供应链规划与执行模组（ 73页）ppt课件

1、供應鏈規劃與執行模組世新大學資管系 鄒慶士 副教授1AgendaOverview/Features of SCMSupply Chain Network DesignAdvanced Planning and SchedulingShop Floor ControlMES/MCS2Enterprise functional silos with conflicting goalsPurchasingManufacturingDistributionCustomer Service/SalesFew change- oversStable schedulesLong run lengthsHig

2、h inventoriesHigh service levelsRegional stocksSOURCEMAKEDELIVERSELL Low pur-chase priceMultiple vendorsLow invent-oriesLow trans-portationOverview of SCM - Issues3Overview and targets of SCM Definition of Supply Chain Management: Supply Chain Management describes all kind of activities across multi

3、plecompanies or locations to optimize the manufacturing of products. Herebyconcerning all interfaces on operational and strategic level for involvedassociates. Main focus Development of heterogeneous global production networks Increased integration of advanced technologies Minimzing costs for invent

4、ories and deliveries Long term relationships (customer / supplier binding) Customer satisfaction ByERP - BasisSCM - ToolsInternet4Overview and targets of SCMBuys Ingredients and ComponentsMakes aProductMoves it to a DistributionCenterStores it atDistributionCentersStores it in aWarehouseMoves itto S

5、toresStores it in the StoreSells it toConsumersMulti Enterprise Supply ChainsSource: I2-Technologies5Overview and targets of SCM Integration of suppliers in planning in consideration of. Suppliers inventories Suppliers manufacturing capacities Transport times and capacitiesReduction of own inventori

6、es6 Integrated planning of supply chains leads to Reduction of inventories Cost savings Capability to meet promised delivery datesIncreased customer satisfactionIntensified customer bindingPerspective to extend the sales marketOverview and targets of SCM7Prerequisites for success No management metho

7、d guarantees itself for success Type of product leads to special type of supply chainPrimarily functional products Dont change much over time Long life cycles Predictable demand Stability invites competition Leads often to low profit marginsPrimarily innovative products Enables higher profit margins

8、 Short life cycle (typically few month) Volatile demand Newness makes demand unpredictable Importance of early sales8Prerequisites for successPrimarily functional products Supply at lowest costs to predictable demand High utilization rate of capacity Minimize inventories Short lead time as it doesnt

9、 increase costs Select suppliers primarily for costs and quality Physical efficiencyMinimize costs by Physical efficiencyPrimarily innovative products Respond quickly to unpredictable demand Deploy excess buffer capacity Deploy significant buffer stocks Invest aggressively to reduce lead time Select

10、 suppliers primarily for speed, flexibility and quality Responsiveness to marketMinimize costs by Highest responsiveness to market Minimize risk of shortages or excess supply9Prerequisites for successEfficientResponsiveFunctionalInnovativematchmatchmismatchmismatchUse of SCM software tools like APO1

11、0Prerequisites for success Share information with your suppliers Keep longer relationships with your suppliers Trust as foundation of relationships with suppliers Fundamentals of supply chain planningZQZL 中国最大的资料库下载11SCM Business ProcessesTechnology helps enable a variety of SCM business processesPu

12、sh to pullProcess orientationOptimizationPostponementMore frequent planningCollaboration12Move from push to pull manufacturingManufacturersDistributors/ WholesalersConsumersSuppliersRetailersManufacturersDistributors/ WholesalersConsumersSuppliersRetailers Make what we will sell, not sell what we wi

13、ll make! Features of SCM13PurchasingManufacturingDistributionCustomer Service /SalesAvailable-to-Promise (ATP) Capable-to-Promise (CTP)Move from functional silos to process-oriented business processes (e.g., order-to-cash, cash-to-cash)Integrated Sales and Operations Planning (S&OP)SOURCEMAKEDELIVER

14、SELLFeatures of SCM14Optimization of all supply chain activitiesSupply Chain OptimizationSynchronized, Concurrent PlanningDemandPlanningDistributionPlanningManufacturing PlanningProcurementPlanningIndependent, Sequential PlanningForecastingDistributionPlanningManufacturing PlanningProcurementPlannin

15、gFeatures of SCM15PostponementMove to MTO,ATO and CTO from MTSFront-end APS suites support ATP/CTPProduct configurationBack-end integration to transaction systemsInternationalTradeLogisticsWarehouseManagementAdvancedPlanning Scheduling CustomerRelationshipManagementLogisticsManufacturingMaterialsMan

16、agementAccounting Human Resources ERPEAIFeatures of SCMSCM16More frequent planning means responsive to changing customer needs while decreasing inventoriesTimeTimeAverageSupplyAverageSupplyPlanning CyclePlanning CycleFeatures of SCM17e-Business will enable supply chain collaboration among trading pa

