供应链规划与执行模组知识讲解英文

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1、,,,,,,,按一下以編輯母片標題樣式,按一下以編輯母片,第二層,第三層,第四層,第五層,*,*,供應鏈規劃與執行模組,世新大學資管系 鄒慶士 副教授,1,Agenda,Overview/Features of SCM,Supply Chain Network Design,Advanced Planning and Scheduling,Shop Floor Control,MES/MCS,,2,Enterprise functional silos with conflicting goals,Purchasing,Manufacturing,Distribution,Customer

2、 Service/,Sales,,Few change- overs,Stable schedules,Long run lengths,,High inventories,High service levels,Regional stocks,,SOURCE,MAKE,DELIVER,SELL,,Low pur-chase price,Multiple vendors,,Low invent-ories,Low trans-portation,Overview of SCM - Issues,3,Overview and targets of SCM,,Definition of Suppl

3、y Chain Management:,Supply Chain Management describes all kind of activities across multiple,companies or locations to optimize the manufacturing of products. Hereby,concerning all interfaces on operational and strategic level for involved,associates.,,Main,focus,,Development of,heterogeneous global

4、,production networks,Increased integration of,advanced technologies,,Minimzing costs,for inventories and deliveries,,Long term,,relationships,(customer / supplier binding),,Customer satisfaction,,By,ERP - Basis,SCM - Tools,Internet,4,Overview and targets of SCM,Buys Ingredients,and Components,Makes

5、aProduct,Moves it to a DistributionCenter,Stores it atDistribution,Centers,Stores it in a,Warehouse,Moves itto Stores,Stores it in the Store,Sells it to,Consumers,Multi Enterprise Supply Chains,Source: I2-Technologies,5,Overview and targets of SCM,,Integration of suppliers in planning in consi

6、deration of...,,Suppliers inventories,,Suppliers manufacturing capacities,,Transport times and capacities,Reduction of own inventories,6,,Integrated planning of supply chains leads to,,Reduction of inventories,,Cost savings,,Capability to meet promised delivery dates,,,Increased customer satisfactio

7、n,,Intensified customer binding,,Perspective to extend the sales market,Overview and targets of SCM,7,Prerequisites for success,,No management method guarantees itself for success,,Type of product leads to special type of supply chain,Primarily functional products,,,Don’t change much over time,,Long

8、 life cycles,,Predictable demand,,Stability invites competition,,Leads often to low profit margins,Primarily innovative products,,,Enables higher profit margins,,Short life cycle (typically few month),,Volatile demand,,Newness makes demand unpredictable,,Importance of early sales,8,Prerequisites for

9、 success,Primarily functional products,,Supply at lowest costs to predictable,demand,,High utilization rate of capacity,Minimize inventories,,Short lead time as it doesn’t increase,costs,,Select suppliers primarily for,costs and quality,,Physical efficiency,,Minimize costs by,,,Physical efficiency,

10、Primarily innovative products,,Respond quickly to unpredictable,demand,,Deploy excess buffer capacity,Deploy significant buffer stocks,,Invest aggressively to reduce lead time,,,Select suppliers primarily for,speed, flexibility and quality,,Responsiveness to market,,Minimize costs by,,Highest respon

11、siveness to market,Minimize risk of shortages or excess,supply,9,Prerequisites for success,,,,Efficient,Responsive,Functional,Innovative,,match,match,mismatch,mismatch,Use of SCM software tools like APO,10,Prerequisitesforsuccess,11,SCMBusinessProcesses,Technology helps enablea varietyofSCM business

12、 processes,Push to pull,Process orientation,Optimization,Postponement,More frequent planning,Collaboration,,12,Move frompushtopull manufacturing,Manufacturers,Distributors/Wholesalers,Consumers,Suppliers,Retailers,Manufacturers,Distributors/,,Wholesalers,Consumers,Suppliers,Retailers,Make whatwewill

13、sell,notsellwhat we willmake!!,,FeaturesofSCM,13,Purchasing,Manufacturing,Distribution,Customer Service,/Sales,Available-to-Promise (ATP) Capable-to-Promise (CTP),Move fromfunctionalsilostoprocess-oriented business processes(e.g.,order-to-cash,cash-to-cash),Integrated Sales and Op

14、erations Planning (S&OP),SOURCE,MAKE,DELIVER,SELL,FeaturesofSCM,14,Optimizationofall supplychainactivities,Supply Chain Optimization,Synchronized, Concurrent Planning,Demand,Planning,Distribution,Planning,Manufacturing Planning,Procurement,Planning,Independent,SequentialPlanning,Forecasting,Distribu

