供應(yīng)鏈規(guī)劃與執(zhí)行模組知識(shí)講解英文

供應(yīng)鏈規(guī)劃與執(zhí)行模組世新大學(xué)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(shí)間太長(zhǎng)PC無(wú)法如期交貨貨Hub會(huì)造成投資風(fēng)風(fēng)險(xiǎn)PC/MC插單Cancel訂單訂單交期變更更頻繁Yield和Rework造成交期Delay無(wú)法確認(rèn)真正正的產(chǎn)能與瓶瓶頸作業(yè)替代料無(wú)法掌掌控ECN頻繁，易產(chǎn)生生呆料34ProbleminIndustryShopFloor開(kāi)製令前無(wú)法法確認(rèn)料是否否備齊臨時(shí)缺料Yield和Rework造成大量未結(jié)結(jié)案工單ShopFloor催M(jìn)C，MC催Buyer，，Buyer催Supplier產(chǎn)能規(guī)劃不合合理，無(wú)法執(zhí)執(zhí)行Buyer無(wú)法確認(rèn)到底底欠哪些料追料頻繁O(jiān)rderCancel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(xiàn)存Transaction系統(tǒng)(ERP)的資訊訊，以以提供供快速速規(guī)劃劃及排排程的的智慧慧型決決策支支援系系統(tǒng)。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將生生產(chǎn)產(chǎn)規(guī)規(guī)劃劃單單位位所所規(guī)規(guī)劃劃的的生生產(chǎn)產(chǎn)訂訂單單(PO)有有效效的的轉(zhuǎn)轉(zhuǎn)變變成成實(shí)實(shí)際際成成品品的的產(chǎn)產(chǎn)出出50ShopFloorControlSystem51FunctionsofShopFloorControlOrderreview/releaseDetailedshopflooroperationsschedulingDatacollection/monitoringControl/feedbackOrderdisposition52OrderReviewandRelease扮演演一一個(gè)個(gè)過(guò)過(guò)濾濾機(jī)機(jī)制制，，控控制制訂訂單單進(jìn)進(jìn)入入現(xiàn)現(xiàn)場(chǎng)場(chǎng)的的流流量量53FocusofOR/RAvailabilityofmaterialsRequiredcapacityRequiredmachinesandtoolingsReal-timeproductionstatusVerifyMRPplansConfirm/modifyBOMstructureConfirm/modifyroutingEvaluateproductionloadsinshopfloorCriteriaofperformanceevaluation54OperationsSchedulingWorkcenterorientedschedulingWorkorderorientedschedulingBackwardschedulingForwardschedulingFiniteschedulingDispatching55DataCollectionandMonitorBarcodeOpticalcharacterrecognitionMagneticstripeVoicerecognitionRadiofrequencyidentificationMachinevisionsystemBluetooth56ControlandFeedbackOrderproblemsvs.ResourcesproblemsIsitsolvable?Whatisthesolution?AdjustandimproveInformationfeedback57OrderDispositionOrdercompletionASplannedOrdercancellationMaterialsshortageReleasepreviouslyassignedresourcesEvaluateproductionperformanceDefineandexplainspecificunexpectedconditions/solutions58ShopFloorControlSystem-Anotherview59AgendaOverview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS60RelationshipsofERP/APS/MES/MCSERPAPSMCSMES61InteractionsBetweenERP/APSandMES62DefinitionofMES將加加工工現(xiàn)現(xiàn)場(chǎng)場(chǎng)中中的的原原物物料料、、半半成成品品、、成成品品、、機(jī)機(jī)器器、、時(shí)時(shí)間間、、成成本本等等資資訊訊以以動(dòng)動(dòng)態(tài)態(tài)且且即即時(shí)時(shí)的的方方式式來(lái)來(lái)收收集集、、匯匯整整與與表表達(dá)達(dá)，，並並追追蹤蹤與與管管制制目目前前正正在在進(jìn)進(jìn)行行中中的的各各項(xiàng)項(xiàng)製製造造作作業(yè)業(yè)的的一一個(gè)個(gè)資資訊訊系系統(tǒng)統(tǒng)(APICS)。。其上上層層銜銜接接APS的生生產(chǎn)產(chǎn)規(guī)規(guī)劃劃結(jié)結(jié)果果，，以以進(jìn)進(jìn)行行即即時(shí)時(shí)性性的的現(xiàn)現(xiàn)場(chǎng)場(chǎng)生生產(chǎn)產(chǎn)派派工工