供應(yīng)鏈管理規(guī)劃與執(zhí)行

1、1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2AgendanOverview/Features of SCMnSupply Chain Network DesignnAdvanced Planning and SchedulingnShop Floor ControlnMES/MCS3nEnterprise functional silos with conflicting goalsPurchasingManufacturingDistributionCustomer Service/SalesFew change- oversStable schedulesLong run len

2、gthsHigh inventoriesHigh service levelsRegional stocksSOURCEMAKEDELIVERSELL Low pur-chase priceMultiple vendorsLow invent-oriesLow trans-portationOverview of SCM - Issues4Overview and targets of SCMn Definition of Supply Chain Management: Supply Chain Management describes all kind of activities acro

3、ss multiplecompanies or locations to optimize the manufacturing of products. Herebyconcerning all interfaces on operational and strategic level for involvedassociates.n Main focusn Development of heterogeneous global production networksn Increased integration of advanced technologiesn Minimzing cost

4、s for inventories and deliveries n Long term relationships (customer / supplier binding)n Customer satisfactionn ByERP - BasisSCM - ToolsInternet5Overview and targets of SCMBuys Ingredients and ComponentsMakes aProductMoves it to a DistributionCenterStores it atDistributionCentersStores it in aWareh

5、ouseMoves itto StoresStores it in the StoreSells it toConsumersMulti Enterprise Supply ChainsSource: I2-Technologies6Overview and targets of SCMn Integration of suppliers in planning in consideration of.n Suppliers inventoriesn Suppliers manufacturing capacitiesn Transport times and capacitiesReduct

6、ion of own inventories7n Integrated planning of supply chains leads ton Reduction of inventoriesn Cost savingsn Capability to meet promised delivery datesIncreased customer satisfactionIntensified customer bindingPerspective to extend the sales marketOverview and targets of SCM8Prerequisites for suc

7、cessn No management method guarantees itself for successn Type of product leads to special type of supply chainPrimarily functional productsn Dont change much over timen Long life cyclesn Predictable demandn Stability invites competitionn Leads often to low profit marginsPrimarily innovative product

8、sn Enables higher profit marginsn Short life cycle (typically few month)n Volatile demandn Newness makes demand unpredictablen Importance of early sales9Prerequisites for successPrimarily functional productsn Supply at lowest costs to predictable demandn High utilization rate of capacityn Minimize i

9、nventoriesn Short lead time as it doesnt increase costsn Select suppliers primarily for costs and quality Physical efficiencyMinimize costs by n Physical efficiencyPrimarily innovative productsn Respond quickly to unpredictable demandn Deploy excess buffer capacityn Deploy significant buffer stocksn

10、 Invest aggressively to reduce lead timen Select suppliers primarily for speed, flexibility and quality Responsiveness to marketMinimize costs byn Highest responsiveness to marketn Minimize risk of shortages or excess supply10Prerequisites for successEfficientResponsiveFunctionalInnovativematchmatch

11、mismatchmismatchUse of SCM software tools like APO11Prerequisites for success12SCM Business ProcessesnTechnology helps enable a variety of SCM business processesnPush to pullnProcess orientationnOptimizationnPostponementnMore frequent planningnCollaboration13nMove from push to pull manufacturingManu

12、facturersDistributors/ WholesalersConsumersSuppliersRetailersManufacturersDistributors/ WholesalersConsumersSuppliersRetailers Make what we will sell, not sell what we will make! Features of SCM14PurchasingManufacturingDistributionCustomer Service /SalesAvailable-to-Promise (ATP) Capable-to-Promise

13、(CTP)nMove from functional silos to process-oriented business processes (e.g., order-to-cash, cash-to-cash)Integrated Sales and Operations Planning (S&OP)SOURCEMAKEDELIVERSELLFeatures of SCM15nOptimization of all supply chain activitiesSupply Chain OptimizationSynchronized, Concurrent PlanningDe

14、mandPlanningDistributionPlanningManufacturing PlanningProcurementPlanningIndependent, Sequential PlanningForecastingDistributionPlanningManufacturing PlanningProcurementPlanningFeatures of SCM16PostponementnMove to MTO,ATO and CTO from MTSnFront-end APS suites support nATP/CTPnProduct configurationn

15、Back-end integration to transaction systemsInternationalTradeLogisticsWarehouseManagementAdvancedPlanning Scheduling CustomerRelationshipManagementLogisticsManufacturingMaterialsManagementAccounting Human Resources EAIFeatures of SCM17nMore frequent planning means responsive to changing customer nee

16、ds while decreasing inventoriesTimeTimeAverageSupplyAverageSupplyPlanning CyclePlanning CycleFeatures of SCM18ne-Business will enable supply chain collaboration among trading partnersManufacturerDistributors/WholesalersSuppliersRetailersCollaborative Demand PlanningCollaborative Logistics PlanningTr

