产能管理知识讲座课件

產能管理

(CapacityManagement)Ahua.liao1產能管理

(CapacityManagement)AhuaOutline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2Outline生產環境演變與相關管理工具之關係2CompetitivePriority1950~1960Cost1970~1980Quality1990~2000Delivery、Flexibility、ServiceGlobal-wise3CompetitivePriority1950~19603CompetitivePriority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4CompetitivePriority手工藝時代大量生產豐PlanningEvolutionMRPMRPIIERP1970198019902000APS5PlanningEvolutionMRPMRPIIERPMRP-1960’sand70’sMaterialRequirementsPlanningMasterProductionSchedulingUnconstrainedDemandSupply6MRP-1960’sand70’sMaterialReMRPII-1980’sUnconstrainedManufacturingPlanningandControl,withmanualprocessesto“closetheloop”CapacityManagementFinancialIntegration7MRPII-1980’sUnconstrained7ERP-1990’sAnaccounting-orientedinformationsystemforidentifyingandplanningtheenterprise-wideresourcesneededtotake,make,ship,andaccountforcustomerorders.[APICSdictionary]8ERP-1990’sAnaccounting-orienTheVisionTheDeliveryMRPMRPIIERPExtendedERPReducedinventorythrough“infinite”manufacturingplanningReducedinventory,fewerstock-outsandaccuratefinancialrecordsthrough“infinite”manufacturingplanningandperiodictransactionprocessing.Customerfocused,dynamicallybalancedenterprisethroughassetoptimizationandreal-timetransactionprocessing.Customerfocused,dynamicallybalancedvaluenetworkthroughassetoptimizationandreal-timetransactionprocessing.MRPMRPIIMRPII(plus)SupplyChainSourceGartnerGroupThevisionofERPisEvolvingtoincludetheExtendedEnterprise9TheVisionTheDeliveryMRPMRPI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資訊系統之演進MRPI--1960~198010資訊系統資料來源:資策會MICITIS計畫11資訊系統資料來源:資策會MICITIS計畫11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12企業應用軟體演變趨勢E-BusinessE-CommerceE-BusinessApplicationArchitecture=e-commerceE-business+ERP+SCM+MES/MCS+KM+CRMCustomerEmployeeSupplierE-ProcurementCustomerRelationshipManagementEnterpriseApplicationsIntegrationManufacturingExecutionManufacturingControlKnowledgeManagementSupplyChainManagementEnterpriseResourcePlanningSellingChainManagement13E-BusinessApplicationArchite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製造環境分類以製造策略分類14製造環境RepetitiveproductionProductJobshopFlow

shopCustomLowvolumedifferentiatedHighvolumedifferentiatedCommoditySpecialtychemicals

anddrugsAerospaceIndustrialmachineryMachinetoolsElectricalandelectronicsPaperContainersBrewersAutomobile

Tireandrubber

SteelproductsMajorchemicalsanddrugsOil

Steel

ForestproductsProcessSource:Tayloretal.,hytheProcessIndustriesAreDifferent,?ProductionandInventoryManagementJournal,1981.One-of-a-kindPERT/CPMMRP;CRPMRP;LineBalancingJIT15製造環境RepetitiveproductionProduManufacturingSystemModelBusinessPlanningSalesPlanningProductionPlanningMPSMRPDemandManagementFinancePlanningResourceRequirementsPlanningRough-CutCapacityPlanningCapacityRequirementsPlanningPurchasingProductionActivityControlMidTermLong-TermShort-TermInventoryManagementInput/OutputControl16ManufacturingSystemModelBusiCapacityManagementinMPSSystemResource

