库存管理与生产计划

制造业的目标提高服务水平降低生产成本降低库存需求供给闭环通讯销售员工厂采购员制造资源计划管理层战略层应收帐成本基础财务库存项目主文件成本数据基础可配置

总帐应付帐经营计划资源BOM计划BOM制造BOM部门工作中心工艺路线运行层性能测试有限顺排主生产计划粗能力计划物料需求计划能力需求计划采购销售计划

订单予测生产计划录车间库存成品库原材料库子部件库部件库库存集成总帐

客户订单处理予测促销与另售分布资源计划成本库存应付帐物料需求计划能力计划主生产计划车间控制JIT/Repetitive制造数据管理采购

销售分析出货后勤项目类型BPCS保留项目类型虚拟件 0可选组合件 3固定组合件 4计划BOM 5非余额项目 6项目/项目类型/项目类别项目类别n

01-49成品010203n

50-69半成品5060n

70-89原材料7080项目主文件

n

产品n部件n另件外购件{{半成品毛坯件

项目类型n

装配件n

采购件n制造件外协件计量单位销售按支制造

按组销售采购/库存采购--桶库存--瓶墨水Ink替换替换项目

替换项目码定义1总替换2基本件不足时替换3替换件足够时替换可求净成品非求净可分配库存非可分配库存样品待验品Scrap在制品在途品可求净库存和可分配库存六级库库存管管理储位批批批批批仓库项目仓库场所容器储位储位储位批批号接收批号空手工输入1YYMMnnnnnn2YYnnnnnnnn3YYDDDnnnnn4用户定义算法批状态态批状态态说明A有效C有条件件通过过E期满H挂起Q因质量量挂起起R拒收V到达Z取消或或保留留已完完成批批订单单批跟踪踪仓库副产品F联产品G批D2批D1批C1批B1批A3批A2批A1批D3批G1批F1批E1原料库产品A产品B产品C产品D产品E加工批1批2批3批5批7批4批6成份AB1成份C1成份D1成份D2成份E1成份E2成份E3VENDORSMARKETPLACE事务影影响事务将将引起起库存存状态态和库库存量量的变变化库存事事务:调整发料收料库存状状态

期初库存-发料+收料+/-调整=现有量现有量

现有量-已分配量可用量变可用量制造数数据管管理粗能力计划

CAP有限顺排

FFS库存INV人员成本会计CST物料需求计划

MRP资源BOM

CAP细能力计划

CAP另部件详情

项目,仓库,

在制品和倒冲物料理生产成本核算关键资源

采购PUR车间控制

SFC/JITBOM和计划信息

详细工作中心可用能力

关键工作中心可用能力

工艺外协制造数据管理

MDM详细工工作中中心可可用能能力物料清清单制造BOM计划BOMBOMBOM单级ACB多级ACBFEDBOM树结结构父项状配项批成分成分制造部件原材料费采购件

制造数数据维维护BOM数据处理组号子项号需求数量废品率有效/失效日期工序号序号有效/失效效日期期项目号号需求量量有效日日期失效日日期AB11/1/YY99/99/99121/1/YY99/99/99211/1/YY5/31/YY2A16/1/YY99/99/991/1/YY99/99/99虚拟件用途：识别制造产产品的固有有另件简化BOM可以有库存存特点：提前期为零零部件订货政策为为直接批量量特征件和可可选件BOM礼品笔笔盒(100%)笔(100%)皮套

(30%)墨水蓝=30%

黑=50%红=20%

合计=100%红木盒

(30%)笔杆圆珠=70%

自来水=30%

合计=100%标准件100%选择%可以小于

100%可选件

合计=100%部门和工作中心场所

CH仓库AA场所

XX仓库CC仓库

BB部门100部门

200部门300部门400工作中心110工作中心

120工作中心210工作中心310工作中心320工作中心1100工作中心维维护工作中心

说明负荷码部门能力效率每日班次每班小时数设备数负荷百分比成本(系数)设备数据维维护设备数据部门固定资产标识从货位有效期截止期平均效率设备速度工艺路线部件库存

工作中心100成品库存

20工作中心200工作中心300304010工序工艺路线维维护工艺路线工序号状态工作中心基本码小时(人工,准备,机器)工具/备注有效/截止日期操作员工序时间或或非加工时间天非加工时间天加工时间小时排队加工机器搬运准备}变化固定固定固定基本码Blank 小时/件C 元/件H小时/件P 件/小时1 小时/10件2 小时/100件3 小时/1000件4 小时/10000件5 小时/100000件6 小时/1000000件替换工艺方方法成品货位工序10工序20工序30工序10工序10工序40工序10工序10工序10原材料货位生产线1方法L1生产线2方法L2生产线3方法L3货位1货位6货位3货位2货位5物料用途查查询层0层1层2用于的产品AEFBFDC生产计划MPSActualBacklogForecastInventoryCapacity总需求总需求生产计划和和MPS/MRP的的关系Daysin