15、tion,Planning,Manufacturing Planning,Procurement,Planning,FeaturesofSCM,15,Postponement,Move to MTO,ATOand CTOfrom MTS,Front-endAPS suitessupport,ATP/CTP,Product configuration,Back-endintegrationtotransactionsystems,International,Trade,Logistics,Warehouse,Management,Advanced,Planning,Scheduling,Cust

16、omer,Relationship,Management,Logistics,Manufacturing,Materials,Management,Accounting,Human,Resources,ERP,,EAI,FeaturesofSCM,SCM,16,More frequent planning means responsivetochangingcustomerneedswhiledecreasinginventories,Time,Time,Average,Supply,,,Average,Supply,PlanningCycle,Planning,Cycle,,Features

17、ofSCM,17,e-Business willenable supplychaincollaboration among tradingpartners,Manufacturer,Distributors/,Wholesalers,Suppliers,Retailers,Collaborative Demand Planning,,Collaborative Logistics Planning,Transportation services,Distribution center services,,Synchronized Production Scheduling,Collaborat

18、ive Product Development,FeaturesofSCM,LogisticsProviders,18,Components of E-Supply Chain,Supply-chainreplenishment,E-procurement,Collaborative planning,Collaborative productdevelopment,E-logistics,Supplywebs,19,EvolutionofIT,AR,AP,GL,Payroll,MRP,,FMIS,,HR,MRPII,Scheduling,planning,Distribution,,,,ER

19、P,,,,APS/SCM,,EIS,EDI,E-Commerce,BI,CRM,,,,,,,E-Business,,,,,,20,Agenda,21,Manufacturers,WholesaleDistributors,Suppliers,Customers,InformationFlows,GoodsFlow,SupplyChainNetworkDesign,Supplier,Exchanges,Customer,Exchanges,Logistics,Exchanges,Contract Manufacturers,Logistics Providers,Virtual Manufact

20、urers,Retailers,Locationdecision,Capacitydecision,Assignment decision,22,StrategicPlanningProblems,Whichproductsshallbeproducedatwhichlocations?,Howare customersassignedtodistributioncenters?,Whereshallnewlocations be opened?,Which locationsshall beclosed?,Whatarecapacity requirements for plants/dis

21、tribution centers?,Whatisthecostsituation within the supplychain?,23,PlanningMethod,Planningoflocationassignmentandtransportation lanes,Locationassignmentbased ongeographical distance,Costoptimallocation assignment,Structural Network Changes,Placement ofa givennumberof locationsbased on geographical

22、 distanceandcosts,Costoptimalselection of locations,24,PlanningParameters,Cost,Transportation costs,Production costs,Storagecosts,Handlingcosts,Procurementcosts,Locationcosts /Location proceeds,Fixmaintenancecosts,Costs for opening and closure oflocations,Public subsidies,Penaltycosts for delayed or

23、non-fulfilled demand,25,PlanningParameters,Capacities,Handlingcapacitiesforplants and distributioncenters,Production capacities ofplants,Demand,Calculationof demand via DemandPlanning,Supported byforecast methods,Simulation of demandscenarios,Variation ofdemand,26,PlanningResults,Supply ChainNetwork

24、,Assignment of locations,Transportation lanes,Allocation of products to locations,Newlocations with geographic position,Selected/ not selectedlocations,Proposalforopeningorclosureof locations,27,PlanningResults,Quantities,Production,transport, handling,storageandprocurement,Costs,Production,transpor

25、t, handling,storageandprocurement,Locationcosts,Openingcosts, maintenance costs, subsidies,etc.,CapacityRequirements,Production,transport, handlingundstorage,28,Outlook,Profit-orientedplanning,Consideration ofpiece-wiselinear costsfortransport and production,Consideration ofstoragecapacities,Integra

26、tionof GIS applications,automatic calculation oftransportationdurationandtransportationcosts,expandedgeographicdisplay,29,Agenda,Overview/Features ofSCM,Supply ChainNetworkDesign,AdvancedPlanning and Scheduling,ShopFloor Control,MES/MCS,30,Production Logistics,Forecast,Customerorder administration,P

27、rimaryrequirementsplanning,Requirementsplanning,Purchasing,Capacityscheduling,Capacityadjustment,Order release,Reservation,Sequencing,Detailedscheduling,Execution,Factorydataentry,Shopfloor control,Planning,Planning/scheduling,Initiation of,implementation functions,31,TypicalPlanningProcess,Supply/D

28、emand,Meeting,MRP/ERP,Manual Adjustment,ReleasePO,Receiving/Receipt,Change Production Plan,Cannotdeliveron time,Longpromisetime,Deaditems &shortage,Customerunsatisfied,32,MRPII PlanningProcess,Top-downprocess,Iterative process,Master Planning,RCCP,MRP,CRP,SFC,33,Problemin Industry,Sales,SO confirm,時