requirements

planningRough-cut

capacity

planningCapacity

requirements

planningPurchasingMaterial

requirements

planningMessageto

BUYorMAKEProductionactivitycontrolMaster

production

schedulingProductionplanningInput/OutputanalysisOperationSequencing17CapacityManagementinMPSSysCapacityPlanningandControlPriorityCapacityPlanningControlPPMPSMRPRRPRCCPCRPInput/OutputControlOperationSequencing18CapacityPlanningandControlPCapacityDefinitionTherateatwhichworkiswithdrawfromthesystem.Thehighestreasonableoutputratewhichcanbeachievedwiththecurrentproductspecifications,productmix,workforce,plant,andequipment.[APICSdictionary]19CapacityDefinitionTherateatCapacityManagementThefunctionofestablishing,measuring,monitoring,andadjustinglimitsorlevelsofcapacityinordertoexecuteallmanufacturingschedules.[APICSdictionary]Includecapacityplanningcapacitycontrol20CapacityManagementThefunctioWorkCenterandLoadWorkCenterAspecificproductionfacility,consistingofoneormorepeopleand/ormachines,whichcanbeconsideredasonunitforpurposesofcapacityrequirementsplanninganddetailedscheduling.[APICSdictionary]LoadTheamountofscheduledworkaheadofamanufacturingfacility,usuallyexpressedintermsofhoursofworkorunitsofproduction.[APICSdictionary]21WorkCenterandLoadWorkCenteWight’sFunnelCAPACITYLOADOUTPUT22Wight’sFunnelCAPACITYLOADOUTPCapacityandLoad[APICS]CapacityLoad(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,Other23CapacityandLoad[APICS]CapacCapacityPlanningTermsLoadAvailableWeekHoursperresourceCapacityPlanningTermsLoadAvaCapacityUtilizationScenariosLoadAvailableLoadAvailableLoadAvailableBalancedUnderloadedOverloadedCapacityUtilizationScenariosDeterminingCapacityAvailableDemonstrated(Measured)Capacitytheaveragerecentoutputactuallyachieved,isfiguredfromhistoricaldataisdefinedasaverageoutput,notmaxoutputRated(Calculated)Capacityavailablehours×utilization×efficiency26DeterminingCapacityAvailable6%6%62%13%13%BreaksR.MaintenanceRunTimeUn-utilizedbutscheduledtimeSetupTimeUtilizationActualtimeused(runandsetup)ScheduledtimeintendedforproductionUtilization=Ameasureofhowintensivelyaresourceisbeingused….276%6%62%13%13%BreaksR.MaintenaUtilizationExample:

Breaks:20minutespershift Routinemaintenance:10minutespershift Runtimecharged:6hours Setuptime:0.5hour Utilization=

28UtilizationExample:28EfficiencyAmeasureofhowcloselypredeterminedstandardsareachieved.Actualoutput(standardhoursearned)Standardoutputexpected(scheduled)efficiency=29EfficiencyAmeasureofhowcloEfficiencyExample:

Workcenter:3machines,two8-hrsshifts,fivedaysaweek Breakdown:12hrsperweekUtilization=

recordsindicatethattheworkcenterproducedanaverageof250.8sta.Hoursofoutput.Efficiency=Capacity=

30EfficiencyExample:30CapacityDeterminationShiftperDay

MachinesorWorkStationsHoursperShiftDaysperWeekUtilizationEfficiency=StandardHoursperWeekEx:

Shifts=3ShiftLength=8hrs5DaysperWeekNumberofMachines=6MachineUtilization=.8Efficiency=.931CapacityDeterminationShiftpeRough-CutCapacityPlanningTheneedforlongplanninghorizonsandthelackofspecific,accuratedataformanyimportantfactorsmakeRCCPtechniquesmorepracticalthandetailedcalculationsAcapacityplanshouldnotbedeferred;rough-cutapproachesareverypractical32Rough-CutCapacityPlanningTheBillofResource(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。33BillofResource(BillofLaboRCCPProcedureConvertingunitsofproductintheMPStostandardhoursofworkinindividualcentersToaccumulateineachperiodintheMPSthetotalhoursofworkrequiredtoproduceallproductsscheduledinthatperiodnoLToffsettingnolot-sizingnosignificantchangesininventoriesofitems34RCCPProcedureConvertingunitsRoutingforProductXProductXSEQ

WorkCenter

UsageOP11 0.1hrs/pcOP22 0.5hrs/pc12438765PERIODSPlannedOrderReleasedProductX100508010040609035RoutingforProductXProductXRoutingforAssy-01Assy-0112438765PERIODSPlannedOrderReleasedAssy-01SEQ