Month生产计划

Jan2020,000Feb1919,000Mar2424,000Apr2020,000MasterProductionScheduleWeek产品A产品B

。。。..Total147505,000153005,000165,000175005,000AprilbyWeeks主生产计划产品德A500-Week17展开需求

500-Week14500-Week12500-Week6SubassemblyComponentRawMaterialPurchPartPurchPart主生产计划划项目类型型MPSMake-to-StockMPSCombination/

Assemble-to-OrderMake-to-OrderMPSEngineer-to-OrderMPS独立需求与与相关需求求DependentDemandSubassembly(alsosoldasservicepart)FinishedGoodsPurchaseComponentPurchaseComponentRawMaterialDependentDemandDependentDemandIndependentDemandDependentandIndependentDemand生产计划举举例PlanningStart

Date 11/15SystemDate 11/18Proration YesCalculation:16daysleftinperiodTotalof30daysinperiodX Forecastquantityof3000 = 1600PeriodQuantityStartDateEndDateDemandDateDemandQuantity1200010/110/31nonenochange2300011/111/3011/1516003200012/112/3112/1nochangePeriodQuantityStartDateEndDateDemandDateDemandQuantity2300011/111/3011/181300Demandtoon-lineinquirieswillchangedynamicallywithsystemdatechange.累计提前期期YABCXY关键路径CumulativeLeadTime = 2+3+5 = 1010987654321CXB产品A53226StartEndCumulativeLeadTime

forParentAMPS展望望期月/年 PlanningStartDate+ MPSHorizonDays= MPSHorizonDateStartdate 6thHorizondays 15Horizondate 21st谁来改变MPS?GeneralManagerMaterialsManagerMasterSchedulerMasterScheduler

cannotchange

withoutapproval

ofhigherlevel

authoritySalescannot

promiseordersSchedulercan

trytoaddIfScheduler

cannotadd,

salesmust

maketradeoffScheduler

limitedto

authorization

overplanningWeek工程改变管理改变改变限制改变能力0481216CumulativeLeadTime需求控制EngineertoOrderMaketoStock装配制造采购生产计划成本ForecastOnlyCustomerOrdersOnlyCumulativeLeadTimeMPSHorizonDemandTimeFenceCustomerOrdersOnlyGreaterofForecastandCustomerOrdersDemandTimeFenceMaketoOrderCustomerOrdersOnlyGreaterofForecastandCustomerOrdersAssembletoOrderDemandTimeFenceToday订货政策A 直接批量F 最新成本G 周期批量H 批量以上直接批量I IncrementAboveLotSizeJ MultipleofLotSizeK PeriodOrderQuantityBlank ReorderPoint和主生产计计划有关的的量GrossRequirementsCustomerOrdersandManufacturingAllocationsScheduledReceiptsProjectedOn-HandNetRequirementsPlannedOrderReceipts

andReleasesAvailable-to-PromiseMPS计计算PeriodOn-hand123456789GrossRequirements75300CustomerOrdersandManufacturingAllocations7550100ScheduledReceiptsProjectedOn-hand17510050-50-50-50-350-350-350-350NetRequirements2550100300PlannedOrderReceipts2550100300PlannedOrderReleases2550100300Available-to-Promise-50计划重排Period123456Required202020101020ScheduledReceipts404040ProjectedOn-Hand2545255-52545Period123456Required202020101020ScheduledReceipts4040ProjectedOn-Hand25525535255x订货应允量量CustomercallstoordermarkersCheckwhatisAvailable-to-PromisePromisemarkers

tocustomerCustomerisgiven

honest,reliabledate

Thiscustomerwill

callagain重订货点Leadtime=2periodsDemand=12.50pcs./periodonavg.ReorderPoint=50pcs.SafetyStock=25pcs.Lotsize=50pcs.QUANTITYTIME提前期安全库存2550750123456789101112ReorderPointMRP做做为库存管管理Leadtime = 2periodsSafetyStock = 25pcs.OrderPolicyCode= A(Discrete)1234567891011120255075TIMEQUANTITY计划量

