生产计划重点复习资料(修正)

PAGEPAGE7一、名词解释1、Engineertoorder订货工程Firstdesignproductsaccordingtocustomer’srequirementafterreceivingorder,thenpurchase,andthenmakethem.2、Assemblytoorder订货组装Firstproducesemi-finishedproducts(partsandcomponents)inadvance,thenassemblethemintodifferentproductsaccordingtocustomerorder.e.g.automobilemanufacturing.3、Maketoorder订货制造Allproductshavebeendesignedinadvancethenaccordingtocustomerorders,buyrawmaterials,parts,andcomponents,andthenmanufactureandassemblythemintoproductsthecustomerrequires.4、Principleofprocessspecialization工艺专业化原则Organizetheproductionunitsaccordingtoaproductionprocesskind.5、Grouptechnology成组技术Allocatedifferentequipmentsintoaproductioncelltoworkonaproductfamilythathavesimilarshapesandprocessrequirements.6、Objectspecialization:对象专业化原则theproduceunitisorganizedaccordingtoaproductkind6、ProductLifeCycle产品生命周期Thetimedurationfromthetimewhenaproductisputintomarkettotimewhenitdisappearinthemarket.Typicalproductlifecycleconsistsoffourmajorsegments:（MatchingProcessandProductLifeCycles）1)Startup引入期2)Rapidgrowth成长期3)Maturation成熟期4)Stabilizationordecline衰退期7、Aggregateplanning综合计划Whichmightalsobecalledmacroplanning,addressesproblemofdecidinghowmanyemployeesthefirmshouldretainand,foramanufacturingfirm,thequantityandthemixofproductstobeproduced.8、AggregateUnits综合单元1）Intermsof“average’item-whentheitemsproducedaresimilar;2）Intermsofweights(tonsofsteel),volume(gallonsofgasoline),amountofworkrequired(worker-yearsofprogrammingtime),anddollarvalue(valueofinventoryindollars)-whenmanykindsofitemsareproduced.9、Inventory库存Inventoryisthestockofanyitemorresourceusedinanorganization.Aninventorysystemisthesetofpoliciesandcontrolsthatmonitorslevelsofinventoryordetermineswhatlevelsshouldbemaintained.Generally,inventoryisbeingacquiredorproducedtomeettheneedofcustomers.10、TypesofInventoriesAnaturalclassificationisbasedonthevalueaddedfrommanufacturingoperations

(1)Rawmaterials:Resourcesrequiredintheproductionorprocessingactivityofthefirm.

(2)Components:Includespartsandsubassemblies.

(3)Work-in-process(WIP):theinventoryeitherwaitinginthesystemforprocessingorbeingprocessed.

