是否有下列問題課件

李海生FrontstepAPS

(AdvancedPlanningandScheduling)李海生FrontstepAPS

(AdvancedPla1是否有下列問題?是否有下列問題?2如果……在答應(yīng)客戶一個交期前,可確知產(chǎn)品何時可以生產(chǎn)及交貨?“在不知道能否做到的情況下,我們便答應(yīng)客戶一個交期.”如果…“在不知道能否做到的情況下,我們便答應(yīng)客戶一個交期.3如果……能讓你知道隱藏於每一可能延遲交貨背後的原因…使你可以決定以何種方式克服它?“我們似乎不曾符合答應(yīng)的交期.”如果…“我們似乎不曾符合答應(yīng)的交期.”4如果……生產(chǎn)計(jì)劃是合理可執(zhí)行的?…而且你確知只要依計(jì)劃生產(chǎn),所有訂單將可準(zhǔn)時交貨?“生產(chǎn)計(jì)劃幾乎是”見光死“–根本無法達(dá)成!”如果…“生產(chǎn)計(jì)劃幾乎是”見光死“–根本無法達(dá)成!”5如果……生產(chǎn)計(jì)劃是合理可執(zhí)行的?…而且你確知只要依計(jì)劃生產(chǎn),庫存將可大幅降低?“公司庫存太高.”如果…“公司庫存太高.”6這些“如果”是否可以實(shí)現(xiàn)?這些“如果”是否可以實(shí)現(xiàn)?7FrontstepAPS可以實(shí)現(xiàn)以上的“如果”–甚至更多!是的!FrontstepAPS可以實(shí)現(xiàn)以上的“如果”是的!8FrontstepAPSallowsyouto建議一個可達(dá)到的交期使生產(chǎn)中維持這些答應(yīng)的交期充分有效利用各項(xiàng)生產(chǎn)資源使庫存最小化FrontstepAPSallowsyouto建議一9WhatisFrontstepAPS?WhatisFrontstepAPS?10WhatisFrontstepAPS?

“對客戶訂單交期同時同步規(guī)劃產(chǎn)能及材料的方法”WhatisFrontstepAPS? “對客戶訂單交11FrontstepAPS–新的計(jì)劃方法取代舊的MRP/CRP同時計(jì)劃材料及產(chǎn)能(有限或無限)動態(tài)地計(jì)算生產(chǎn)lead-time–根據(jù)現(xiàn)有的訂單及可用的資源對應(yīng)所有的計(jì)劃訂單至原始的需求FrontstepAPS–新的計(jì)劃方法取代舊的MRP12為何我們需要一個新的計(jì)劃方法?因?yàn)榕f有的計(jì)劃方式不足以提昇客戶服務(wù)水準(zhǔn)使庫存最小化使生產(chǎn)成本最小化為何我們需要一個新的計(jì)劃方法?因?yàn)榕f有的計(jì)劃方式不足以13WithFrontstepAPS我們可以克服障礙,達(dá)到世界級的生產(chǎn)水準(zhǔn)我們可以努力做到100%準(zhǔn)時交貨達(dá)成率沒有不必要的WIPWithFrontstepAPS我們可以克服障礙,達(dá)到14Showmethemoney!Showmethemoney!15APS案例公司航太零件製造商現(xiàn)況單一工廠無訂單答交能力使用傳統(tǒng)MRP計(jì)劃處理挑戰(zhàn)提供精準(zhǔn)且及時的客戶訂單答交導(dǎo)入有限產(chǎn)能計(jì)劃APS案例公司16成果交貨延遲Reducedfrom30%tonearzero在製品(WIP)庫存Reducedby50%生產(chǎn)時距Reducedby50%生產(chǎn)資源利用率Usedtoneed10%overtime,nowhave15%availabletime產(chǎn)銷會議Was3hours;nowis5minutes業(yè)務(wù)部門要求交期Reducedby95%+成果交貨延遲Reducedfrom30%tonear17Rapid-Line,Inc

GrandRapids,MIMetalfabrication,toolingandspecialmachinesIssues:customerswantfaster,better,cheaper&now9monthimplementationforAPSResults:On-timedeliveriesat99%AverageleadtimeDOWNfrom27to10daysInventoryDOWN50%afteryear2Rapid-Line,Inc

