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1、供應鏈規劃與執行模組世新大學資管系 鄒慶士 副教授1AgendanOverview/Features of SCMnSupply Chain Network DesignnAdvanced Planning and SchedulingnShop Floor ControlnMES/MCS2nEnterprise functional silos with conflicting goalsPurchasingManufacturingDistributionCustomer Service/SalesFew change-oversStable schedulesLong run lengt
2、hsHigh inventoriesHigh service levelsRegional stocksSOURCEMAKEDELIVERSELL Low pur-chase priceMultiple vendorsLow invent-oriesLow trans-portationOverview of SCM-Issues3Overview and targets of SCMn Definition of Supply Chain Management:Supply Chain Management describes all kind of activities across mu
3、ltiplecompanies 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 costs for
4、inventories and deliveries n Long term relationships(customer/supplier binding)n Customer satisfactionn ByERP-BasisSCM-ToolsInternet4Overview and targets of SCMBuys Ingredients and ComponentsMakes aProductMoves it to a DistributionCenterStores it atDistributionCentersStores it in aWarehouseMoves itt
5、o StoresStores it in the StoreSells it toConsumersMulti Enterprise Supply ChainsSource:I2-Technologies5Overview and targets of SCMn Integration of suppliers in planning in consideration of.n Suppliers inventoriesn Suppliers manufacturing capacitiesn Transport times and capacitiesReduction of own inv
6、entories6n 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 SCM7Prerequisites for successn No manag
7、ement 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 productsn Enables hig
8、her profit marginsn Short life cycle(typically few month)n Volatile demandn Newness makes demand unpredictablen Importance of early sales8Prerequisites for successPrimarily functional productsn Supply at lowest costs to predictable demandn High utilization rate of capacityn Minimize inventoriesn Sho
9、rt 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 Invest aggress
10、ively 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 supply9Prerequisites for successEfficientResponsiveFunctionalInnovativematchmatchmismatchmismatchU
11、se of SCM software tools like APO10Prerequisites for success11SCM Business ProcessesnTechnology helps enable a variety of SCM business processesnPush to pullnProcess orientationnOptimizationnPostponementnMore frequent planningnCollaboration12nMove from push to pull manufacturingManufacturersDistribu
12、tors/WholesalersConsumersSuppliersRetailersManufacturersDistributors/WholesalersConsumersSuppliersRetailers Make what we will sell,not sell what we will make!Features of SCM13PurchasingManufacturingDistributionCustomer Service/SalesAvailable-to-Promise(ATP)Capable-to-Promise(CTP)nMove from functiona
13、l silos to process-oriented business processes(e.g.,order-to-cash,cash-to-cash)Integrated Sales and Operations Planning(S&OP)SOURCEMAKEDELIVERSELLFeatures of SCM14nOptimization of all supply chain activitiesSupply Chain OptimizationSynchronized,Concurrent PlanningDemandPlanningDistributionPlanningMa
14、nufacturing PlanningProcurementPlanningIndependent,Sequential PlanningForecastingDistributionPlanningManufacturing PlanningProcurementPlanningFeatures of SCM15PostponementnMove to MTO,ATO and CTO from MTSnFront-end APS suites support nATP/CTPnProduct configurationnBack-end integration to transaction
15、 systemsInternationalTradeLogisticsWarehouseManagementAdvancedPlanning Scheduling CustomerRelationshipManagementLogisticsManufacturingMaterialsManagementAccounting Human Resources Features of SCM16nMore frequent planning means responsive to changing customer needs while decreasing inventoriesTimeTim
16、eAverageSupplyAverageSupplyPlanning CyclePlanning CycleFeatures of SCM17ne-Business will enable supply chain collaboration among trading partnersManufacturerDistributors/WholesalersSuppliersRetailersCollaborative Demand PlanningCollaborative Logistics PlanningTransportation servicesDistribution cent
17、er servicesSynchronized Production SchedulingCollaborative Product DevelopmentFeatures of SCMLogistics Providers18Components of E-Supply ChainnSupply-chain replenishmentnE-procurementnCollaborative planningnCollaborative product developmentnE-logisticsnSupply webs19Evolution of ITARAPGLPayrollMRPFMI
18、SHRMRPIISchedulingplanningDistributionERPAPS/SCMEISEDIE-CommerceBICRME-Business20Agenda精品资料网21ManufacturersWholesale DistributorsSuppliersCustomers Information FlowsGoods FlowSupply Chain Network DesignSupplier ExchangesCustomer ExchangesLogisticsExchangesContract ManufacturersLogistics ProvidersVir