29、間太長,PC,無法如期,交,交貨,Hub,會造成投,資,資風險,PC/MC,插單,Cancel,訂單,訂單交期,變,變更頻繁,Yield,和,Rework,造成交期,Delay,無法確認,真,真正的產,能,能與瓶頸,作,作業,替代料無,法,法掌控,ECN,頻繁，易,產,產生呆料,34,Problemin Industry,ShopFloor,開製令前,無,無法確認,料,料是否備,齊,齊,臨時缺料,Yield,和,Rework,造成大量,未,未結案工,單,單,ShopFloor,催,MC，MC,催,Buyer，Buyer,催,Supplier,產能規劃,不,不合理，,無,無法執行,Buyer,無

30、法確認,到,到底欠哪,些,些料,追料頻繁,Order Cancel,頻繁,未考慮,LeadTime,35,Drawbacks inTraditionalProductionPlanning,Sequential planning,Problemin scheduling logic,Independentdemand and supply planning,Lackofintegration,Batch process,Single pointplanning,Lackofsimulation capability,36,SCMInformationSystem,37,Definitionof

31、APS,…,there,’,’snoprecisedefinitionofAPSsystems,butitisquiteintuitivetosaythattheAPSsystems,resolvetheshortcomingsoftheERPsystemsasaplanningtool,….APSsystemsconsidermaterialrequirementsandplantcapacitytogeneratenewplans,andsomeofthemcreateadetailedproductionschedulethatsequencestheproductionoptimall

32、y,,toachievetheorganizationgoalsaswellascustomer,’,’sduedate,.(AMR,1998),…APSsystemsapplyprofound,advancedtechnologies,toachieveimprovedplansthattakeintoaccountmostofthe,factorsandconstraints,thatlimittheabilitytodeliverontime.(ForrestResearch,1996),38,FeaturesofAPS,Synchronizedconcurrentplanning,Co

33、nstraint-basedplanning,Optimizedplanning,Real-timeplanning,Decisionsupportcapability,What-ifsimulation,Peggingbetweendemandandsupply,Speedandperformance,,39,SynchronizedPlanning,40,Constraint-basedPlanning,,APS,,Constraint,Supply,Demand,Output,,Time:,PurchaseLT,Mfg.LT,Trasf.LT,DueDate,,Capacity:,Res

34、ourceload,Routing,,Material:,AlternateParts,ECNParts,SourcingRule,,Demand:,Forecast,SalesOrder,,Supply Data:,On-hand,WIP,PurchasingOrder,,Optimal Plan,41,OptimizedTechnologies inAPS,Demand Planning,Exponential Smoothing,System Dynamics,Multiple LinearRegression,ProductionPlanning& Scheduling,Linear

35、Programming/MixedInteger LP,Genetic Algorithms,SimulationAnnealing,HeuristicMethods,Distribution Planning & Deployment,FlowAlgorithms,Branch-and-Bound Algorithm,,42,Scopeof APS,Supply chain strategic planning,Supply chain networkplanning,Demand planningandforecasting,Inventoryplanning,Supply chain p

36、lanning,Supply planning,Distribution planning,Transportationplanning,Shopflooroperationscheduling,Shipment scheduling,43,Functionsof APS,44,APS,是使用現存,Transaction,系統(,ERP),的資訊，以,提,提供快速規,劃,劃及排程的,智,智慧型決策,支,支援系統。,Purchasing,OrderEntry,Manufacturing,Logistics/Shipping,ERP,Current,Situation,Final,Plan,Sup

37、ply Chain Planner,InputData,Demand,Capacity,Materials,Output,ProductionPlan,Shipping Plan,Promise Plan,APS and ERP,45,Multi-SitePlanning,Complex multi-site manufacturing refersto the environment wheretherearemultiple sitesthatare dependent upon each otherfor material and assemblies.,Supply Planningf

38、ora complexmulti-sitemanufacturingenvironment involvestheconsolidation of data from theindividual sites into acorporateconsolidation database.,46,Multi-SitePlanning,Global APSEngine,Demand PlanningEngine,OrderPromisingEngine,APS,Engine,APS,Engine,APS,Engine,Master Plan,Master Plan,Master Plan,Supply

39、 Plan,Supply Plan,Supply Plan,Demand Plan,Supply Plan,47,,,*,Source: AMR, 1996,Performance Results,Late Order,25-50% Improvement,Order Lead Time,10-40% Improvement,Planning Cycle,95% Improvement,Production Lead Time,10-50% Improvement,Inventory,10-60% Improvement,Operating Expense,10-50% Improvement