(4)Finishedgood:alsoknownasenditemsorthefinalproducts.11、MRP(MaterialsRequirementsPlanning)物料需求计划MRPisthethespecificpartsandmaterialsrequiredtoproduceenditemsplannedbyMPS;theexactnumbersneeded;Thedatewhenordersforthesematerialsshouldbereleasedandbereceivedorcompletedwithintheproductioncycle.13、BOM（BillofMateriel）物料清单MRP-InputsBOMcontainscompletedescription,listingnotonlythematerials,parts,andcomponentsbutalsothesequenceinwhichtheproductiscreated;BOM,alongwithMPSandinventoryrecordarethethreeinputs.BOMisoftencalledproductstructurefileorproducttreebecauseitshowhowallthematerials,parts,components,andsubassembliesareputtogethertoformaproduct.15、Jobshop作业车间Ajobshopisorganizedbymachineswhicharegroupedaccordingtotheirfunctions,nosimilarpatternofmovementofjobsfromonemachinetothenext.16、Flowshop流线型车间Inaflowshopeachofthenjobsmustbeprocessedthroughthemmachinesinthesameorder,andeachjobisprocessedexactlyonceoneachmachine.alljobsfollowthesamepathsfromonemachinetothenext.17、FlowtimeTheflowtimeofjobiisthetimethatelapsesfromtheinitiationofthefirstjobonthefirstmachinetothecompletionofjobi.Themeanflowtime,whichisacommonmeasureofsystemperformance,isthearithmeticaverageoftheflowtimesforallnjobs18、Make-spanThemake-spanisthetimerequiredtocompleteagroupofjobs(allnjobs).Minimizingthemake-spanisacommonobjectiveinmultiple-machinesequencingproblems.二、简答题1、Classifiedbasedoncustomization:1)maketostock.2)productionfororder(assemblytoorder、maketoorder、engineertoorder).Maketostock备货型生产Characteristic:(1)productionbasedontheforecasting(2)massproduction,inbigbatch(3)highproductinventory(4)highproductivity(5)simpleproductionorganizationDisadvantage:highriskofexcessinventoryororderoutofstockProductionfororder订货型生产Characteristics:(1)productionbasedontheorder(2)differentproducthasdifferentspecification,quantity,qualityanddeliverytime（交货时间）(3)nearlyzeroinventory(4)deliverytimeisthekey(5)multi-productandlowvolumeproduction(6)complexproductionorganizationandmanagement(7)highcustomersatisfactionproductionfororderbecomesmoreandmorepopular.Accordingtothelevelofcustomization,itcanbefurtherclassifiedintoassemblytoorder订货组装,maketoorder订货制造andengineertoorder订货工程2、OperationStrategyFrameworkTwoTraditionalStrategicDimensionsLowerCost低成本战略Newentrantstoamarketoperateonlowcoststrategy;Examples:Koreanautomakers:Hyundai,DaewooandKia;Discountoutlets:CostcoRetailers:Wal-Mart;Maybesuccessfulovershortterm,butriskyinlongrun-lowcost<>poorquality;ProductDifferentiation产品差异化战略Providinguniquenesstobuyers:BMW--highperformance,wellmadecars;evenhighprice;Productdifferentiationwithinafirmtocapturedifferentmarketsegments:GM-asuccessfulcase,HenryFordasoppositecase.OtherStrategicDimensionsQuality;质量Deliveryspeed;交货速度Deliveryreliability;交货可靠性Flexibility;柔性3、TheClassicalViewofOperationStrategy(1)Timehorizon:ithastheimpactsofshort-term/medium-short/long-termstrategy.