17、ansportation servicesDistribution center servicesSynchronized Production SchedulingCollaborative Product DevelopmentFeatures of SCMLogistics Providers19Components of E-Supply ChainnSupply-chain replenishmentnE-procurementnCollaborative planningnCollaborative product developmentnE-logisticsnSupply we

18、bs20Evolution of ITARAPGLPayrollMRPFMISHRMRPIISchedulingplanningDistributionERPAPS/SCMEISEDIE-CommerceBICRME-Business21Agenda22ManufacturersWholesale DistributorsSuppliersCustomers Information FlowsGoods FlowSupply Chain Network DesignSupplier ExchangesCustomer ExchangesLogisticsExchangesContract Ma

19、nufacturersLogistics ProvidersVirtual ManufacturersRetailersnLocation decisionnCapacity decisionnAssignment decision23Strategic Planning ProblemsnWhich products shall be produced at which locations?nHow are customers assigned to distribution centers?nWhere shall new locations be opened?nWhich locati

20、ons shall be closed?nWhat are capacity requirements for plants/distribution centers?nWhat is the cost situation within the supply chain?24Planning MethodnPlanning of location assignment and transportation lanesnLocation assignment based on geographical distancenCost optimal location assignmentnStruc

21、tural Network ChangesnPlacement of a given number of locations based on geographical distance and costsnCost optimal selection of locations25Planning ParametersnCostnTransportation costsnProduction costsnStorage costsnHandling costsnProcurement costsnLocation costs / Location proceedsnFix maintenanc

22、e costsnCosts for opening and closure of locationsnPublic subsidiesnPenalty costs for delayed or non-fulfilled demand26Planning ParametersnCapacitiesnHandling capacities for plants and distribution centersnProduction capacities of plantsnDemandnCalculation of demand via Demand PlanningnSupported by

23、forecast methodsnSimulation of demand scenariosnVariation of demand27Planning ResultsnSupply Chain NetworknAssignment of locationsnTransportation lanesnAllocation of products to locationsnNew locations with geographic positionnSelected / not selected locationsnProposal for opening or closure of loca

24、tions28Planning ResultsnQuantitiesnProduction, transport, handling, storage and procurementnCostsnProduction, transport, handling, storage and procurementnLocation costsnOpening costs, maintenance costs, subsidies, etc.nCapacity RequirementsnProduction, transport, handling und storage29OutlooknProfi

25、t-oriented planningnConsideration of piece-wise linear costs for transport and productionnConsideration of storage capacitiesnIntegration of GIS applicationsnautomatic calculation of transportation duration and transportation costsnexpanded geographic display30AgendanOverview/Features of SCMnSupply

26、Chain Network DesignnAdvanced Planning and SchedulingnShop Floor ControlnMES/MCS31Production LogisticsForecastCustomer order administrationPrimary requirements planningRequirements planningPurchasingCapacity schedulingCapacity adjustmentOrder releaseReservationSequencingDetailed schedulingExecutionF

27、actory data entryShop floor controlPlanningPlanning/schedulingInitiation of implementation functions32Typical Planning ProcessSupply/DemandMeetingMRP/ERPManual AdjustmentRelease POReceiving/ReceiptChange Production PlannCan not deliver on timenLong promise timenDead items & shortagenCustomer uns

28、atisfied33MRP II Planning ProcessnTop-down processnIterative processMaster PlanningRCCPMRPCRPSFC34Problem in IndustrynSalesnSO confirm時間太長nPC 無法如期交貨nHub會造成投資風(fēng)險nPC/MCn插單nCancel訂單n訂單交期變更頻繁nYield和Rework造成交期Delayn無法確認(rèn)真正的產(chǎn)能與瓶頸作業(yè)n替代料無法掌控nECN頻繁，易產(chǎn)生呆料35Problem in IndustrynShop Floorn開製令前無法確認(rèn)料是否備齊n臨時缺料nYield

29、和Rework造成大量未結(jié)案工單nShop Floor催M(jìn)C，MC催Buyer，Buyer催Suppliern產(chǎn)能規(guī)劃不合理，無法執(zhí)行nBuyern無法確認(rèn)到底欠哪些料n追料頻繁nOrder Cancel頻繁n未考慮Lead Time36Drawbacks in Traditional Production PlanningnSequential planningnProblem in scheduling logicnIndependent demand and supply planningnLack of integrationnBatch processnSingle point pl

30、anningnLack of simulation capability37SCM Information System38Definition of APSntheres no precise definition of APS systems, but it is quite intuitive to say that the APS systems resolve the shortcomings of the ERP systems as a planning tool.APS systems consider material requirements and plant capac

31、ity to generate new plans, and some of them create a detailed production schedule that sequences the production optimally, to achieve the organization goals as well as customers due date. (AMR, 1998)nAPS systems apply profound advanced technologies to achieve improved plans that take into account mo