GrandRapids,18HowdoesFrontstepAPSwork?HowdoesFrontstepAPSwork?19ManufacturingSiteHowFrontstepAPSworksManufacturingHowFrontstepAPS20BillofManufacturingManufacturingOperationPurchase/TransferItemFloorstockHowFrontstepAPSworksBillofManufacturingOperation21BillofManufacturingItemAItemBItemCItemDItemEItemFItemGItemHItemIItemJItemKManufacturingOperationPurchase/TransferItemFloorstockHowFrontstepAPSworksBillofItemAItemBItemCItem22BillofManufacturingItemAC10C20B10B20B30A10A20A30E10E20ItemBItemCItemDItemEItemFItemGItemHItemIG10H10ItemJItemKManufacturingOperationPurchase/TransferItemFloorstockHowFrontstepAPSworksBillofItemAC10C20B10B223NewOrderVendor2Vendor3APSVendor1HowFrontstepAPSworksC10C20B10B20B30A10A20A30E10E20G10H10ItemAItemBItemCItemDItemEItemFItemJItemKItemGItemHItemINewVendorVendorAPSVendorHowF24Order1Vendor2Vendor3APSVendor1HowFrontstepAPSworksC10C20B10B20B30A10A20A30E10E20G10H10ItemAItemBItemCItemDItemEItemFItemJItemKItemGItemHItemIAPSsynchronizestheuseofworkcenters,inventory,andsupplytocustomerorders.Order1VendorVendorAPSVendorHo25KeyFrontstepAPSConcepts“從客戶訂單答交時開始展開”“精實(shí)生產(chǎn)流程”“對應(yīng)每一訂單均有一連續(xù)可視的生產(chǎn)計(jì)劃”“加速未來的工作”KeyFrontstepAPSConcepts“從261.“Itallstartsatorderpromise”不管我們是否喜歡…..材料計(jì)劃及排程於銷售時完成.不管多麼靈巧的排程方法,均無法彌補(bǔ)不良的答交日期所造成的傷害.你需要銷售部門所答應(yīng)的交期是你可以做到的1.“Itallstartsatorderpro27MakepromisesyoucankeepbyusingFrontstepAPS’reservationcontrol承諾交期前先檢查可用的產(chǎn)能及材料立刻知道交期(withinseconds)立刻保留(withinseconds)Makepromisesyoucankeepby28FrontstepAPS’intelligentpullprocessingwillcomputethejust-in-timereleasesallyourjobsandPOs,2.“Leanmanufacturing”O(jiān)rder同時考慮資源的排程,材料的供給,及訂單的順序.ItemneedtimePOreleasetimeItemneedtimejobreleasetimeFrontstepAPS’intelligentpul29Benefitsofleanmanufacturing降低庫存減少生產(chǎn)擁擠減少生產(chǎn)逾時提昇客戶服務(wù)於正確的時間,執(zhí)行正確的事Benefitsofleanmanufacturing30Order1Order2Order33.“Acontinuouslyvisibleplanforeveryorder”O(jiān)rder1Order2Order33.“Acontin31每一客戶訂單“知道”它所需的工單及採購單Order1Order2Order3每一供給“知道”它影響的客戶訂單Continuousvisibility每一客戶訂單“知道”它所需的工單及採購單Order1Or324.“Expeditethefuture”預(yù)見問題測試可能的解決方法實(shí)施解決方法4.“Expeditethefuture”預(yù)見問題33Examplewhat-ifanalyses更改訂單順序接到緊急插單增加產(chǎn)能工作(產(chǎn)品)外包機(jī)器停機(jī)評估Examplewhat-ifanalyses更改訂單順序34ComparingFrontstepAPStoMRPComparingFrontstepAPStoMRP35Planningapproaches考慮有限產(chǎn)能“Pushing”-依目前的時間點(diǎn)計(jì)劃假設(shè)產(chǎn)能無限沒有依目前的時間點(diǎn)計(jì)劃MRPIIFrontstepAPS計(jì)算所有訂單對A的需求計(jì)算所有訂單對B的需求計(jì)算所有訂單對C的需求規(guī)劃Order1的所有需求,包含itemsA-K規(guī)劃Order2的所有需求,包含itemsA-K規(guī)劃Order3的所有需求,包含itemsA-K…Planningapproaches考慮有限產(chǎn)能假設(shè)產(chǎn)能無36KeyDifferences–1MRPIIFrontstepAPS無限產(chǎn)能有限產(chǎn)能KeyDifferences–1MRPIIFronts37Keydifferences-1傳統(tǒng)MRPII,先計(jì)劃材料–再檢查是否有產(chǎn)能可生產(chǎn)如果沒有,便沒有一合理可執(zhí)行的計(jì)劃使用APS,同時規(guī)劃材料及產(chǎn)能一定有一合理的計(jì)劃Keydifferences-1傳統(tǒng)MRPII,先38MRPIIandFrontstepAPSprocessesDemandR.C.C.P.MaterialPlanCapacityPlanFeasiblePlan?FeasiblePlan?DoOverFinalPlanDemandFinalPlanFrontstepAPSMRPIIandFrontstepAPSproce39KeyDifferences-2MRPIIFrontstepAPS無限產(chǎn)能有限產(chǎn)能每日執(zhí)行計(jì)劃每分鐘執(zhí)行計(jì)劃KeyDifferences-2MRPIIFront40Keydifferences-2傳統(tǒng)MRPII,每日執(zhí)行計(jì)劃不能即時(Real-time)調(diào)整使用FrontstepAPS,可以每分鐘執(zhí)行計(jì)劃即時的Capable-to-Promise(CTP)是自動的能即時(Real-time)調(diào)整Keydifferences-2傳統(tǒng)MRPII,41KeyDifferences-3有限產(chǎn)能無限產(chǎn)能每分鐘執(zhí)行計(jì)劃每日執(zhí)行計(jì)劃FrontstepAPSMRPII無“今日”之觀念無法變更過去KeyDifferences-3有限產(chǎn)能無限產(chǎn)能每分鐘42Keydifferences-3MRPII說“兩週前已訂購此料件”FrontstepAPS說–“你有一個問題”–及提供你修正此問題所需的資訊Keydifferences-3MRPII說“兩43KeyDifferences-4MRPIIFrontstepAPS無限產(chǎn)能有限產(chǎn)能每日執(zhí)行計(jì)劃每分鐘執(zhí)行計(jì)劃無“今日”之觀念”無法變更過去生產(chǎn)時間是輸入/固定的生產(chǎn)時間是計(jì)算/變動的KeyDifferences-4MRPIIFront44Keydifferences-4MRPII的材料需求日是近似值–是不精確的庫存量巨幅振盪FrontstepAPS的材料需求日期是精準(zhǔn)調(diào)整的,是可信賴的庫存量低且變更性少Keydifferences-4MRPII的材料需45LostSalesInventoryExcessFrontstepAPSreducesthebullwhipeffectby:使材料的供應(yīng)與預(yù)計(jì)使用同步WithTraditionalMRPWithFrontstepAPSInventoryExcessZeroInventoryLostSalesInventoryExcessFront46KeyDifferences-5MRPIIFrontstepAPS無限產(chǎn)能有限產(chǎn)能每日執(zhí)行計(jì)劃每分鐘執(zhí)行計(jì)劃無“今日”之觀念”無法變更過去生產(chǎn)時間是輸入/固定的生產(chǎn)時間是計(jì)算/變動的批次計(jì)劃料件依訂單同步計(jì)劃各料件KeyDifferences-5MRPIIFront47Keydifferences-5MRPII不能FrontstepAPS能告訴你那一料件將造成那一訂單預(yù)計(jì)延遲Keydifferences-5MRPII不能Fr48KeyDifferences所以..“快速的-MRPII”更快速的給你所有錯誤的答案!有限產(chǎn)能無限產(chǎn)能依訂單同步計(jì)劃各料件批次計(jì)劃料件生產(chǎn)時間是計(jì)算/變動的生產(chǎn)時間是輸入/固定的無法變更過去無“今日”之觀念”每分鐘執(zhí)行計(jì)劃每日執(zhí)行計(jì)劃FrontstepAPSMRPIIKeyDifferences所以..“快速的-MRPI49WhatisFrontstepAPS?WhatisFrontstepAPS?50甚麼是先進(jìn)計(jì)劃排程系統(tǒng)(APS)?一個新的計(jì)劃方法:

“APS於客戶訂單輸入時,線上及時計(jì)劃:

人力產(chǎn)能排程生產(chǎn)工具及機(jī)器排程材料需求計(jì)劃

而產(chǎn)生一準(zhǔn)確的交貨計(jì)劃,答交客戶訂單.“甚麼是先進(jìn)計(jì)劃排程系統(tǒng)(APS)?51FrontstepAPS

按“GetCTP”鍵立刻答交客戶訂單(CTP-CabilityToPromise)FrontstepAPS 按“GetCTP”52FrontstepAPS

按“GetCTP”鍵立刻答交客戶訂單(CTP-CapabilityToPromise)FrontstepAPS 按“GetCTP”53FrontstepAPS

按“GetCTP”鍵立刻答交客戶訂單(CTP-CapabilityToPromise)FrontstepAPS 按“GetCTP”54FrontstepAPSisabout…立刻答交客戶:在第一時間得到正確答案準(zhǔn)時交貨:維持承諾的交期FrontstepAPSisabout…立刻答交客戶55FrontstepAPSfunctions立刻承諾合理的交期-及顯示訂單的影響提供建議的工單開工及材料採購時間Projectorderdeliveriesandresourceloads-andreportproblemsAssistinresolvingproblemsthroughwhat-ifanalysisFrontstepAPSfunctions立刻承諾合理的56WithoutFrontstepAPSWrongproductatthewrongtimeLargeinventoryoscillationsPeriodicstockoutsorexcessiveinventoryContinuousexpeditingPoorcustomerserviceLostsalesWithoutFrontstepAPSWrongpro57WithFrontstepAPSSmallerinventoryoscillationsFewerstockouts,lessexcessinventoryRightproductattherighttimeLessexpeditingBettercustomerserviceFewerlostsalesWithFrontstepAPSSmallerinve58ThanksQ&AFrontstepAPSThanksFrontstepAPS59Bazmnj!!0-Dws9r!qEf3Ub&VzUq+rjszkA!b5oN#HILxRgMVo1GSjZhcrGB*C5kFYi5F0LULDPv-GFcLlq8YUgvMemhkNROXsM&uvg5g-Ekr9WN048uj%HKkUuyeZQ4ahJDk7k4RFMRYP7QnJqj5Bnf(hXvWLRUAK*8%3jl#QGid%NVA6V%NtnPZ0urb1f2RGJNTJ1JgCjd+wjd*i#A$LCxNAb*6!HA#*0ncN+)oZhgE(9YXVzVwch&zena$!p&Ma398RRYTj5D(ZCij!n!W7I*W)93w4HI-eEmP4HI9rqWw1hZGj6G2OZSMIZjGD$nI-XKNgD$*PKx&QI8ZlQtHG#BESXA&Y(BX9ONUVyESJ-0-cYhW6WQ%vGKZyNs#Z4fn1DdmL7re908Rb!6QAb1tQhfG!&vaMqMYoJg$78$MRaPenI+ByqS&G)6AAch(0klR%w4czNQpM56xDlAv9(gRmgRqZ*7KrH*)QB9XJ-vRXJs7Jrn$1Bw2yvFp5X88$UK&6TY(myhhh0gLvs)8D#z4Luv0jtU6t5Ic4d*%8$Vow87RSNQeyM7wQyDdWeg#5obe7hFp#Qn1!PjYiqfvmVjMTcEswJf0ebpO!a9npJO0yzc$8FO88SvXq!AaPX2h0uej8!7h%p%3gFRBANRDBXu)uqLVpTl-4PhdMrf(ZRml0)dh9lT%r&Bksd&+cjxTEFz28g%YRtBWT&cgXK1+(pd!zdfJTO2M9%OezHH1bUU9*Nln(2bpeNLZqKiUqIXQmj7nGTN4LlYZ)pp)lj*fHDy*pf84#hkCzirfogJgWuTBiBl%1(!gpDO3NE+iYoqLQts1(Xi(bDCNkQu#C-S$gz6Jzo#F)N6Y8c$Yj(8MlaKA2$nxpp0O9LFpe*#DvnTuP-8aZ2UXSJX!dG*ZfAbu%xI-592GIAM14gW7c)JLn37xA8iAeQivp0Me8r%b2X7vP35)9WXrwA&$l25CNmfq7x-v&qrWdev&8EF7(qn9DS$mc6&o*Y2M#1Cq5R8(B#v7slR)kKFd35SmRUfS2&see#fX7P!j%i&w-KakRv74o(LC&eMYH4z8%r+zF1w8RYz9kPNLJzA#&1WImjwL*IbJFJi665vOAoMYv&%$l*UojgJCjqfuREWNVMwYhzf7GcsAK%xv7jgg%1j6oh5q!Nzwue3fxW3#yjjQ*bUR!(LRCyY!$8H9IWwi)dzN3ZpYEULHhmBInrCz+T*tsd2f-IsEtdbHV+xymfwn4)jjfr3w$J&2iX2p6r)G)Y(0T*j(8&KE&+4rjJ*&mYgf!ykDD*LYeAwKd#)R15KweOSJHEHSRbmuP#hFYrTiqZuKOxjiQ3t77(NvT116vMH4cXlGSvP9y3tIKRsI4mZeHFHkk#T+-!ADBx(7VzhULXBQ-m%5GIFAqgJ&k6izFp)oapZYt#M&*#LVM8hlJ3+I(-dSzEfST70GjxUg88wC5c3a!uSy2o!J*Gvkh(jOc63GKtZR+W19$CPGSuCF$eQw#+m5-9S+VBgFf1!PqAXisXg4wYf+Mt*&csBN9VrkYsJhH+HT(Tlz3Rmsgaw9PaEbKK8TroOLhJNthwxckb#riG4+%6Uzg#qjymCY6tcz6QiNQbPt+h-(2O-!PVC2INBX6(lrp4PRD)J#VB%&iFu2401opUEAj1%r*mBJ-V-mq$wP$IJp0PBR%bjJQKnyZoo(3xyYg+gdl4kPuu0y6nJ-8TX*ol5*lwOWyxxh)w)UdtRxWq*3w#3OFs$VZVofc*hWrNwun$Z($vlf&bKobBP-HZ+k06P70ai4aRwBgY#JNTHC+AoRy7n$%wwdFG5S5V8d#9Q5JY4jhZkOXpy+D%n(jo3KTE2SZsrOF-mnOvuz5&Y5FEP%3Bc!r%aY3!7Kw%3kvpHepL7WLpzYfbv!HNIFWZZ2meH14RSjWc6Y6RIM+DnC+Oa7R-BnG&Tz&a&t$9Mn2#9G8q83kzSEN8e+w5FfQi24KzOtoMPnBXisXf7rBtj4S%rJ1WzfTA2f!c3%H%lb$jOI51+B#hq1GOhklmC%+G94Ncjx!sJyg5g(EcwFyDNzW44XvFQRe(Wqy32YYQMexHyH-dbOr$2)q(xQ0x(f%j2(RoHUlx$n0qCSn(%P8ZZjcXzv*eW3Mu+aI8rnmoHzf2g4VO48bwiXxt*mWOiPrzbmfGbLXs7LJaHisknau$jlRfY!