WorkCenter

UsageOP12 0.2hrs/pcOP23 0.8hrs/pc100508020018040609036RoutingforAssy-01Assy-011243ResourceLoadProfileWorkCenter205010015020025012345678PeriodLoadOthersAssy-01ProXCapacity37ResourceLoadProfileWorkCentBOMforFG38BOMforFG38ItemMasterFilesforFG39ItemMasterFilesforFG39RoutingFilesforFG40RoutingFilesforFG40WorkCenterMasterFiles41WorkCenterMasterFiles41MPSforPart10042MPSforPart10042RCCP-ProcessTimeComputation43RCCP-ProcessTimeComputation4RCCP-BORComputation44RCCP-BORComputation44RoughCutCapacityRequirements45RoughCutCapacityRequirementRCCP46RCCP46RCCPA11A12A22A21WC1WC2P1P2B11B12B22B21P1P2M1M2C11C12C22C21WC1WC2M1M2RCCPMPSBOR47RCCPA11A12A22A21WC1WC2P1P2B11BBackwardandForwardSchedulingOPNOPN-1OP1………ForwardschedulingBackwardschedulingOrderDueDateOrderStartDateOPN-148BackwardandForwardSchedulinInfiniteandFiniteLoadingInfiniteFiniteCapacityCapacity49InfiniteandFiniteLoadingInfCRPDefinitionThefunctionofestablishing,measuring,andadjustinglimitsorlevelofcapacityTheprocessofdeterminingindetailtheamountoflaborandmachineresourcesrequiredtoaccomplishthetasksofproduction[APICSDictionary]50CRPDefinitionThefunctionofCapacityRequirementsPlanningCapacityRequirementsPlanningPlannedordersReleasedordersRoutingWorkcenterWorkcenterloadreportRevisedschedule51CapacityRequirementsPlanningManufacturingOrderandRoutingManufacturingOrder(WorkOrder)Adocument,groupofdocuments,orscheduleidentityconveyingauthorityforthemanufactureofspecifiedpartsorproductsinspecifiedquantities.[APICSdictionary]RoutingAsetofinformationdetailingthemethodofmanufactureofaparticularitem.Itincludestheoperationstobeperformed,theirsequence,thevariousworkcenterstobeinvolved,andthestandardsforsetupandrun(times).[APICSdictionary]52ManufacturingOrderandRoutinInputsNeededforCRPOpenOrderFilePlannedOrderReleasesRoutingFileoperationstobeperformedsequenceofoperationsworkcenterstobeusedpossiblealternateworkcenterstoolingneededateachoperationstandardtimes:setuptimes,runtimesWorkCenterFilemovetime,waittime,queuetimeShopCalendar53InputsNeededforCRPOpenOrdLeadTimeManufacturingLTqueue,setup,process,wait,moveAverageQ(SU+RT)1+(SU+RT)2+…+(SU+RT)nqueuesetupprocesswaitmove12nW/C……..WIP54LeadTimeManufacturingLTqueueExpectedQueueingTimeActivationQueueingTime0.80.840.880.920.961.00Assumption:M/M/1queueingsystemE(Q)=a/[s(a-s)];a:ave.arrivalrate;s:ave.servicerateActivation=a/s55ExpectedQueueingTimeActivatiARevisedDefinitionofCapacityAvailableCapacityavailable=TimeavailableEfficiencyAvailabilityActivationAvailability1-thefractionoftimedownduetomachinebreakdownand/orabsenteeismActivation1-thefractionofdownduetolackofworkUTILIZATION56ARevisedDefinitionofCapaciHowLoadIsDetermined?TheproductionplanlongrangerateofproductionTheMPSdriveMRPMRPgenerateplannedordersreleased(open)ordersCRP(capacityrequirementsplanning)calculatesstdhoursrequired,byW/C,bytimeperiod,basedonplannedandopenorders57HowLoadIsDetermined?TheproLoadDeterminationOpenOrders(fromorderfilestatusfilemaintainedbyproductioncontrol)orderduedateorderquantityoperationscompletedoperationremainingMRP-plannedOrderReleases(fromMRP’soutput)plannedorderreleasedateplannedorderreceiptdateplannedquantity58LoadDeterminationOpenOrdersDataRequirementsforCRPValidduedatesonallreleasedandplannedordersUp-to-dateroutingsandprocessinginformationAccuratestandardsforsetupandprocessingtimeAschedulingprogramtohandlealloperationsAloadingprogramtoassignworktotimeperiodsStandardqueueallowancesforallworkcentersEstimatesofloadduetounplannedoccurrences59DataRequirementsforCRPValidMRPforFG60MRPforFG60CRPComputationSetuptimecomputationforplannedorderRuntimecomputationforplannedorderSetuptimecomputationforopenorderRuntimecomputationforopenorderCRPloadreport61CRPComputationSetuptimecompPlannedOrderReleases62PlannedOrderReleases62SetupTimeMatricesforFG63SetupTimeMatricesforFG63RunTimeMatricesforFG64RunTimeMatricesforFG64CapacityReq.ofPlannedReleases65CapacityReq.ofPlannedReleaCapacityReq.byReleasedOrders66CapacityReq.byReleasedOrdeCapacityRequirementsPlanforFG67CapacityRequirementsPlanforCRP68CRP68W/CCapacityvs.AverageLoadTheformalplandoesnotincludealltheloaditwillbenecessarytohandlenewproductsnotinthecurrentMPSuseofalternateroutingsandprocessingscrapreplenishmentandreworkoperationsadditionalprocessingneededforanyreasonrecorderrorsresultinginadditionalmaterialrequirementsSomeoftheloadmustremaininthecentertoprovidetheplannedstandardqueue69W/CCapacityvs.AverageLoadInput/OutputControlInputRateControlOutputRateControlQueue(WIP,Load)70Input/OutputControlInputRateInput/OutputControlInput/Outputcontrolisamethodtomanagequeuesandwork-in-processleadtimesInput/OutputControlReportWeekEnding:06/0606/1306/2006/2707/0307/1007/17InputPlanned182203172178193205208Actual197180168191189CumDeviation15-8-121-3OutputPlanned207207207207207207207Actual213202206210212CumDeviation61038QueueBegging:300hrsPlanned275271236207193191192Actual28426222420518271Input/OutputControlInput/OutpDefinitionPlannedInputWorkexpectedtoarrivebytimeperiodbasedonCRPconstraintsexpressedinstandardhoursorothercommonunitofmeasurePlannedOutputWorktobereducedbytimeperiodtoreducequeue,planoutputgreaterthaninputmakecapacityavailable72DefinitionPlannedInput72DefinitionPlannedQueueBeginningqueue+plannedinput-plannedoutputweekending06/06:300+182-207=275weekending06/13:275+203-207=271continuingforeachsucceedingweekActualInputWorkarrivingatworkcenterbytimeperiod,sameunitofmeasureobtainedfromreportingsystemsormanuallogsaffectedbyreleasestoshop,flowfromprioroperations73DefinitionPlannedQueue73DefinitionActualInputWorkarrivingatworkcenterbytimeperiod,sameunitofmeasureobtainedfromreportingsystemsormanuallogsaffectedbyreleasestoshop,flowfromprioroperationsActualOutputStandardhoursproducedduringeachperiodfromreportingsystemsormanuallogsaffectedbyresources,efficiency,workload74DefinitionActualInput74DefinitionActualQueueBegging(orpriorperiod)queue+actualinput-actualoutputweekending06/06:300+197-213=284verifiedperiodicallytoconfirmaccuracyofinputandoutputdataControlmeasureactualtoplanactualoutputvs.plannedoutputactualoutputvs.actualinputactualinputvs.plannedinput75DefinitionActualQueue75Input/OutputComparisonsActualoutputplannedoutputQueues,LTnotenoughinput?Insufficientcapacity?Actualoutputplannedoutputmayrunoutofwork,excesscapacityActualinputplannedinputmayrunoutofworkfeedingw/cbehindschedule,lateorder76Input/OutputComparisonsActualInput/OutputComparisonsActualinputplannedinputworkreleasedearly,queue<feedingw/caheadofscheduleActualoutputactualinputworkreleasedearly,queue<notenoughcapacityActualoutputactualinputworkreleasedlate,mayrunoutofworkfeedingw/cbehindschedule,idlecapacity,lateorder77Input/OutputComparisonsActualDispatchingRulesFirstcome,firstserved(FCFS)EarliestJobDueDate(EDD)EarliestOperationDueDate(ODD)OperationstartdatesCriticalratios(CR)Shortestprocesstime(SPT)OthermethodsDispatchingRulesFirstcome,fDispatchingRules79DispatchingRules79CapacityManagement80CapacityManagement80製造環境特性特性