安全库存提前期计划下达计划接收废品率与产产出率AYieldof90%C(1)NoScrapB(1)Scrapfactorof1.11111needed

toyield1000(Yieldof90%)1111neededtomake1111(NoScrap)1222neededtomake1111(Scrapfactorof1.1)Example和MRP有有关的量毛需求予计接收予计库存净需求计划接收计划下达达物料需求求计划GrossRequirementsScheduledReceiptsProjectedOn-HandPlannedOrderReceiptPlannedOrderReleaseAllocationsNetRequirementsGrossRequirementsScheduledReceiptsProjectedOn-HandPlannedOrderReceiptPlannedOrderReleaseAllocationsNetRequirementsDemandSupplyDifferencePlanDemandSupplyDifferencePlanPartAPeriod:12345505050303030301010-10-60105010501050PartBPeriod:12345SparePartsForecastforPartB(IndependentDemand)10201001020704020-80-80-9080100100(Assumesminimumbalance=0)A2BPartALeadTime=2PeriodsOrderPolicy:Discrete(lotforlot)PartBLeadTime=1PeriodOrderPolicy:Lotsize=100pcs.计划反查查A12MPSItemAPO10011/10-11/18PO10011/21-11/23B23MPSItemBFPO7511/16-11/19PO5011/17-11/20CommonItem2PO10011/9FPO7511/15PO5011/16PO10011/20PO=PlannedOrdersFPO=FirmPlannedOrders粗能力与与细能力力RoughCutDetailMPSOnlyMPSandMRPBillofResourcesRoutingCriticalWorkCentersAllWorkCentersMasterScheduledItemsAllManufacturedItemsPlannedOrdersPlannedOrdersFirmPlannedOrdersFirmPlannedOrdersReleasedProductionOrders工作中心心负荷图图HoursTimePeriodsCurrentCapacityPlannedLoad交叉排序序可用能力力Releasable?ReleaseShortNoNoYesYesYesManufacturingSchedulePre-ProductionReleaseMRP510ScheduleAdjustmentNoOn-handElsewhereNoteChangesSFC350MaterialAvailabilityMRP250ReleasableOrdersReportMaterialOK?CapacityOK?NoYesProductionMeetingAlternateItem计划下达达车间定单单打包分配例外领料单汇总领料单工艺卡工票Just-In-Time/Repetitive流流程图Work

FileJIT620ProductionUpdateProduction

UpdateProduction

Release/PrintJIT610ProductionDataListJIT600ProductionReporting物料发放放GatewayWorkCenterOperationSingleIssueIJMultipleIssueKitScheduleInstructionsSFC560OrderPickListSFC521SummarizedPickListLOCALOCBLOCDLOCCWarehouse计划短缺缺INV500IssueMaterialSFC400MassAllocationsMaterial

Received

ShortWarehouseSFC560ShopPacketReprintSFC720Lot/LocationAllocation数据收集集OrderNumberItemNumberScheduledStartDateOperationNumberWorkCenterDepartmentEmployeeNumberQuantityGoodQuantityRejectStartTimeStopTime工单反冲冲WarehouseMaterialIssueMaterialReceiptWorkcenter100Workcenter200Workcenter300Operation10Operation20Operation30RunMoveQueueSetupRunMoveQueueMachineREPORTINGPOINTQuantityHours退料接收收质量/实实验室产产品集成成质量管理系统QMSCapacityPlanningCAPCIMPathCIMAdvancedProcessIndustriesAPIJustinTime/RepetitiveJITInventoryINVLaboratoryManagementSystemLMSMRP/MPSProductionActivityControlPACSystemSYSPurchasingPURQMS处处理流流程质量检验书采样测试结果材料性能ISO9000系列列ISO9000ISO9001ISO9002ISO9003ISO9004ISO9004ISO9004ISO9004指南ManagementandSystemsQualityCostsMarketingDesignandSpecificationsPurchasingandProcessesVerificationCalibrationNonconformingCorrectiveActionPostproductionQualityRecordsPersonnelSafetyStatisticalMethodsISO9004导向QMSAPISFCMDMJITPURORDINV

