供應鏈規(guī)劃與執(zhí)行模組知識講解英文

供應鏈規(guī)劃與執(zhí)行模組世新大學資管系鄒慶士副教授1AgendaOverview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS2EnterprisefunctionalsiloswithconflictinggoalsPurchasingManufacturingDistributionCustomerService/SalesFewchange-oversStableschedulesLongrunlengthsHighinventoriesHighservicelevelsRegionalstocksSOURCEMAKEDELIVERSELL

Lowpur-chasepriceMultiplevendorsLowinvent-oriesLowtrans-portationOverviewofSCM-Issues3OverviewandtargetsofSCM

DefinitionofSupplyChainManagement:SupplyChainManagementdescribesallkindofactivitiesacrossmultiplecompaniesorlocationstooptimizethemanufacturingofproducts.Herebyconcerningallinterfacesonoperationalandstrategiclevelforinvolvedassociates.

Mainfocus

DevelopmentofheterogeneousglobalproductionnetworksIncreasedintegrationofadvancedtechnologies

Minimzingcostsforinventoriesanddeliveries

Longterm

relationships(customer/supplierbinding)

Customersatisfaction

ByERP-BasisSCM-ToolsInternet4OverviewandtargetsofSCMBuysIngredientsandComponentsMakesa

ProductMovesittoa

Distribution

CenterStoresitat

DistributionCentersStoresitinaWarehouseMovesit

toStoresStoresitin

theStoreSellsittoConsumersMultiEnterpriseSupplyChainsSource:I2-Technologies5OverviewandtargetsofSCM

Integrationofsuppliersinplanninginconsiderationof...

SuppliersinventoriesSuppliersmanufacturingcapacitiesTransporttimesandcapacitiesReductionofowninventories6

IntegratedplanningofsupplychainsleadstoReductionofinventoriesCostsavingsCapabilitytomeetpromiseddeliverydates

Increasedcustomersatisfaction Intensifiedcustomerbinding PerspectivetoextendthesalesmarketOverviewandtargetsofSCM7Prerequisitesforsuccess

NomanagementmethodguaranteesitselfforsuccessTypeofproductleadstospecialtypeofsupplychainPrimarilyfunctionalproducts

Don’tchangemuchovertimeLonglifecyclesPredictabledemandStabilityinvitescompetitionLeadsoftentolowprofitmarginsPrimarilyinnovativeproducts

EnableshigherprofitmarginsShortlifecycle(typicallyfewmonth)VolatiledemandNewnessmakesdemandunpredictableImportanceofearlysales8PrerequisitesforsuccessPrimarilyfunctionalproductsSupplyatlowestcoststopredictabledemandHighutilizationrateofcapacityMinimizeinventoriesShortleadtimeasitdoesn’tincreasecostsSelectsuppliersprimarilyforcostsandqualityPhysicalefficiencyMinimizecostsby

PhysicalefficiencyPrimarilyinnovativeproductsRespondquicklytounpredictabledemandDeployexcessbuffercapacityDeploysignificantbufferstocksInvestaggressivelytoreduceleadtimeSelectsuppliersprimarilyforspeed,flexibilityandqualityResponsivenesstomarketMinimizecostsbyHighestresponsivenesstomarketMinimizeriskofshortagesorexcesssupply9PrerequisitesforsuccessEfficientResponsiveFunctionalInnovativematchmatchmismatchmismatchUseofSCMsoftwaretoolslikeAPO10Prerequisitesforsuccess11SCMBusinessProcessesTechnologyhelpsenableavarietyofSCMbusinessprocessesPushtopullProcessorientationOptimizationPostponementMorefrequentplanningCollaboration12MovefrompushtopullmanufacturingManufacturersDistributors/WholesalersConsumersSuppliersRetailersManufacturersDistributors/