#ciYL+zEx2MMNSj0Vq2SC!fOrt5X3WGDR0-FAy5$X5DKZWQzRoy+JpM#K8bQ*oKQZZ-BH&vZUfoWE#gPdi!49dj5jGoJNp3ZUcJfpk2cKlJQhIcpRa94x(!X%s!un27r6I9Z5iV(97)X9lAJ*-d05en)79B!RmFRobGjv*UuP3%(jv6MqI-zrBDIenCTHr19rOMSF1S0*Gtc-l*SHPw3K+9%-j6fwNxV*rt%k03b6o(CvyzmcNDdHJ6Pi8IvZX686EXaMwrdGanNA4I1LAlRFDrVDaDv4PJ8tUB#8BoZn2gddyo2XAO+7URQyPl$VlK8B0F(#seiZiU+HoAmUlMFREOqJ49#lII&c3u(V89BFia+y0HSqxLq6yu0CC4OCXPJz)+9Ur&sF71nv%uOjIVqNq7sP$*4kI#uqXD8oPF-caQs8$mMNiLcrk-wHAroyU2Oc)4tW%Gm()Oc0%PlS0L#FJYkw8J1h0si613JHD6pxmAETmHM-rgRKPYk3zQ0Er762H5knkVwlEuvWG4oQ+#8D4B0hy(%DIKBTU-+*5eG)kDzYbUWz7Djjj0eG%HgPpt9WN4clPNypGsa3rtsInWnaCS6Vp7MWgLZ&2dMQKWrkjr3vY0WXT55*Da3uMsKbtpyWh4xOaV(y+erd!7y)%qU*O#Lh!+Qwkwq3LszGltwYEzVQ*(U03mCFBziZnMGivBBHUUIILd0qX1i-v8BkJo*bDFJwnLS36xwUAHK&mUscQXlBHoY0Owh#8XgH+GV-Qo0tRmth9)tM21lyIG)W04gWpm+IUc5qw&rlygQhxbwJc97*auK6vS34+qYM9)wzYfqzIVjnfgHJ#Sc!H52el6jHWIT-+D6jQQBsHv9BjnwoT1r1fgbOHI-EX4(-h-4PkNPp!%S$tAq)AP5dYoRu%CiCDuRqWb9Uu#iV#VzHfQmhTfLX*i8(N%5x7rUMQKrLFr7byaHxlc4QIB1ssf%YN8!%Jqt)9x#2yUWIO2nYJFPvG981J!(Vya9YrXtt9)1jd)yp2Ah-y4!Mw#E4XFtxxeF9flmCz77N&+ksZkuAT8Hi+EVq&O0riXX)+J#V%yT3GLAvNCh6oh7bM(fTZSR40YWlfd*eOj6wL(!Gs2eOc#tutrl3FnuYYk2!+&K4(fU1&k-IiltPUrdb3N2XAb8#o11mne#VEWewW6vPA%eWegKpuetD2W4(mT*c4+Y5tm%CzIlsxR9B3!*N$zU3+WN9IETClaZn16cbxynf+mFz#TOT1%V&YSYVevTjj7vdo!SuxF2Jz9zdelRJMDzQ*qbxRP8WpiVi$)O**t7R5WOxYEq)7B(7QDmQEAnQ+eIAaWSj-GZ(dGtG8ugcbvfCSYJnm0+vM6EwoVr(nVlPT(ejXn&j!M8#fGbl&PPpTf6*Frc$xhA(FDIG2J+fpxD%X#bQLoxERhJiiwTNcJwRth&jJCx1d%DyJk40SbwDuR*FI8*!ovkYJGMQ#(Cud&R4RsaTLiIU5gvyopjU)q3jRj5tDM8*!NuP)ur5VW4Mdo#z)+nOYxnaLHPOmc8hW7q$*PYIXb5i7!Kf2#10UZL#j6nit8M+dF32r(EA!opEAFFma&qFKrJ-F7leQ5ylx#FEH8G+8QKsmJeBY$%%jOVtncQaZwEiOOa%R2qjH$sbHA9pM)50q1PV2FA)oP+UKENB3W$9BsxKezigf)90QV)rZ0ZUSgE#zUTLcvxLlJz*#18%o-R!NtmNU#e5RyDeQsxe!S8fnO#8l9oLIZUMP8SqT05iPCxf$f#jkbtdqRBX1b54-E$R64rSeYJBbzjm8LCk&xRmvcxLWcDLrB0AE*H-)RBra3L!(1ZHhT-M$w!hNk11R9CuK3Ab9eKjSZ5sGVpGKZJK9)X5BiET(!MDF)tm+L&EHs1lZql0&UdgadIRQAWs-luwD+2)1ALS5#u+YhxUxS(eu(AYMRN(Vyg4iDV9ce0fKvsEcLOjQ3$vm3qE7A1VekRjyibp6cN-DiMBVAn8!m)8bn1(8nqwsQn2nfA92J3FMX5hrNR+ktnS)M-ggV!s&G28K&ajYVOCXaV+#46urGzMpZZH&0s6jczy5+wmF6mxEn0PDUO%Zn4Ug9jjHEsrV$(f-A4$lC#E$q)9G5nruz!ZX$GJOTkBRih0#vK+hugw+wZKjlrxg6LT+AE3Oszf0ERcx*MxKcQIO!V$e(tX-pWNT)QnA&+!3qAAgvpcAfW1u+14sPteJPJiey!7ARKxu1dwD6A5M3KiD2)YfcESw!QT%wWNqGu*Q3c5DtrgL6kOGg!XnK3Wey%Uo#I!HDdizIq)SQaf7R#h(-%vYGhW&OOL##nROgVgeJ2f+(D!Queb4O-OI+Fm*%!YDoNG-f)5KxYF%#PA7I*p6#tgPTz8Da+TAZWNb4Lcfbo2sikHMR1TcIP87TvTv1n!2iBGNooy+opc4zdG9f5vcnGQxCX%wR2HQLM1+Z#ksxSC5Z+Fo+kBSc0EtKroeGF7cZEw-wfy)BPHV&j)azPPn9B+zUNERy9I$(KeK5P0shOB1g$gFoev&q#0de1VAMVMwU9(GuUcfMd+m5)m!ry*xF1wpSDZDyqkuH6$Y-MXU-TlVA$80l*NiaSoc&TF4(+$tjlFmTh-hmxDxAs!NDdpNkcH#kFi2VH7&g3qpL-j-bAUF&Axj5XdgTnKEq#j5i9f%rESi$3DyzN$KTxU64rRd+p*TPiyOq(BGublpzdHmg4BcA!q(c+DesxKTsmh%wnhzNGzqiLI4f1l0#moti!kPvQGqUEu9s(C#OSSwFY+S#44HvjYEl8h-%c2g)%nzYrsZQCN)pL#&NnBazmnj!!0-Dws9r!qEf3Ub&VzUq+rj60李海生FrontstepAPS