19、tual ManufacturersRetailersnLocation decisionnCapacity decisionnAssignment decision22Strategic Planning ProblemsnWhich products shall be produced at which locations?nHow are customers assigned to distribution centers?nWhere shall new locations be opened?nWhich locations shall be closed?nWhat are cap
20、acity requirements for plants/distribution centers?nWhat is the cost situation within the supply chain?23Planning MethodnPlanning of location assignment and transportation lanesnLocation assignment based on geographical distancenCost optimal location assignmentnStructural Network ChangesnPlacement o
21、f a given number of locations based on geographical distance and costsnCost optimal selection of locations24Planning ParametersnCostnTransportation costsnProduction costsnStorage costsnHandling costsnProcurement costsnLocation costs/Location proceedsnFix maintenance costsnCosts for opening and closu
22、re of locationsnPublic subsidiesnPenalty costs for delayed or non-fulfilled demand25Planning ParametersnCapacitiesnHandling capacities for plants and distribution centersnProduction capacities of plantsnDemandnCalculation of demand via Demand PlanningnSupported by forecast methodsnSimulation of dema
23、nd scenariosnVariation of demand26Planning ResultsnSupply Chain NetworknAssignment of locationsnTransportation lanesnAllocation of products to locationsnNew locations with geographic positionnSelected/not selected locationsnProposal for opening or closure of locations27Planning ResultsnQuantitiesnPr
24、oduction,transport,handling,storage and procurementnCostsnProduction,transport,handling,storage and procurementnLocation costsnOpening costs,maintenance costs,subsidies,etc.nCapacity RequirementsnProduction,transport,handling und storage28OutlooknProfit-oriented planningnConsideration of piece-wise
25、linear costs for transport and productionnConsideration of storage capacitiesnIntegration of GIS applicationsnautomatic calculation of transportation duration and transportation costsnexpanded geographic display29AgendanOverview/Features of SCMnSupply Chain Network DesignnAdvanced Planning and Sched
26、ulingnShop Floor ControlnMES/MCS30Production LogisticsForecastCustomer order administrationPrimary requirements planningRequirements planningPurchasingCapacity schedulingCapacity adjustmentOrder releaseReservationSequencingDetailed schedulingExecutionFactory data entryShop floor controlPlanningPlann
27、ing/schedulingInitiation of implementation functions31Typical Planning ProcessSupply/DemandMeetingMRP/ERPManual AdjustmentRelease POReceiving/ReceiptChange Production PlannCan not deliver on timenLong promise timenDead items&shortagenCustomer unsatisfied32MRP II Planning ProcessnTop-down processnIte
28、rative processMaster PlanningRCCPMRPCRPSFC33Problem in IndustrynSalesnSO confirm時間太長nPC 無法如期交貨nHub會造成投資風險nPC/MCn插單nCancel訂單n訂單交期變更頻繁nYield和Rework造成交期Delayn無法確認真正的產能與瓶頸作業n替代料無法掌控nECN頻繁，易產生呆料34Problem in IndustrynShop Floorn開製令前無法確認料是否備齊n臨時缺料nYield和Rework造成大量未結案工單nShop Floor催MC，MC催Buyer，Buyer催Supplier
29、n產能規劃不合理，無法執行nBuyern無法確認到底欠哪些料n追料頻繁nOrder Cancel頻繁n未考慮Lead Time35Drawbacks in Traditional Production PlanningnSequential planningnProblem in scheduling logicnIndependent demand and supply planningnLack of integrationnBatch processnSingle point planningnLack of simulation capability36SCM Information
30、System37Definition 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 capacity to generate new plans,and some of them create a det
31、ailed 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 most of the factors and constraints that limit the ability to
32、 deliver on time.(Forrest Research,1996)38Features of APSnSynchronized concurrent planningnConstraint-based planningnOptimized planningnReal-time planningnDecision support capabilitynWhat-if simulationnPegging between demand and supplynSpeed and performance39Synchronized Planning40Constraint-based P
33、lanningAPSConstraintSupplyDemandOutputTime:Purchase LTMfg.LTTrasf.LTDue DateCapacity:Resource loadRoutingMaterial:Alternate PartsECN PartsSourcing RuleDemand:ForecastSales OrderSupply Data:On-handWIPPurchasing OrderOptimal Plan41Optimized Technologies in APSnDemand PlanningnExponential SmoothingnSys
34、tem DynamicsnMultiple Linear RegressionnProduction Planning&SchedulingnLinear Programming/Mixed Integer LPnGenetic AlgorithmsnSimulation AnnealingnHeuristic MethodsnDistribution Planning&DeploymentnFlow AlgorithmsnBranch-and-Bound Algorithm42Scope of APSnSupply chain strategic planningnSupply chain