WholesalersConsumersSuppliersRetailersMakewhatwewillsell,notsellwhatwewillmake!!FeaturesofSCM13PurchasingManufacturingDistributionCustomerService/SalesAvailable-to-Promise(ATP)Capable-to-Promise(CTP)Movefromfunctionalsilostoprocess-orientedbusinessprocesses(e.g.,order-to-cash,cash-to-cash)IntegratedSalesandOperationsPlanning(S&OP)SOURCEMAKEDELIVERSELLFeaturesofSCM14OptimizationofallsupplychainactivitiesSupplyChainOptimizationSynchronized,ConcurrentPlanningDemandPlanningDistributionPlanningManufacturingPlanningProcurementPlanningIndependent,SequentialPlanningForecastingDistributionPlanningManufacturingPlanningProcurementPlanningFeaturesofSCM15PostponementMovetoMTO,ATOandCTOfromMTSFront-endAPSsuitessupportATP/CTPProductconfigurationBack-endintegrationtotransactionsystemsInternationalTradeLogisticsWarehouseManagementAdvancedPlanningSchedulingCustomerRelationshipManagementLogisticsManufacturingMaterialsManagementAccountingHumanResourcesERPEAIFeaturesofSCMSCM16MorefrequentplanningmeansresponsivetochangingcustomerneedswhiledecreasinginventoriesTimeTimeAverageSupplyAverageSupplyPlanningCyclePlanningCycleFeaturesofSCM17e-BusinesswillenablesupplychaincollaborationamongtradingpartnersManufacturerDistributors/WholesalersSuppliersRetailersCollaborativeDemandPlanningCollaborativeLogisticsPlanningTransportationservicesDistributioncenterservicesSynchronizedProductionSchedulingCollaborativeProductDevelopmentFeaturesofSCMLogisticsProviders18ComponentsofE-SupplyChainSupply-chainreplenishmentE-procurementCollaborativeplanningCollaborativeproductdevelopmentE-logisticsSupplywebs19EvolutionofITARAPGLPayrollMRPFMISHRMRPIISchedulingplanningDistributionERPAPS/SCMEISEDIE-CommerceBICRME-Business20Agenda21ManufacturersWholesaleDistributorsSuppliersCustomersInformationFlowsGoodsFlowSupplyChainNetworkDesignSupplierExchangesCustomerExchangesLogisticsExchangesContractManufacturersLogisticsProvidersVirtualManufacturersRetailersLocationdecisionCapacitydecisionAssignmentdecision22StrategicPlanningProblemsWhichproductsshallbeproducedatwhichlocations?Howarecustomersassignedtodistributioncenters?Whereshallnewlocationsbeopened?Whichlocationsshallbeclosed?Whatarecapacityrequirementsforplants/distributioncenters?Whatisthecostsituationwithinthesupplychain?23PlanningMethodPlanningoflocationassignmentandtransportationlanesLocationassignmentbasedongeographicaldistanceCostoptimallocationassignmentStructuralNetworkChangesPlacementofagivennumberoflocationsbasedongeographicaldistanceandcostsCostoptimalselectionoflocations24PlanningParametersCostTransportationcostsProductioncostsStoragecostsHandlingcostsProcurementcostsLocationcosts/LocationproceedsFixmaintenancecostsCostsforopeningandclosureoflocationsPublicsubsidiesPenaltycostsfordelayedornon-fulfilleddemand25PlanningParametersCapacitiesHandlingcapacitiesforplantsanddistributioncentersProductioncapacitiesofplantsDemandCalculationofdemandviaDemandPlanningSupportedbyforecastmethodsSimulationofdemandscenariosVariationofdemand26PlanningResultsSupplyChainNetworkAssignmentoflocationsTransportationlanesAllocationofproductstolocationsNewlocationswithgeographicpositionSelected/notselectedlocationsProposalforopeningorclosureoflocations27PlanningResultsQuantitiesProduction,transport,handling,storageandprocurementCostsProduction,transport,handling,storageandprocurementLocationcostsOpeningcosts,maintenancecosts,subsidies,etc.CapacityRequirementsProduction,transport,handlingundstorage28OutlookProfit-orientedplanningConsiderationofpiece-wiselinearcostsfortransportandproductionConsiderationofstoragecapacitiesIntegrationofGISapplicationsautomaticcalculationoftransportationdurationandtransportationcostsexpandedgeographicdisplay29AgendaOverview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS30ProductionLogisticsForecastCustomerorderadministrationPrimaryrequirementsplanningRequirementsplanningPurchasingCapacityschedulingCapacityadjustmentOrderreleaseReservationSequencingDetailedschedulingExecutionFactorydataentryShopfloorcontrolPlanningPlanning/schedulingInitiationofimplementationfunctions31TypicalPlanningProcessSupply/DemandMeetingMRP/ERPManualAdjustmentReleasePOReceiving/ReceiptChangeProductionPlanCannotdeliverontimeLongpromisetimeDeaditems&shortageCustomerunsatisfied32MRPIIPlanningProcessTop-downprocessIterativeprocessMasterPlanningRCCPMRPCRPSFC33ProbleminIndustrySalesSOconfirm時間太長PC無法如期交貨貨Hub會造成投資風風險PC/MC插單Cancel訂單訂單交期變更更頻繁Yield和Rework造成交期Delay無法確認真正正的產能與瓶瓶頸作業(yè)替代料無法掌掌控ECN頻繁，易產生生呆料34ProbleminIndustryShopFloor開製令前無法法確認料是否否備齊臨時缺料Yield和Rework造成大量未結結案工單ShopFloor催MC，MC催Buyer，，Buyer催Supplier產能規(guī)劃不合合理，無法執(zhí)執(zhí)行Buyer無法確認到底底欠哪些料追料頻繁O(jiān)rderCancel頻繁未考慮LeadTime35DrawbacksinTraditionalProductionPlanningSequentialplanningProbleminschedulinglogicIndependentdemandandsupplyplanningLackofintegrationBatchprocessSinglepointplanningLackofsimulationcapability36SCMInformationSystem37DefinitionofAPS…there’’snoprecisedefinitionofAPSsystems,butitisquiteintuitivetosaythattheAPSsystemsresolvetheshortcomingsoftheERPsystemsasaplanningtool….APSsystemsconsidermaterialrequirementsandplantcapacitytogeneratenewplans,andsomeofthemcreateadetailedproductionschedulethatsequencestheproductionoptimally,toachievetheorganizationgoalsaswellascustomer’sduedate.(AMR,1998)…APSsystemsapplyprofoundadvancedtechnologiestoachieveimprovedplansthattakeintoaccountmostofthefactorsandconstraintsthatlimittheabilitytodeliverontime.(ForrestResearch,1996)38FeaturesofAPSSynchronizedconcurrentplanningConstraint-basedplanningOptimizedplanningReal-timeplanningDecisionsupportcapabilityWhat-ifsimulationPeggingbetweendemandandsupplySpeedandperformance39SynchronizedPlanning40Constraint-basedPlanningAPSConstraintSupplyDemandOutputTime:PurchaseLTMfg.LTTrasf.LTDueDateCapacity:ResourceloadRoutingMaterial:AlternatePartsECNPartsSourcingRuleDemand:ForecastSalesOrderSupplyData:On-handWIPPurchasingOrderOptimalPlan41OptimizedTechnologiesinAPSDemandPlanningExponentialSmoothingSystemDynamicsMultipleLinearRegressionProductionPlanning&SchedulingLinearProgramming/MixedIntegerLPGeneticAlgorithmsSimulationAnnealingHeuristicMethodsDistributionPlanning&DeploymentFlowAlgorithmsBranch-and-BoundAlgorithm42ScopeofAPSSupplychainstrategicplanningSupplychainnetworkplanningDemandplanningandforecastingInventoryplanningSupplychainplanningSupplyplanningDistributionplanningTransportationplanningShopflooroperationschedulingShipmentscheduling43FunctionsofAPS44APS是使用現存Transaction系統(tǒng)(ERP)的資訊訊，以以提供供快速速規(guī)劃劃及排排程的的智慧慧型決決策支支援系系統(tǒng)。