32、st of the factors and constraints that limit the ability to deliver on time. (Forrest Research, 1996)39Features of APSnSynchronized concurrent planningnConstraint-based planningnOptimized planningnReal-time planningnDecision support capabilitynWhat-if simulationnPegging between demand and supplynSpe

33、ed and performance40Synchronized Planning41Constraint-based PlanningAPSConstraintSupplyDemandOutputTime:Purchase LTMfg.LTTrasf.LTDue DateCapacity:Resource loadRoutingMaterial:Alternate PartsECN PartsSourcing RuleDemand:ForecastSales OrderSupply Data:On-handWIPPurchasing OrderOptimal Plan42Optimized

34、Technologies in APSnDemand PlanningnExponential SmoothingnSystem DynamicsnMultiple Linear RegressionnProduction Planning & SchedulingnLinear Programming/Mixed Integer LPnGenetic AlgorithmsnSimulation AnnealingnHeuristic MethodsnDistribution Planning & DeploymentnFlow AlgorithmsnBranch-and-Bo

35、und Algorithm43Scope of APSnSupply chain strategic planningnSupply chain network planningnDemand planning and forecastingnInventory planningnSupply chain planningnSupply planningnDistribution planningnTransportation planningnShop floor operation schedulingnShipment scheduling44Functions of APS45nAPS

36、是使用現(xiàn)存Transaction系統(tǒng)(ERP)的資訊，以提供快速規(guī)劃及排程的智慧型決策支援系統(tǒng)。PurchasingOrder EntryManufacturingLogistics/ShippingERPCurrent SituationFinalPlanSupply Chain PlannerInput DataDemandCapacityMaterialsOutputProduction PlanShipping PlanPromise PlanAPS and ERP46Multi-Site PlanningnComplex multi-site manufacturing refers

37、 to the environment where there are multiple sites that are dependent upon each other for material and assemblies.nSupply Planning for a complex multi-site manufacturing environment involves the consolidation of data from the individual sites into a corporate consolidation database.47Multi-Site Plan

38、ningGlobal APS EngineDemand Planning EngineOrder Promising EngineAPSEngineAPSEngineAPSEngineMaster PlanMaster PlanMaster PlanSupply PlanSupply PlanSupply PlanDemand PlanSupply Plan48*Source: AMR, 1996Performance ResultsLate Order25-50% ImprovementOrder Lead Time10-40% ImprovementPlanning Cycle95% Im

39、provementProduction Lead Time10-50% ImprovementInventory10-60% ImprovementOperating Expense10-50% ImprovementThroughput2-5% Improvement49AgendanOverview/Features of SCMnSupply Chain Network DesignnAdvanced Planning and SchedulingnShop Floor ControlnMES/MCS50Purpose of Shop Floor Controln將生產(chǎn)規(guī)劃單位所規(guī)劃的生

40、產(chǎn)訂單(PO)有效的轉(zhuǎn)變成實際成品的產(chǎn)出51Shop Floor Control System52Functions of Shop Floor ControlnOrder review/releasenDetailed shop floor operations schedulingnData collection/monitoringnControl/feedbacknOrder disposition53Order Review and Releasen扮演一個過濾機(jī)制，控制訂單進(jìn)入現(xiàn)場的流量54Focus of OR/RnAvailability of materialsnRequir

41、ed capacitynRequired machines and toolingsnReal-time production statusnVerify MRP plansnConfirm/modify BOM structurenConfirm/modify routingnEvaluate production loads in shop floornCriteria of performance evaluation55Operations SchedulingnWork center oriented schedulingnWork order oriented scheduling

42、nBackward schedulingnForward schedulingnFinite schedulingnDispatching56Data Collection and MonitornBarcodenOptical character recognitionnMagnetic stripenVoice recognitionnRadio frequency identificationnMachine vision systemnBlue tooth57Control and FeedbacknOrder problems vs. Resources problemsnIs it

43、 solvable? What is the solution?nAdjust and improvenInformation feedback 58Order DispositionnOrder completionnAS plannednOrder cancellationnMaterials shortagenRelease previously assigned resourcesnEvaluate production performancenDefine and explain specific unexpected conditions/solutions59Shop Floor

44、 Control System-Another view60AgendanOverview/Features of SCMnSupply Chain Network DesignnAdvanced Planning and SchedulingnShop Floor ControlnMES/MCS61Relationships of ERP/APS/MES/MCSERPAPSMCSMES62Interactions Between ERP/APS and MES63Definition of MESn將加工現(xiàn)場中的原物料、半成品、成品、機(jī)器、時間、成本等資訊以動態(tài)且即時的方式來收集、匯整與表達(dá)，並追蹤與管制目前正在進(jìn)行中的各項製造作業(yè)的一個