35、network planningnDemand planning and forecastingnInventory planningnSupply chain planningnSupply planningnDistribution planningnTransportation planningnShop floor operation schedulingnShipment scheduling43Functions of APS44nAPS是使用現存Transaction系統(ERP)的資訊，以提供快速規劃及排程的智慧型決策支援系統。PurchasingOrder EntryManu
36、facturingLogistics/ShippingERPCurrent SituationFinalPlanSupply Chain PlannerInput DataDemandCapacityMaterialsOutputProduction PlanShipping PlanPromise PlanAPS and ERP45Multi-Site PlanningnComplex multi-site manufacturing refers to the environment where there are multiple sites that are dependent upo
37、n 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.46Multi-Site PlanningGlobal APS EngineDemand Planning EngineOrder Promising EngineAPSEngin
38、eAPSEngineAPSEngineMaster PlanMaster PlanMaster PlanSupply PlanSupply PlanSupply PlanDemand PlanSupply Plan47*Source:AMR,1996Performance ResultsLate Order25-50%ImprovementOrder Lead Time10-40%ImprovementPlanning Cycle95%ImprovementProduction Lead Time10-50%ImprovementInventory10-60%ImprovementOperat
39、ing Expense10-50%ImprovementThroughput2-5%Improvement48AgendanOverview/Features of SCMnSupply Chain Network DesignnAdvanced Planning and SchedulingnShop Floor ControlnMES/MCS49Purpose of Shop Floor Controln將生產規劃單位所規劃的生產訂單(PO)有效的轉變成實際成品的產出50Shop Floor Control System51Functions of Shop Floor ControlnO
40、rder review/releasenDetailed shop floor operations schedulingnData collection/monitoringnControl/feedbacknOrder disposition52Order Review and Releasen扮演一個過濾機制，控制訂單進入現場的流量53Focus of OR/RnAvailability of materialsnRequired capacitynRequired machines and toolingsnReal-time production statusnVerify MRP
41、plansnConfirm/modify BOM structurenConfirm/modify routingnEvaluate production loads in shop floornCriteria of performance evaluation54Operations SchedulingnWork center oriented schedulingnWork order oriented schedulingnBackward schedulingnForward schedulingnFinite schedulingnDispatching55Data Collec
42、tion and MonitornBarcodenOptical character recognitionnMagnetic stripenVoice recognitionnRadio frequency identificationnMachine vision systemnBlue tooth56Control and FeedbacknOrder problems vs.Resources problemsnIs it solvable?What is the solution?nAdjust and improvenInformation feedback 57Order Dis
43、positionnOrder completionnAS plannednOrder cancellationnMaterials shortagenRelease previously assigned resourcesnEvaluate production performancenDefine and explain specific unexpected conditions/solutions58Shop Floor Control System-Another view59AgendanOverview/Features of SCMnSupply Chain Network D
44、esignnAdvanced Planning and SchedulingnShop Floor ControlnMES/MCS60Relationships of ERP/APS/MES/MCSERPAPSMCSMES61Interactions Between ERP/APS and MES62Definition of MESn將加工現場中的原物料、半成品、成品、機器、時間、成本等資訊以動態且即時的方式來收集、匯整與表達，並追蹤與管制目前正在進行中的各項製造作業的一個資訊系統(APICS)。n其上層銜接APS的生產規劃結果，以進行即時性的現場生產派工；下層則連結MCS，根據派工結果控制
45、設備進行實際加工生產，並即時收集與回饋現場生產資訊。63Functions of MES64Order&Operations ManagementnSelect ordernAssign routingnDispatchingnTrace WIPnOrder progress65Material&Resource ManagementnMonitor materials supplynDeploy resourcesnManage operatorsnToolings(e.g.Fixtures,Jigs)controlnEquipments maintenancenTrace equipmen
46、t statusnControl scrapes66Quality ManagementnInternal vs.External QCnPerformance analysisnQC for raw materials and finished goodsnSPCnSQCnEngineering data analysis67Reporting&Documents ManagementnWork instructionsnQC reportsnSOPnMachining codenWork order recordnLot documentsnEngineering change notic
47、esnISO documents68Manufacturing Control SystemnMan machine interface(MMI)nSupervisory control and data acquisition(SCADA)nDistributed control system(DCS)nManual process control69*Source:PRTM Integrated Supply Chain Benchmarking Study,1997Typical Quantified Benefits from Integrated the Supply Chain D
48、elivery Performance16%-28%ImprovementInventory Reduction25%-60%ImprovementFulfillment Cycle Time30%-50%ImprovementForecast Accuracy25%-80%ImprovementOverall Productivity10%-16%ImprovementLower Supply-Chain Costs25%-50%ImprovementFill Rates20%-30%ImprovementImproved Capacity Realization10%-20%Improvement70ConclusionsnAPS can enhance ERPnMatch of Business Needs and APS SoftwarenIntegration with ERP and MESnAccurate datanSCM is more like a philosophynEnabler-IT 71References精品资料网72Questions and CommentsE-MAIL:cstsoucc.shu.edu.tw73