PurchasingOrderEntryManufacturingLogistics/ShippingERPCurrentSituationFinalPlanSupplyChainPlannerInputDataDemandCapacityMaterialsOutputProductionPlanShippingPlanPromisePlanAPSandERP45Multi-SitePlanningComplexmulti-sitemanufacturingreferstotheenvironmentwheretherearemultiplesitesthataredependentuponeachotherformaterialandassemblies.SupplyPlanningforacomplexmulti-sitemanufacturingenvironmentinvolvestheconsolidationofdatafromtheindividualsitesintoacorporateconsolidationdatabase.46Multi-SitePlanningGlobalAPSEngineDemandPlanningEngineOrderPromisingEngineAPSEngineAPSEngineAPSEngineMasterPlanMasterPlanMasterPlanSupplyPlanSupplyPlanSupplyPlanDemandPlanSupplyPlan47*Source:AMR,1996PerformanceResultsLateOrder25-50%ImprovementOrderLeadTime10-40%ImprovementPlanningCycle95%ImprovementProductionLeadTime10-50%ImprovementInventory10-60%ImprovementOperatingExpense10-50%ImprovementThroughput2-5%Improvement48AgendaOverview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS49PurposeofShopFloorControl將生生產產規(guī)規(guī)劃劃單單位位所所規(guī)規(guī)劃劃的的生生產產訂訂單單(PO)有有效效的的轉轉變變成成實實際際成成品品的的產產出出50ShopFloorControlSystem51FunctionsofShopFloorControlOrderreview/releaseDetailedshopflooroperationsschedulingDatacollection/monitoringControl/feedbackOrderdisposition52OrderReviewandRelease扮演演一一個個過過濾濾機機制制，，控控制制訂訂單單進進入入現現場場的的流流量量53FocusofOR/RAvailabilityofmaterialsRequiredcapacityRequiredmachinesandtoolingsReal-timeproductionstatusVerifyMRPplansConfirm/modifyBOMstructureConfirm/modifyroutingEvaluateproductionloadsinshopfloorCriteriaofperformanceevaluation54OperationsSchedulingWorkcenterorientedschedulingWorkorderorientedschedulingBackwardschedulingForwardschedulingFiniteschedulingDispatching55DataCollectionandMonitorBarcodeOpticalcharacterrecognitionMagneticstripeVoicerecognitionRadiofrequencyidentificationMachinevisionsystemBluetooth56ControlandFeedbackOrderproblemsvs.ResourcesproblemsIsitsolvable?Whatisthesolution?AdjustandimproveInformationfeedback57OrderDispositionOrdercompletionASplannedOrdercancellationMaterialsshortageReleasepreviouslyassignedresourcesEvaluateproductionperformanceDefineandexplainspecificunexpectedconditions/solutions58ShopFloorControlSystem-Anotherview59AgendaOverview/FeaturesofSCMSupplyChainNetworkDesignAdvancedPlanningandSchedulingShopFloorControlMES/MCS60RelationshipsofERP/APS/MES/MCSERPAPSMCSMES61InteractionsBetweenERP/APSandMES62DefinitionofMES將加加工工現現場場中中的的原原物物料料、、半半成成品品、、成成品品、、機機器器、、時時間間、、成成本本等等資資訊訊以以動動態(tài)態(tài)且且即即時時的的方方式式來來收收集集、、匯匯整整與與表表達達，，並並追追蹤蹤與與管管制制目目前前正正在在進進行行中中的的各各項項製製造造作作業(yè)業(yè)的的一一個個資資訊訊系系統(tǒng)統(tǒng)(APICS)。。其上上層層銜銜接接APS的生生產產規(guī)規(guī)劃劃結結果果，，以以進進行行即即時時性性的的現現場場生生產產派派工工