BPCS执行指南ISO9001ISO9002ISO9003BASISImplementation換uality,intheISOmodel,isnotanisolatedbusinessfunction換uality,intheBPCSframework,isnotanisolatedbusinessfunctionBPCS和ISO质质量模模型QMSBPCSQualityManagementSystemTheWorldofISOTheWorldofBPCSIntegratedintotheMRPIIenvironmentQualityactivitiesoccurinrealtimeCompletespecificationmanagementsystemUserdefinedsamplelevelsandtypesUserdefinedsamplingplans,i.e.Mil-StdUserdefinedtestplansUserdefinedprocesscontrolsCompletecalibrationsystemExtensivecontrolsfornonconformingproductDatabaseaccessforstatisticalanalysisBPCS质量量管理系系统计划BOMPenGift

SetPackaging(100%)Pen

(100%)LeatherCase

(30%)Ink

Blue=30%

Black=50%Red=20%

Total=100%Mahogany

Case

(30%)Cartridge

Rollerball=70%

Fountain=30%

Total=100%Standard

Component100%Option%canbe

lessthan100%FeatureGroup

Total=100%装配计计划下达达FASPacketPrint订单输入

计划BOMBOM600PickListMRP530FASOrderNotReleasedInstructionsScheduleandDispatch订货书材料足够

OK?FAS500FAS下达

YesNoToShippingFAS510配置管理理流程的的改进OrderFulfillmentOrderEntryConfigurationManagementQuoteEntrySalesandMarketingEngineeringAccountingTimeTimeTimeFlowwithoutConfigurationManagementFlowwithConfigurationManagement配置管理理主文件件设置ManufacturingDataManagementBOM500RoutingMaintenanceSFC100ConfigurationStructureCFG550RulesMasterCFG130InheritedDataInheritedDataItemMasterINV100AttributeMasterCFG110VariableMasterCFG560在线销售售定单配配置StartSystempreparesCustomConfiguredOrderDoyouwantastandardsize?Whatwidthdoyouwant?Whatlengthdoyouwant?Wantwoodormetalmodel?Powerassistedoption?Systemautomaticallyspecifiesheavy-dutymotorSystemcalculatesareaandweightCalculatedweightmorethan

40Kg?YesNoYesNoDoyou

wantlight

orheavy

motor?工程改变变控制CustomersMarketingChangeControlEngineeringQualityControlFinanceManufacturingHumanResourcesPurchasingResearchandDevelopmentNeedsDesiresProposalsContractsOptimizeproduct,processandcostsAssesstechnicalfeasibility,developconcepts,process,andprototypeDefine,testandrefineproductrequirements,communicatecustomerreactionandproductpotentialDeterminecostandavailabilityofpurchasesJudgeeconomicopportunityandfeasibility,establishcostandinvestmentlimitsCanwedoit?Whatdoweneedtodoit?Assessskillsandheadcount,availability,andneedsDocurrentcontrolsapply?Whatmoreisneeded?Communicate,managetimeframe工程改变变YesBOM110EngineeringChangeControlledItemsBOM100EngineeringChangeOrderMaintenanceInternalProgramBOMMassUpdateProcessingBOM550ApprovalProcessingBOM190ManufacturingNotesMaintenanceBOM100ECODetailLineMaintenanceOrderClosedClosedECOInquiryBOM350EngineeringChangeOrderReportBOM205NoBOM620StockBasedEffectivityProcessingStatusComplete?9、静夜夜四无无邻，，荒居居旧业业贫。。。12月月-2212月月-22Thursday,December29,202210、雨中黄黄叶树，，灯下白白头人。。。13:18:2013:18:2013:1812/29/20221:18:20PM11、以我独独沈久，，愧君相相见频。。。12月-2213:18:2113:18Dec-2229-Dec-2212、故故人人江江海海别别，，几几度度隔隔山山川川。。。。13:18:2113:18:2113:18Thursday,December29,202213、乍见翻疑梦梦，相悲各问问年。。12月-2212月-2213:18:2113:18:21December29,202214、他乡生白白发，旧国国见青山。。。29十二二月20221:18:21下下午13:18:2112月-2215、比不不了得得就不不比，，得不不到的的就不不要。。。。十二月月221:18下下午午12月月-2213:18December29,202216、行动出出成果，，工作出出财富。。。2022/12/2913:18:2113:18:2129December202217、做前，能能够环视四四周；做时时，你只能能或者最好好沿着以脚脚为起点的的射线向前前。。1:18:21下下午1:18下下午13:18:2112月-229、没有失失败，只只有暂时时停止成成功！。。12月-2212月-22Thursday,December29,202210、很多事情情努力了未未必有结果果，但是不不努力却什什么改变也也没有。。。13:18:2113:1