40、,Throughput,2-5% Improvement,48,Agenda,Overview/Features ofSCM,Supply Chain NetworkDesign,Advanced Planning and Scheduling,ShopFloorControl,MES/MCS,,49,Purpose ofShopFloor Control,將生產規劃,單,單位所規劃,的,的生產訂單(PO)有,效,效的轉變成,實,實際成品的,產,產出,50,ShopFloorControl System,51,Functionsof Shop Floor Control,Orderreview

41、/release,Detailed shop flooroperationsscheduling,Datacollection/monitoring,Control/feedback,Orderdisposition,52,OrderReview and Release,扮演一個過,濾,濾機制，控,制,制訂單進入,現,現場的流量,,53,Focusof OR/R,Availability ofmaterials,Required capacity,Required machines and toolings,Real-timeproductionstatus,Verify MRPplans,C

42、onfirm/modifyBOM structure,Confirm/modifyrouting,Evaluate productionloadsin shop floor,Criteria of performance evaluation,54,OperationsScheduling,Workcenter orientedscheduling,Workorderorientedscheduling,Backward scheduling,Forward scheduling,Finite scheduling,Dispatching,55,DataCollectionandMonitor

43、,Barcode,Optical character recognition,Magnetic stripe,Voicerecognition,Radiofrequencyidentification,Machine visionsystem,Bluetooth,56,Control and Feedback,Orderproblemsvs. Resources problems,Is itsolvable?Whatis the solution?,Adjust andimprove,Information feedback,57,OrderDisposition,Ordercompletio

44、n,AS planned,Ordercancellation,Materialsshortage,Release previously assigned resources,Evaluate productionperformance,Define andexplain specific unexpected conditions/solutions,58,ShopFloorControl System-Another view,59,Agenda,Overview/Features ofSCM,Supply ChainNetworkDesign,AdvancedPlanning and Sc

45、heduling,ShopFloor Control,MES/MCS,60,Relationships ofERP/APS/MES/MCS,,ERP,,,APS,,,MCS,,,MES,,61,InteractionsBetweenERP/APSandMES,62,Definition of MES,將加工現,場,場中的原,物,物料、半,成,成品、成,品,品、機器,、,、時間、,成,成本等資,訊,訊以動態,且,且即時的,方,方式來收,集,集、匯整,與,與表達，,並,並追蹤與,管,管制目前,正,正在進行,中,中的各項,製,製造作業,的,的一個資,訊,訊系統(,APICS) 。,其上層銜,接,接,

46、APS,的生產規,劃,劃結果，,以,以進行即,時,時性的現,場,場生產派,工,工；下層,則,則連結,MCS，,根據派工,結,結果控制,設,設備進行,實,實際加工,生,生產，並,即,即時收集,與,與回饋現,場,場生產資,訊,訊。,63,Functions ofMES,64,Order &Operations Management,Select order,Assign routing,Dispatching,Trace WIP,Order progress,65,Material& ResourceManagement,Monitormaterials supply,Deploy resourc

47、es,Manage operators,Toolings(e.g.Fixtures, Jigs…) control,Equipments maintenance,Trace equipmentstatus,Controlscrapes,66,QualityManagement,Internalvs.External QC,Performanceanalysis,QC for raw materialsandfinished goods,SPC,SQC,Engineeringdataanalysis,67,Reporting &Documents Management,Workinstructi

48、ons,QC reports,SOP,Machining code,Workorder record,Lotdocuments,Engineeringchange notices,ISOdocuments,68,Manufacturing Control System,Manmachineinterface(MMI),Supervisorycontrolanddataacquisition(SCADA),Distributedcontrolsystem(DCS),Manual process control,69,,,*,Source:PRTMIntegratedSupply ChainBen

49、chmarking Study,1997,TypicalQuantified BenefitsfromIntegratedtheSupply Chain,Delivery Performance,16%-28%,Improvement,Inventory Reduction,25%-60%,Improvement,Fulfillment Cycle Time,30%-50%,Improvement,Forecast Accuracy,25%-80%,Improvement,Overall Productivity,10%-16%,Improvement,Lower Supply-Chain C

50、osts,25%-50%,Improvement,Fill Rates,20%-30%,Improvement,Improved Capacity Realization,10%-20%,Improvement,70,Conclusions,APScanenhanceERP,Match ofBusiness NeedsandAPSSoftware,IntegrationwithERPandMES,Accuratedata,SCMis morelikea philosophy,Enabler- IT,71,References,72,Questions and Comments,73,演讲完毕,，,，谢谢观,看,看！,