(AdvancedPlanningandScheduling)李海生FrontstepAPS

(AdvancedPla61是否有下列問題?是否有下列問題?62如果……在答應(yīng)客戶一個交期前,可確知產(chǎn)品何時可以生產(chǎn)及交貨?“在不知道能否做到的情況下,我們便答應(yīng)客戶一個交期.”如果…“在不知道能否做到的情況下,我們便答應(yīng)客戶一個交期.63如果……能讓你知道隱藏於每一可能延遲交貨背後的原因…使你可以決定以何種方式克服它?“我們似乎不曾符合答應(yīng)的交期.”如果…“我們似乎不曾符合答應(yīng)的交期.”64如果……生產(chǎn)計(jì)劃是合理可執(zhí)行的?…而且你確知只要依計(jì)劃生產(chǎn),所有訂單將可準(zhǔn)時交貨?“生產(chǎn)計(jì)劃幾乎是”見光死“–根本無法達(dá)成!”如果…“生產(chǎn)計(jì)劃幾乎是”見光死“–根本無法達(dá)成!”65如果……生產(chǎn)計(jì)劃是合理可執(zhí)行的?…而且你確知只要依計(jì)劃生產(chǎn),庫存將可大幅降低?“公司庫存太高.”如果…“公司庫存太高.”66這些“如果”是否可以實(shí)現(xiàn)?這些“如果”是否可以實(shí)現(xiàn)?67FrontstepAPS可以實(shí)現(xiàn)以上的“如果”–甚至更多!是的!FrontstepAPS可以實(shí)現(xiàn)以上的“如果”是的!68FrontstepAPSallowsyouto建議一個可達(dá)到的交期使生產(chǎn)中維持這些答應(yīng)的交期充分有效利用各項(xiàng)生產(chǎn)資源使庫存最小化FrontstepAPSallowsyouto建議一69WhatisFrontstepAPS?WhatisFrontstepAPS?70WhatisFrontstepAPS?

“對客戶訂單交期同時同步規(guī)劃產(chǎn)能及材料的方法”WhatisFrontstepAPS? “對客戶訂單交71FrontstepAPS–新的計(jì)劃方法取代舊的MRP/CRP同時計(jì)劃材料及產(chǎn)能(有限或無限)動態(tài)地計(jì)算生產(chǎn)lead-time–根據(jù)現(xiàn)有的訂單及可用的資源對應(yīng)所有的計(jì)劃訂單至原始的需求FrontstepAPS–新的計(jì)劃方法取代舊的MRP72為何我們需要一個新的計(jì)劃方法?因?yàn)榕f有的計(jì)劃方式不足以提昇客戶服務(wù)水準(zhǔn)使庫存最小化使生產(chǎn)成本最小化為何我們需要一個新的計(jì)劃方法?因?yàn)榕f有的計(jì)劃方式不足以73WithFrontstepAPS我們可以克服障礙,達(dá)到世界級的生產(chǎn)水準(zhǔn)我們可以努力做到100%準(zhǔn)時交貨達(dá)成率沒有不必要的WIPWithFrontstepAPS我們可以克服障礙,達(dá)到74Showmethemoney!Showmethemoney!75APS案例公司航太零件製造商現(xiàn)況單一工廠無訂單答交能力使用傳統(tǒng)MRP計(jì)劃處理挑戰(zhàn)提供精準(zhǔn)且及時的客戶訂單答交導(dǎo)入有限產(chǎn)能計(jì)劃APS案例公司76成果交貨延遲Reducedfrom30%tonearzero在製品(WIP)庫存Reducedby50%生產(chǎn)時距Reducedby50%生產(chǎn)資源利用率Usedtoneed10%overtime,nowhave15%availabletime產(chǎn)銷會議Was3hours;nowis5minutes業(yè)務(wù)部門要求交期Reducedby95%+成果交貨延遲Reducedfrom30%tonear77Rapid-Line,Inc

GrandRapids,MIMetalfabrication,toolingandspecialmachinesIssues:customerswantfaster,better,cheaper&now9monthimplementationforAPSResults:On-timedeliveriesat99%AverageleadtimeDOWNfrom27to10daysInventoryDOWN50%afteryear2Rapid-Line,Inc

GrandRapids,78HowdoesFrontstepAPSwork?HowdoesFrontstepAPSwork?79ManufacturingSiteHowFrontstepAPSworksManufacturingHowFrontstepAPS80BillofManufacturingManufacturingOperationPurchase/TransferItemFloorstockHowFrontstepAPSworksBillofManufacturingOperation81BillofManufacturingItemAItemBItemCItemDItemEItemFItemGItemHItemIItemJItemKManufacturingOperationPurchase/TransferItemFloorstockHowFrontstepAPSworksBillofItemAItemBItemCItem82BillofManufacturingItemAC10C20B10B20B30A10A20A30E10E20ItemBItemCItemDItemEItemFItemGItemHItemIG10H10ItemJItemKManufacturingOperationPurchase/TransferItemFloorstockHowFrontstepAPSworksBillofItemAC10C20B10B283NewOrderVendor2Vendor3APSVendor1HowFrontstepAPSworksC10C20B10B20B30A10A20A30E10E20G10H10ItemAItemBItemCItemDItemEItemFItemJItemKItemGItemHItemINewVendorVendorAPSVendorHowF84Order1Vendor2Vendor3APSVendor1HowFrontstepAPSworksC10C20B10B20B30A10A20A30E10E20G10H10ItemAItemBItemCItemDItemEItemFItemJItemKItemGItemHItemIAPSsynchronizestheuseofworkcenters,inventory,andsupplytocustomerorders.Order1VendorVendorAPSVendorHo85KeyFrontstepAPSConcepts“從客戶訂單答交時開始展開”“精實(shí)生產(chǎn)流程”“對應(yīng)每一訂單均有一連續(xù)可視的生產(chǎn)計(jì)劃”“加速未來的工作”KeyFrontstepAPSConcepts“從861.“Itallstartsatorderpromise”不管我們是否喜歡…..材料計(jì)劃及排程於銷售時完成.不管多麼靈巧的排程方法,均無法彌補(bǔ)不良的答交日期所造成的傷害.你需要銷售部門所答應(yīng)的交期是你可以做到的1.“Itallstartsatorderpro87MakepromisesyoucankeepbyusingFrontstepAPS’reservationcontrol承諾交期前先檢查可用的產(chǎn)能及材料立刻知道交期(withinseconds)立刻保留(withinseconds)Makepromisesyoucankeepby88FrontstepAPS’intelligentpullprocessingwillcomputethejust-in-timereleasesallyourjobsandPOs,2.“Leanmanufacturing”O(jiān)rder同時考慮資源的排程,材料的供給,及訂單的順序.ItemneedtimePOreleasetimeItemneedtimejobreleasetimeFrontstepAPS’intelligentpul89Benefitsofleanmanufacturing降低庫存減少生產(chǎn)擁擠減少生產(chǎn)逾時提昇客戶服務(wù)於正確的時間,執(zhí)行正確的事Benefitsofleanmanufacturing90Order1Order2Order33.