17、rtnersManufacturerDistributors/WholesalersSuppliersRetailersCollaborative Demand PlanningCollaborative Logistics PlanningTransportation servicesDistribution center servicesSynchronized Production SchedulingCollaborative Product DevelopmentFeatures of SCMLogistics Providers18Components of E-Supply Ch

18、ainSupply-chain replenishmentE-procurementCollaborative planningCollaborative product developmentE-logisticsSupply webs19Evolution of ITARAPGLPayrollMRPFMISHRMRPIISchedulingplanningDistributionERPAPS/SCMEISEDIE-CommerceBICRME-Business20AgendaOverview/Features of SCMSupply Chain Network DesignAdvance

19、d Planning and SchedulingShop Floor ControlMES/MCSZQZL 中国最大的资料库下载21ManufacturersWholesale DistributorsSuppliersCustomers Information FlowsGoods FlowSupply Chain Network DesignSupplier ExchangesCustomer ExchangesLogisticsExchangesContract ManufacturersLogistics ProvidersVirtual ManufacturersRetailers

20、Location decisionCapacity decisionAssignment decision22Strategic Planning ProblemsWhich products shall be produced at which locations?How are customers assigned to distribution centers?Where shall new locations be opened?Which locations shall be closed?What are capacity requirements for plants/distr

21、ibution centers?What is the cost situation within the supply chain?23Planning MethodPlanning of location assignment and transportation lanesLocation assignment based on geographical distanceCost optimal location assignmentStructural Network ChangesPlacement of a given number of locations based on ge

22、ographical distance and costsCost optimal selection of locations24Planning ParametersCostTransportation costsProduction costsStorage costsHandling costsProcurement costsLocation costs / Location proceedsFix maintenance costsCosts for opening and closure of locationsPublic subsidiesPenalty costs for

23、delayed or non-fulfilled demand25Planning ParametersCapacitiesHandling capacities for plants and distribution centersProduction capacities of plantsDemandCalculation of demand via Demand PlanningSupported by forecast methodsSimulation of demand scenariosVariation of demand26Planning ResultsSupply Ch

24、ain NetworkAssignment of locationsTransportation lanesAllocation of products to locationsNew locations with geographic positionSelected / not selected locationsProposal for opening or closure of locations27Planning ResultsQuantitiesProduction, transport, handling, storage and procurementCostsProduct

25、ion, transport, handling, storage and procurementLocation costsOpening costs, maintenance costs, subsidies, etc.Capacity RequirementsProduction, transport, handling und storage28OutlookProfit-oriented planningConsideration of piece-wise linear costs for transport and productionConsideration of stora

26、ge capacitiesIntegration of GIS applicationsautomatic calculation of transportation duration and transportation costsexpanded geographic display29AgendaOverview/Features of SCMSupply Chain Network DesignAdvanced Planning and SchedulingShop Floor ControlMES/MCS30Production LogisticsForecastCustomer o

27、rder administrationPrimary requirements planningRequirements planningPurchasingCapacity schedulingCapacity adjustmentOrder releaseReservationSequencingDetailed schedulingExecutionFactory data entryShop floor controlPlanningPlanning/schedulingInitiation of implementation functions31Typical Planning P

28、rocessSupply/DemandMeetingMRP/ERPManual AdjustmentRelease POReceiving/ReceiptChange Production PlanCan not deliver on timeLong promise timeDead items & shortageCustomer unsatisfied32MRP II Planning ProcessTop-down processIterative processMaster PlanningRCCPMRPCRPSFC33Problem in IndustrySalesSO confi

29、rm時間太長PC 無法如期交貨Hub會呵斥投資風險PC/MC插單Cancel訂單訂單交期變更頻繁Yield和Rework呵斥交期Delay無法確認真正的產能與瓶頸作業替代料無法掌控ECN頻繁，易產生呆料34Problem in IndustryShop Floor開製令前無法確認料能否備齊臨時缺料Yield和Rework呵斥大量未結案工單Shop Floor催MC，MC催Buyer，Buyer催Supplier產能規劃不合理，無法執行Buyer無法確認究竟欠哪些料追料頻繁Order Cancel頻繁未考慮Lead Time35Drawbacks in Traditional Productio

30、n PlanningSequential planningProblem in scheduling logicIndependent demand and supply planningLack of integrationBatch processSingle point planningLack of simulation capability36SCM Information System37Definition of APStheres no precise definition of APS systems, but it is quite intuitive to say tha

31、t the APS systems resolve the shortcomings of the ERP systems as a planning tool.APS systems consider material requirements and plant capacity to generate new plans, and some of them create a detailed production schedule that sequences the production optimally, to achieve the organization goals as w