JobShop

Repetitive/Batch產品定位策略 Make-to-order Make-to-stock Engineer-to-order Assemble-to-order產量 低 高批量 分攤setupcost 1Queue,move,waittime 高(70%~90%) 低產能 Standardhours CycletimeRoutings 變動 固定Dispatching 複雜 FCFSlayout 功能別佈置 產品別佈置SFC推式(push)拉式(pull)Reportingdetail 高 低81製造環境特性特性 JobS製造環境比較

One-of-a-KindFixedlocationFixedbyjobsiteTrucks,cranesSingleproductHighVerylongSatellites,constructionPlantOrganizationRoutingMaterialHandlingProductMixAmountWIPTimetoManufactureExamplesJobShopVariablebyproductFunctionaldepartmentsForklifts,totebinsManyproductsHighVariablebyproductTools,furnitureRepetitiveFixedbyassemblylineFixedbylineConveyors,containersSimilarproductsLowShortAutoassembly,tiresFlowShopFixedbyplantFixedbyplantConveyors,pipelinesSimilarproductsLowShortwithlongrunsOil,steel,cementSource:APICS,CPIMmaterials199882製造環境比較One-of-a-KindFixedlocaConclusionsManagingorderLTsrequiresmanagingbothpriorityandcapacityCapacityplansshouldusethebroadestpossibleproductgroupsthatgothroughsimilarmanufacturingoperationsCapacitymustbeadequatetosupporttheMPSandhandleadditionalunplanneddemands83ConclusionsManagingorderLTs產能管理

(CapacityManagement)Ahua.liao84產能管理

(CapacityManagement)AhuaOutline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85Outline生產環境演變與相關管理工具之關係2CompetitivePriority1950~1960Cost1970~1980Quality1990~2000Delivery、Flexibility、ServiceGlobal-wise86CompetitivePriority1950~19603CompetitivePriority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87CompetitivePriority手工藝時代大量生產豐PlanningEvolutionMRPMRPIIERP1970198019902000APS88PlanningEvolutionMRPMRPIIERPMRP-1960’sand70’sMaterialRequirementsPlanningMasterProductionSchedulingUnconstrainedDemandSupply89MRP-1960’sand70’sMaterialReMRPII-1980’sUnconstrainedManufacturingPlanningandControl,withmanualprocessesto“closetheloop”CapacityManagementFinancialIntegration90MRPII-1980’sUnconstrained7ERP-1990’sAnaccounting-orientedinformationsystemforidentifyingandplanningtheenterprise-wideresourcesneededtotake,make,ship,andaccountforcustomerorders.[APICSdictionary]91ERP-1990’sAnaccounting-orienTheVisionTheDeliveryMRPMRPIIERPExtendedERPReducedinventorythrough“infinite”manufacturingplanningReducedinventory,fewerstock-outsandaccuratefinancialrecordsthrough“infinite”manufacturingplanningandperiodictransactionprocessing.Customerfocused,dynamicallybalancedenterprisethroughassetoptimizationandreal-timetransactionprocessing.Customerfocused,dynamicallybalancedvaluenetworkthroughassetoptimizationandreal-timetransactionprocessing.MRPMRPIIMRPII(plus)SupplyChainSourceGartnerGroupThevisionofERPisEvolvingtoincludetheExtendedEnterprise92TheVisionTheDeliveryMRPMRPI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快速反應市場需求跨地區、跨幣別的即時、整合資訊93資訊系統之演進MRPI--1960~198010資訊系統資料來源:資策會MICITIS計畫94資訊系統資料來源:資策會MICITIS計畫11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95企業應用軟體演變趨勢E-BusinessE-CommerceE-BusinessApplicationArchitecture=e-commerceE-business+ERP+SCM+MES/MCS+KM+CRMCustomerEmployeeSupplierE-ProcurementCustomerRelationshipManagementEnterpriseApplicationsIntegrationManufacturingExecutionManufacturingControlKnowledgeManagementSupplyChainManagementEnterpriseResourcePlanningSellingChainManagement96E-BusinessApplicationArchite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-stock97製造環境分類以製造策略分類14製造環境RepetitiveproductionProductJobshopFlow

shopCustomLowvolumedifferentiatedHighvolumedifferentiatedCommoditySpecialtychemicals

anddrugsAerospaceIndustrialmachineryMachinetoolsElectricalandelectronicsPaperContainersBrewersAutomobile