(2)Focus:Fivekeycharacteristicsofthefocusedfactory:1)Processtechnologies2)Marketdemand3)Productvolumes4)Qualitylevels5)Manufacturingtasks(3)Evaluation:Dimensionsforevaluatingproductionandoperations,including:1)Cost2)Quality3)Profitability4)Customersatisfaction(4)Consistency:Strategyisthecompositeofallcompanypoliciesthataffectmanufacturing.4、ModernOperationsStrategy(1)BPRBusinessProcessReengineering(BPR)isnotaspecifictechnique,instead,itistheideathatbusinessprocessescanbechangedandimproved.GeneralprinciplesforBPR：SeveraljobsarecombinedintooneWorkersmakedecisionsThestepsintheprocessareperformedinanaturalwayProcessesshouldhavemultipleversionsWorkisperformedwhereitmakethemostsense(2)JITJITisbothamanufacturingprocessononehandandbroad-basedoperationstrategyontheotherhand;Thecoreofitsphilosophyistoeliminatewastebyefficientschedulingofincomingorders,work-in-process(WIP)inventories,andfinishedgoodsinventories.JITadvantagesoverconventionalsystems：ReducedcostresultedfromeliminatingWIP;Enabledquickdetectionofquality;Tighteneduprelationshipwithsuppliers;JITisnottheanswerforallmanufacturingsituations：variationinconsumerdemand;variationinherentintheproductionprocessorequipment.(3)Time-BasedCompetitionTime-basedcompetitionisakeyfactorleadingtosuccessorfailure.Time-basedcompetitionfocusonentirevalue-deliverysystem,attemptstotransformanorganizationintoonethatfocusonthetotaltimeneededfordeliveringaproductoraservice.Thegoalisnottodesignthebestwaytoperformatask,buttoeithereliminatethetaskaltogetherorperformitinparallelwithothertasksinordertoreduceoverallsystemresponsetime.(4)CompetingonQualityQualitymeansdifferentthingsindifferentcontexts:Ahigh-qualityproductperformwellasitwasdesignedtoperform;Productswillperformastheyaredesignedtoperform,ifthereislittlevariationinmanufacturingprocess;ItispossibleforapoorlydesignedproducttoperformwellandItispossibleforawelldesignedtoperformpoorly.Forexample,Fordimprovedbothqualityandinnovation,providingbuyerswithreliableandtechnologicallyadvancedcars.5、ComparingofES(指数平滑)andMA(移动平均)Similarities:(1)Bothmethodsarebasedonassumptionthatunderlyingdemandisstationary.(2)Bothmethodsdependonasingleparameters.(3)Bothmethodswilllagbehindatrendifoneexits.Differences:(1)MAisbetterthanEAinthatitneedsonlypastNdata,whileEAneedsallthepastdata;(2)ItissignificantadvantageofEAoverMAthatitonlyneedstosavethelastforecast,whileMAneedstostoreNpastdata.8、AP-CostsinAggregatePlanning(1)Smoothingcost-Occursasresultofchangingtheproductionlevelfromoneperiodtothenext.(2)Holdingcosts-Occursasaresultofhavingcapitaltiedupininventory.(3)Shortagecosts-Shortageoccurswhendemandsarehigherthananticipated.(4)Regulartimecosts-Involvethecostofproducingoneunitofoutputduringregularworkinghours.(5)Overtimeandsubcontractingcosts-costsofproductionunitsnotproducedonregulartime.(6)Idletimecosts-underutilizationofworkforce.9、MotivationforHoldingInventories(1)Foreconomiesofscale