32、ell as customers due date. (AMR, 1998)APS systems apply profound advanced technologies to achieve improved plans that take into account most of the factors and constraints that limit the ability to deliver on time. (Forrest Research, 1996)38Features of APSSynchronized concurrent planningConstraint-b

33、ased planningOptimized planningReal-time planningDecision support capabilityWhat-if simulationPegging between demand and supplySpeed and performance39Synchronized Planning40Constraint-based PlanningAPSConstraintSupplyDemandOutputTime:Purchase LTMfg.LTTrasf.LTDue DateCapacity:Resource loadRoutingMate

34、rial:Alternate PartsECN PartsSourcing RuleDemand:ForecastSales OrderSupply Data:On-handWIPPurchasing OrderOptimal Plan41Optimized Technologies in APSDemand PlanningExponential SmoothingSystem DynamicsMultiple Linear RegressionProduction Planning & SchedulingLinear Programming/Mixed Integer LPGenetic

35、 AlgorithmsSimulation AnnealingHeuristic MethodsDistribution Planning & DeploymentFlow AlgorithmsBranch-and-Bound Algorithm42Scope of APSSupply chain strategic planningSupply chain network planningDemand planning and forecastingInventory planningSupply chain planningSupply planningDistribution plann

36、ingTransportation planningShop floor operation schedulingShipment scheduling43Functions of APS44APS是运用現存Transaction系統(ERP)的資訊，以提供快速規劃及排程的智慧型決策援助系統。PurchasingOrder EntryManufacturingLogistics/ShippingERPCurrent SituationFinalPlanSupply Chain PlannerInput DataDemandCapacityMaterialsOutputProduction Pl

37、anShipping PlanPromise PlanAPS and ERP45Multi-Site PlanningComplex multi-site manufacturing refers to the environment where there are multiple sites that are dependent upon each other for material and assemblies.Supply Planning for a complex multi-site manufacturing environment involves the consolid

38、ation of data from the individual sites into a corporate consolidation database.46Multi-Site PlanningGlobal APS EngineDemand Planning EngineOrder Promising EngineAPSEngineAPSEngineAPSEngineMaster PlanMaster PlanMaster PlanSupply PlanSupply PlanSupply PlanDemand PlanSupply Plan47*Source: AMR, 1996Per

39、formance ResultsLate Order25-50% ImprovementOrder Lead Time10-40% ImprovementPlanning Cycle95% ImprovementProduction Lead Time10-50% ImprovementInventory10-60% ImprovementOperating Expense10-50% ImprovementThroughput2-5% Improvement48AgendaOverview/Features of SCMSupply Chain Network DesignAdvanced

40、Planning and SchedulingShop Floor ControlMES/MCS49Purpose of Shop Floor Control將生產規劃單位所規劃的生產訂單(PO)有效的轉變成實際废品的產出50Shop Floor Control System51Functions of Shop Floor ControlOrder review/releaseDetailed shop floor operations schedulingData collection/monitoringControl/feedbackOrder disposition52Order R

41、eview and Release扮演一個過濾機制，控制訂單進入現場的流量53Focus of OR/RAvailability of materialsRequired capacityRequired machines and toolingsReal-time production statusVerify MRP plansConfirm/modify BOM structureConfirm/modify routingEvaluate production loads in shop floorCriteria of performance evaluation54Operatio

42、ns SchedulingWork center oriented schedulingWork order oriented schedulingBackward schedulingForward schedulingFinite schedulingDispatching55Data Collection and MonitorBarcodeOptical character recognitionMagnetic stripeVoice recognitionRadio frequency identificationMachine vision systemBlue tooth56C

43、ontrol and FeedbackOrder problems vs. Resources problemsIs it solvable? What is the solution?Adjust and improveInformation feedback 57Order DispositionOrder completionAS plannedOrder cancellationMaterials shortageRelease previously assigned resourcesEvaluate production performanceDefine and explain

44、specific unexpected conditions/solutions58Shop Floor Control System-Another view59AgendaOverview/Features of SCMSupply Chain Network DesignAdvanced Planning and SchedulingShop Floor ControlMES/MCS60Relationships of ERP/APS/MES/MCSERPAPSMCSMES61Interactions Between ERP/APS and MES62Definition of MES將

45、加工現場中的原物料、半废品、废品、機器、時間、本钱等資訊以動態且即時的方式來搜集、匯整與表達，並追蹤與控制目前正在進行中的各項製造作業的一個資訊系統(APICS) 。其上層銜接APS的生產規劃結果，以進行即時性的現場生產派工；下層則連結MCS，根據派工結果控制設備進行實際加工生產，並即時搜集與回饋現場生產資訊。63Functions of MES64Order & Operations ManagementSelect orderAssign routingDispatchingTrace WIPOrder progress65Material & Resource ManagementMonitor mat