint: violate LPST constraint will deteriorate the order-fulfillment performance,ICP - Inventory Assignment (cont.),Backward Schedule,Subassembly 1,R.W. #1,R.W. #2,Sub assembly 2,Computer,Order Due Date,Task Due Date (LPST),LPST,LPST,Mfg order #

15、1,Mfg order #3,Mfg order #2,ICP - Inventory Assignment (cont.),Inventory Assignment Prioritize demand orders (due date, priority, quantity) Sort prioritized demand orders Sort parts from end-item to raw materials Calculate demands Allocate supplies,ICP - Inventory Assignment (cont.),Forward Schedule

16、 Definition: Earliest Possible Start Time (EPST) - the earliest date that a manufacturing task can begin (constrained by materials) EPST = max (Server Start Time, Material Available Time) Calculates the EPST for each manufacturing task Each manufacturing task will have an EPST Hard constraint: produ

17、ction cannot be started without materials available,ICP - Inventory Assignment (cont.),Sub assembly 1,R.W. #1,R.W. #2,Computer,Order Completion Time,Material Available Time (EPST),EPST,EPST,Mfg order #1,Mfg order #3,Mfg order #2,Forward Schedule,Sub assembly 2,ICP - Planned Start Time,Assign PST for

18、 each task Definition: Planned Start Time (PST) is the expected start date that a task will begin taking material availability into consideration Calculation: PST= max (EPST, LPST) Each manufacturing task will have a PST PST values may be overriden through the user interface,ICP - Capacity Utilizati

19、on,Determine bucket (operation time interval) configuration - from variable capacity bucket size data Calculate capacity for each bucket - from resource calendar data Calculate work load in each bucket based on PST and run time of each task,FP Finite Capacity Planning,Identify the constrained resour

20、ces Balance and offload loads for constrained resources in a GLOBAL view (Global optimization) Plan based on flexible strategy options (e.g. Minimize WIP) Respond quickly,FP Detail Scheduling,Schedule based on flexible strategy options (e.g. FIFO) Able to specify the scheduling horizon Able to gener

21、ate a global optimized production schedule Generate the dispatch list for execution Intelligent scheduling algorithm and results,How to make it successful,User-own project Trust and Cooperation What are our game rules? Forecast/Acceptance, S/O, P/O, etc. Thinking of future, reasonable procedures Dat

22、a Clean-up Should be started from the very beginning Where, when, who, how, etc. etc.,Rhythm FP Features,List of Some Features,Transfer Batching Manufacturing Lot Sizing (CMO) Procurement Lot Sizing WIP Reporting Advanced Scheduler (AS) Due Date Quoting Batch Client,Alternates Alternate Parts Alternate Resources Alternate Routing ECN Effectivity Date effectivi