Tireandrubber

SteelproductsMajorchemicalsanddrugsOil

Steel

ForestproductsProcessSource:Tayloretal.,hytheProcessIndustriesAreDifferent,?ProductionandInventoryManagementJournal,1981.One-of-a-kindPERT/CPMMRP;CRPMRP;LineBalancingJIT98製造環境RepetitiveproductionProduManufacturingSystemModelBusinessPlanningSalesPlanningProductionPlanningMPSMRPDemandManagementFinancePlanningResourceRequirementsPlanningRough-CutCapacityPlanningCapacityRequirementsPlanningPurchasingProductionActivityControlMidTermLong-TermShort-TermInventoryManagementInput/OutputControl99ManufacturingSystemModelBusiCapacityManagementinMPSSystemResource

requirements

planningRough-cut

capacity

planningCapacity

requirements

planningPurchasingMaterial

requirements

planningMessageto

BUYorMAKEProductionactivitycontrolMaster

production

schedulingProductionplanningInput/OutputanalysisOperationSequencing100CapacityManagementinMPSSysCapacityPlanningandControlPriorityCapacityPlanningControlPPMPSMRPRRPRCCPCRPInput/OutputControlOperationSequencing101CapacityPlanningandControlPCapacityDefinitionTherateatwhichworkiswithdrawfromthesystem.Thehighestreasonableoutputratewhichcanbeachievedwiththecurrentproductspecifications,productmix,workforce,plant,andequipment.[APICSdictionary]102CapacityDefinitionTherateatCapacityManagementThefunctionofestablishing,measuring,monitoring,andadjustinglimitsorlevelsofcapacityinordertoexecuteallmanufacturingschedules.[APICSdictionary]Includecapacityplanningcapacitycontrol103CapacityManagementThefunctioWorkCenterandLoadWorkCenterAspecificproductionfacility,consistingofoneormorepeopleand/ormachines,whichcanbeconsideredasonunitforpurposesofcapacityrequirementsplanninganddetailedscheduling.[APICSdictionary]LoadTheamountofscheduledworkaheadofamanufacturingfacility,usuallyexpressedintermsofhoursofworkorunitsofproduction.[APICSdictionary]104WorkCenterandLoadWorkCenteWight’sFunnelCAPACITYLOADOUTPUT105Wight’sFunnelCAPACITYLOADOUTPCapacityandLoad[APICS]CapacityLoad(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,Other106CapacityandLoad[APICS]CapacCapacityPlanningTermsLoadAvailableWeekHoursperresourceCapacityPlanningTermsLoadAvaCapacityUtilizationScenariosLoadAvailableLoadAvailableLoadAvailableBalancedUnderloadedOverloadedCapacityUtilizationScenariosDeterminingCapacityAvailableDemonstrated(Measured)Capacitytheaveragerecentoutputactuallyachieved,isfiguredfromhistoricaldataisdefinedasaverageoutput,notmaxoutputRated(Calculated)Capacityavailablehours×utilization×efficiency109DeterminingCapacityAvailable6%6%62%13%13%BreaksR.MaintenanceRunTimeUn-utilizedbutscheduledtimeSetupTimeUtilizationActualtimeused(runandsetup)ScheduledtimeintendedforproductionUtilization=Ameasureofhowintensivelyaresourceisbeingused….1106%6%62%13%13%BreaksR.MaintenaUtilizationExample:

Breaks:20minutespershift Routinemaintenance:10minutespershift Runtimecharged:6hours Setuptime:0.5hour Utilization=

111UtilizationExample:28EfficiencyAmeasureofhowcloselypredeterminedstandardsareachieved.Actualoutput(standardhoursearned)Standardoutputexpected(scheduled)efficiency=112EfficiencyAmeasureofhowcloEfficiencyExample:

Workcenter:3machines,two8-hrsshifts,fivedaysaweek Breakdown:12hrsperweekUtilization=

recordsindicatethattheworkcenterproducedanaverageof250.8sta.Hoursofoutput.Efficiency=Capacity=

113EfficiencyExample:30CapacityDeterminationShiftperDay

MachinesorWorkStationsHoursperShiftDaysperWeekUtilizationEfficiency=StandardHoursperWeekEx:

Shifts=3ShiftLength=8hrs5DaysperWeekNumberofMachines=6MachineUtilization=.8Efficiency=.9114CapacityDeterminationShiftpeRough-CutCapacityPlanningTh