(2)Copingwithuncertainties(3)Forspeculation(4)Transportation(5)Smoothing(6)Logistics

(7)Controlcosts10、HPPconsidersworkforcesizesandproductionratesatvarietyoflevelsofthefirm.Therecommendedhierarchyisasfollows(层次生产计划)(1)Items-correspondtoindividualmodelsofwashingmachines.(2)Families-agroupofitems,e.g.allwashingmachines.(3)Types-groupsoffamilies,e.g.largehouseappliances.11、ThethreeinputsofMRP1)MPS:specifiesthenumberofitemstobeproducedduringspecifictimeperiods.2)BOM:identifiesthespecificmaterialsusedtomakeeachitemandcorrectquantitiesofeach.3)TheInventoryrecord:suppliesdatasuchasthenumberofunitsonhandandonorder.三、论述题1、Comparedifferenttypeofproductionsystemclassifiedbasedoncustomizationdegree,pointoutinwhichsituationtheycanbeused,illustratetheiradvantagesanddisadvantages.Classifiedbasedoncustomization:(1)maketostock备货型生产(2)productionfororder订货型生产maketostock备货型生产Characteristic:(1)productionbasedontheforecasting(2)massproduction,inbigbatch(3)highproductinventory(4)highproductivity(5)simpleproductionorganizationDisadvantage:(1)highriskofexcessinventoryororderoutofstockproductionfororder订货型生产Characteristics:(1)productionbasedontheorder(2)differentproducthasdifferentspecification,quantity,qualityanddeliverytime(3)nearlyzeroinventory(4)deliverytimeisthekey(5)multi-productandlowvolumeproduction(6)complexproductionorganizationandmanagement(7)highcustomersatisfactionProductionfororderbecomesmoreandmorepopular.Accordingtothelevelofcustomization,itcanbefurtherclassifiedintoassemblytoorder订货组装,maketoorder订货制造andengineertoorder订货工程Forexample:automobilemanufacturingisassemblytoorder,firstproducesemi-finishedproducts(partsandcomponents)inadvance,thenassemblethemintodifferentproductsaccordingtocustomerorder.theproductionofpartsandcomponentsaremadeandstoredwithfollowingproperties:highstandardizationandgeneralizationpartsorcomponents,bigproductionbatch,highproductivity,useflowproductionline.2、Theproduct-processMatrix(PPM).产品过程矩阵PPM:Linkproductandprocesslifecyclesintwodimensions.1)TheFourStagesintheevolutionofthemanufacturingprocessintermofprocessstructure—JobShop(jumbledflow);BatchProduction(disconnectedlineflow);AssemblyLine(connectedlineflow);andContinuousFlow(forprocessindustries,suchaschemicalplant).2)TheFourPhasesinproductLifeCyclesintermofproductionvolumeandthenumberofproducttypes—lowvolume,one-of-akind;lowvolume,multipleproducts;fewermajorsproducts,highervolume;andfewproducts,highvolume.Function:1、Tomatchappropriateindustryinitsmaturephasewiththeappropriateprocess.a、ItprovidesmeansofassessingifafirmisoperatingintheproperconditionsasshowninthediagonalinPPM,thatis,iftheprocessisproperlymatchedwithproductstructure;b、Firmschoosingtooperateonoffthediagonalshouldclearlyunderstandthereasonfordoingso.2、Toidentifythepropermatchoftheproductionprocesseswiththephasesoftheproductlifecycle.a、Inthestart-upphaseofproductdevelopment,thecompanywouldtypicallybepositionedontheupperleft-handcornerofthematrix;b、Asthemarketfortheproductmatures,thefirmwouldmovedownthediagonaltoachieveeconomiesofscale;c、Finally,thefirmwouldsettleatthepositiononthematrixthatwouldbeappropriatebasedonthecharacteristicsoftheproduct.对角线企业的特点:1)Locatedintheupperleftcornerarecompaniesthatspecializein“one-of-a-kind”jobsinwhichthemanufacturingfunctionhasthecharacteristicsofajumbledflowshop.Productionisinrelativelysmalllots,andtheshopisorganizedformaximumflexibility.2)Fartherdownthediagonalarefirmsthatstillrequireagreatdealofflexibilitybutproducealimitedlineofstandardizeditems.Adisconnectedlinewouldprovideenoughflexibility.3)The3rdclassdownthediagonalarefirmsthatproducealinestandardizedproductsforalarger-volumemarket.Theassemblylinewouldbeanappropriateprocesstechnology.4)Thelowerright-handportionareappropriateforproductsinvolvingcontinuousflowline,whicharecharacterizedbylowcost,standardizationofproduct,highsalevolume,andinflexibilityoftheproductionprocess.3、FrameworkofProductionPlanningActivities生产计划活动框架ProcessPlanningdeterminesthespecifictechnologiesandproceduresrequiredtoproduceaproductoraservice.ProductionStrategicplanningdetermineslong-termcapabilities(e.g.sizeandscope)andproductiondesicionAggregateplanningconcernswithsettingupproductionratebyproductfamilyorothercategoriesforintermediateterm(6-18months).Masterproductionschedulinggeneratestheamountsanddatesofspecificitemsrequiredbyorders.TheinputsintoMPSarearrivedordersandAPresults.TheinputsintoMPSarearrivedordersandAPresults.Rough-cutcapacityplanningisusedtoverifythattheproductionandwarehousefacilities,equipment,andlaborareavailable,andthekeysuppliershaveallocatedsufficientcapacitytoprovidematerialswhenneededMaterialrequirementplanningtakestheendproductrequirementsfromMPSandbreaksthemdownintotheircomponentsandsubassembliestocreateamaterialplan(productionordersandpurchaseorder).Capacityrequirementplanning(CRP)allocateproductionresourcestoeachproductionorder.Operationsschedulingallocatesjobstospecificmachines,productionlinesorworkcenters.4、MatchingProcessandProductLifeCycles(1)ProductLifeCycleThetimedurationfromthetimewhenaproductisputintomarkettotimewhenitdisappearinthemarket.TheProductlifecycles-indifferentphases,differentcompetitionstrategymaybeadopted.Typicalproductlifecycleconsistsoffourmajorsegments:1)Startup引入期Startup—thecompetitionisgenerallynotaproblem;concernonimprovementoftheproductionandmarketingfunctions;2)Rapidgrowth成长期Rapidgrowth—begintoseecompetition;establishtheproductasfirmlyaspossibleinthemarketplac