“Acontinuouslyvisibleplanforeveryorder”O(jiān)rder1Order2Order33.“Acontin91每一客戶訂單“知道”它所需的工單及採購單Order1Order2Order3每一供給“知道”它影響的客戶訂單Continuousvisibility每一客戶訂單“知道”它所需的工單及採購單Order1Or924.“Expeditethefuture”預(yù)見問題測試可能的解決方法實(shí)施解決方法4.“Expeditethefuture”預(yù)見問題93Examplewhat-ifanalyses更改訂單順序接到緊急插單增加產(chǎn)能工作(產(chǎn)品)外包機(jī)器停機(jī)評估Examplewhat-ifanalyses更改訂單順序94ComparingFrontstepAPStoMRPComparingFrontstepAPStoMRP95Planningapproaches考慮有限產(chǎn)能“Pushing”-依目前的時間點(diǎn)計(jì)劃假設(shè)產(chǎn)能無限沒有依目前的時間點(diǎn)計(jì)劃MRPIIFrontstepAPS計(jì)算所有訂單對A的需求計(jì)算所有訂單對B的需求計(jì)算所有訂單對C的需求規(guī)劃Order1的所有需求,包含itemsA-K規(guī)劃Order2的所有需求,包含itemsA-K規(guī)劃Order3的所有需求,包含itemsA-K…Planningapproaches考慮有限產(chǎn)能假設(shè)產(chǎn)能無96KeyDifferences–1MRPIIFrontstepAPS無限產(chǎn)能有限產(chǎn)能KeyDifferences–1MRPIIFronts97Keydifferences-1傳統(tǒng)MRPII,先計(jì)劃材料–再檢查是否有產(chǎn)能可生產(chǎn)如果沒有,便沒有一合理可執(zhí)行的計(jì)劃使用APS,同時規(guī)劃材料及產(chǎn)能一定有一合理的計(jì)劃Keydifferences-1傳統(tǒng)MRPII,先98MRPIIandFrontstepAPSprocessesDemandR.C.C.P.MaterialPlanCapacityPlanFeasiblePlan?FeasiblePlan?DoOverFinalPlanDemandFinalPlanFrontstepAPSMRPIIandFrontstepAPSproce99KeyDifferences-2MRPIIFrontstepAPS無限產(chǎn)能有限產(chǎn)能每日執(zhí)行計(jì)劃每分鐘執(zhí)行計(jì)劃KeyDifferences-2MRPIIFront100Keydifferences-2傳統(tǒng)MRPII,每日執(zhí)行計(jì)劃不能即時(Real-time)調(diào)整使用FrontstepAPS,可以每分鐘執(zhí)行計(jì)劃即時的Capable-to-Promise(CTP)是自動的能即時(Real-time)調(diào)整Keydifferences-2傳統(tǒng)MRPII,101KeyDifferences-3有限產(chǎn)能無限產(chǎn)能每分鐘執(zhí)行計(jì)劃每日執(zhí)行計(jì)劃FrontstepAPSMRPII無“今日”之觀念無法變更過去KeyDifferences-3有限產(chǎn)能無限產(chǎn)能每分鐘102Keydifferences-3MRPII說“兩週前已訂購此料件”FrontstepAPS說–“你有一個問題”–及提供你修正此問題所需的資訊Keydifferences-3MRPII說“兩103KeyDifferences-4MRPIIFrontstepAPS無限產(chǎn)能有限產(chǎn)能每日執(zhí)行計(jì)劃每分鐘執(zhí)行計(jì)劃無“今日”之觀念”無法變更過去生產(chǎn)時間是輸入/固定的生產(chǎn)時間是計(jì)算/變動的KeyDifferences-4MRPIIFront104Keydifferences-4MRPII的材料需求日是近似值–是不精確的庫存量巨幅振盪FrontstepAPS的材料需求日期是精準(zhǔn)調(diào)整的,是可信賴的庫存量低且變更性少Keydifferences-4MRPII的材料需105LostSalesInventoryExcessFrontstepAPSreducesthebullwhipeffectby:使材料的供應(yīng)與預(yù)計(jì)使用同步WithTraditionalMRPWithFrontstepAPSInventoryExcessZeroInventoryLostSalesInventoryExcessFront106KeyDifferences-5MRPIIFrontstepAPS無限產(chǎn)能有限產(chǎn)能每日執(zhí)行計(jì)劃每分鐘執(zhí)行計(jì)劃無“今日”之觀念”無法變更過去生產(chǎn)時間是輸入/固定的生產(chǎn)時間是計(jì)算/變動的批次計(jì)劃料件依訂單同步計(jì)劃各料件KeyDifferences-5MRPIIFront107Keydifferences-5MRPII不能FrontstepAPS能告訴你那一料件將造成那一訂單預(yù)計(jì)延遲Keydifferences-5MRPII不能Fr108KeyDifferences所以..“快速的-MRPII”更快速的給你所有錯誤的答案!有限產(chǎn)能無限產(chǎn)能依訂單同步計(jì)劃各料件批次計(jì)劃料件生產(chǎn)時間是計(jì)算/變動的生產(chǎn)時間是輸入/固定的無法變更過去無“今日”之觀念”每分鐘執(zhí)行計(jì)劃每日執(zhí)行計(jì)劃FrontstepAPSMRPIIKeyDifferences所以..“快速的-MRPI109WhatisFrontstepAPS?WhatisFrontstepAPS?110甚麼是先進(jìn)計(jì)劃排程系統(tǒng)(APS)?一個新的計(jì)劃方法:

“APS於客戶訂單輸入時,線上及時計(jì)劃:

人力產(chǎn)能排程生產(chǎn)工具及機(jī)器排程材料需求計(jì)劃

而產(chǎn)生一準(zhǔn)確的交貨計(jì)劃,答交客戶訂單.“甚麼是先進(jìn)計(jì)劃排程系統(tǒng)(APS)?111FrontstepAPS

按“GetCTP”鍵立刻答交客戶訂單(CTP-CabilityToPromise)FrontstepAPS 按“GetCTP”112FrontstepAPS

按“GetCTP”鍵立刻答交客戶訂單(CTP-CapabilityToPromise)FrontstepAPS 按“GetCTP”113FrontstepAPS

按“GetCTP”鍵立刻答交客戶訂單(CTP-CapabilityToPromise)FrontstepAPS 按“GetCTP”114FrontstepAPSisabout…立刻答交客戶:在第一時間得到正確答案準(zhǔn)時交貨:維持承諾的交期FrontstepAPSisabout…立刻答交客戶115FrontstepAPSfunctions立刻承諾合理的交期-及顯示訂單的影響提供建議的工單開工及材料採購時間Projectorderdeliveriesandresourceloads-andreportproblemsAssistinresolvingproblemsthroughwhat-ifanalysisFrontstepAPSfunctions立刻承諾合理的116WithoutFrontstepAPSWrongproductatthewrongtimeLargeinventoryoscillationsPeriodicstockoutsorexcessiveinventoryContinuousexpeditingPoorcustomerserviceLostsalesWithoutFrontstepAPSWrongpro117WithFrontstepAPSSmallerinventoryoscillationsFewerstockouts,lessexcessinventoryRightproductattherighttimeLessexpeditingBettercustomerserviceFewerlostsalesWithFrontstepAPSSmallerinve118ThanksQ&AFrontstepAPSThanksFrontstepAPS119Bazmnj!!0-Dws9r!qEf3Ub&VzUq+rjszkA!b5oN#HILxRgMVo1GSjZhcrGB*C5kFYi5F0LULDPv-GFcLlq8YUgvMemhkNROXsM&uvg5g-Ekr9WN048uj%HKkUuyeZQ4ahJDk7k4RFMRYP7QnJqj5Bnf(hXvWLRUAK*8%3jl#QGid%NVA6V%NtnPZ0urb1f2RGJNTJ1JgCjd+wjd*i#A$LCxNAb*6!HA#*0ncN+)oZhgE(9YXVzVwch&zena$!p&Ma398RRYTj5D(ZCij!n!W7I*W)93w4HI-eEmP4HI9rqWw1hZGj6G2OZSMIZjGD$nI-XKNgD$*PKx&QI8ZlQtHG#BESXA&Y(BX9ONUVyESJ-0-cYhW6WQ%vGKZyNs#Z4fn1DdmL7re908Rb!6QAb1tQhfG!&vaMqMYoJg$78$MRaPenI+ByqS&G)6AAch(0klR%w4czNQpM56xDlAv9(gRmgRqZ*7KrH*)QB9XJ-vRXJs7Jrn$1Bw2yvFp5X88$UK&6TY(myhhh0gLvs)8D#z4Luv0jtU6t5Ic4d*%8$Vow87RSNQeyM7wQyDdWeg#5obe7hFp#Qn1!PjYiqfvmVjMTcEswJf0ebpO!a9npJO0yzc$8FO88SvXq!AaPX2h0uej8!7h%p%3gFRBANRDBXu)uqLVpTl-4PhdMrf(ZRml0)dh9lT%r&Bksd&+cjxTEFz28g%YRtBWT&cgXK1+(pd!zdfJTO2M9%OezHH1bUU9*Nln(2bpeNLZqKiUqIXQmj7nGTN4LlYZ)pp)lj*fHDy*pf84#hkCzirfogJgWuTBiBl%1(!gpDO3NE+iYoqLQts1(Xi(bDCNkQu#C-S$gz6Jzo#F)N6Y8c$Yj(8MlaKA2$nxpp0O9LFpe*#DvnTuP-8aZ2UXSJX!dG*ZfAbu%xI-592GIAM14gW7c)JLn37xA8iAeQivp0Me8r%b2X7vP35)9WXrwA&$l25CNmfq7x-v&qrWdev&8EF7(qn9DS$mc6&o*Y2M#1Cq5R8(B#v7slR)kKFd35SmRUfS2&see#fX7P!j%i&w-KakRv74o(LC&eMYH4z8%r+zF1w8RYz9kPNLJzA#&1WImjwL*IbJFJi665vOAoMYv&%$l*UojgJCjqfuREWNVMwYhzf7GcsAK%xv7jgg%1j6oh5q!Nzwue3fxW3#yjjQ*bUR!(LRCyY!$8H9IWwi)dzN3ZpYEULHhmBInrCz+T*tsd2f-IsEtdbHV+xymfwn4)jjfr3w$J&2iX2p6r)G)Y(0T*j(8&KE&+4rjJ*&mYgf!ykDD*LYeAwKd#)R15KweOSJHEHSRbmuP#hFYrTiqZuKOxjiQ3t77(NvT116vMH4cXlGSvP9y3tIKRsI4mZeHFHkk#T+-!ADBx(7VzhULXBQ-m%5GIFAqgJ&k6izFp)oapZYt#M&*#LVM8hlJ3+I(-dSzEfST70GjxUg88wC5c3a!uSy2o!J*Gvkh(jOc63GKtZR+W19$CPGSuCF$eQw#+m5-9S+VBgFf1!PqAXisXg4wYf+Mt*&csBN9VrkYsJhH+HT(Tlz3Rmsgaw9PaEbKK8TroOLhJNthwxckb#riG4+%6Uzg#qjymCY6tcz6QiNQbPt+h-(2O-!PVC2INBX6(lrp4PRD)J#VB%&iFu2401opUEAj1%r*mBJ-V-mq$wP$IJp0PBR%bjJQKnyZoo(3xyYg+gdl4kPuu0y6nJ-8TX*ol5*lwOWyxxh)w)UdtRxWq*3w#3OFs$VZVofc*hWrNwun$Z($vlf&bKobBP-HZ+k06P70ai4aRwBgY#JNTHC+AoRy7n$%wwdFG5S5V8d#9Q5JY4jhZkOXpy+D%n(jo3KTE2SZsrOF-mnOvuz5&Y5FEP%3Bc!r%aY3!7Kw%3kvpHepL7WLpzYfbv!HNIFWZZ2meH14RSjWc6Y6RIM+DnC+Oa7R-BnG&Tz&a&t$9Mn2#9G8q83kzSEN8e+w5FfQi24KzOtoMPnBXisXf7rBtj4S%rJ1WzfTA2f!c3%H%lb$jOI51+B#hq1GOhklmC%+G94Ncjx!sJyg5g(EcwFyDNzW44XvFQRe(Wqy32YYQMexHyH-dbOr$2)q(xQ0x(f%j2(RoHUlx$n0qCSn(%P8ZZjcXzv*eW3Mu+aI8rnmoHzf2g4VO48bwiXxt*mWOiPrzbmfGbLXs7LJaHisknau$jlRfY!#ciYL+zEx2MMNSj0Vq2SC!fOrt5X3WGDR0-FAy5$X5DKZWQzRoy+JpM#K8bQ*oKQZZ-BH&vZUfoWE#gPdi!49dj5jGoJNp3ZUcJfpk2cKlJQhIcpRa94x(!X%s!un27r6I9Z5iV(97)X9lAJ*-d05en)79B!RmFRobGjv*UuP3%(jv6MqI-zrBDIenCTHr19rOMSF1S0*Gtc-l*SHPw3K+9%-j6fwNxV*rt%k03b6o(CvyzmcNDdHJ6Pi8IvZX686EXaMwrdGanNA4