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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1培训专用AgendanOverview/Features of SCMnSupply Chain Network DesignnAdvanced Planning and SchedulingnShop Floor ControlnMES/MCS2培训专用nEnterprise functional silos with conflicting goalsPurchasingManufacturingDistributionCustomer Service/SalesFew change-oversStable schedulesLong r
2、un lengthsHigh inventoriesHigh service levelsRegional stocksSOURCEMAKEDELIVERSELL Low pur-chase priceMultiple vendorsLow invent-oriesLow trans-portationOverview of SCM-Issues3培训专用Overview and targets of SCMn Definition of Supply Chain Management:Supply Chain Management describes all kind of activiti
3、es across 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 Minimzin
4、g costs for inventories and deliveries n Long term relationships(customer/supplier binding)n Customer satisfactionn ByERP-BasisSCM-ToolsInternet4培训专用Overview and targets of SCMBuys Ingredients and ComponentsMakes aProductMoves it to a DistributionCenterStores it atDistributionCentersStores it in aWa
5、rehouseMoves itto StoresStores it in the StoreSells it toConsumersMulti Enterprise Supply ChainsSource:I2-Technologies5培训专用Overview and targets of SCMn Integration of suppliers in planning in consideration of.n Suppliers inventoriesn Suppliers manufacturing capacitiesn Transport times and capacities
6、Reduction of own inventories6培训专用n 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 SCM7培训专用Prerequ
7、isites for successn 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 inno
8、vative productsn Enables higher profit marginsn Short life cycle(typically few month)n Volatile demandn Newness makes demand unpredictablen Importance of early sales8培训专用Prerequisites for successPrimarily functional productsn Supply at lowest costs to predictable demandn High utilization rate of cap
9、acityn Minimize inventoriesn 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 significa
10、nt buffer stocksn 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 supply9培训专用Prerequisites for successEfficientResponsiveFunctionalI
11、nnovativematchmatchmismatchmismatchUse of SCM software tools like APO10培训专用Prerequisites for success11培训专用SCM Business ProcessesnTechnology helps enable a variety of SCM business processesnPush to pullnProcess orientationnOptimizationnPostponementnMore frequent planningnCollaboration12培训专用nMove from
12、 push to pull manufacturingManufacturersDistributors/WholesalersConsumersSuppliersRetailersManufacturersDistributors/WholesalersConsumersSuppliersRetailers Make what we will sell,not sell what we will make!Features of SCM13培训专用PurchasingManufacturingDistributionCustomer Service/SalesAvailable-to-Pro
13、mise(ATP)Capable-to-Promise(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 SCM14培训专用nOptimization of all supply chain activitiesSupply Chain OptimizationSynchronized
14、,Concurrent PlanningDemandPlanningDistributionPlanningManufacturing PlanningProcurementPlanningIndependent,Sequential PlanningForecastingDistributionPlanningManufacturing PlanningProcurementPlanningFeatures of SCM15培训专用PostponementnMove to MTO,ATO and CTO from MTSnFront-end APS suites support nATP/C
15、TPnProduct configurationnBack-end integration to transaction systemsInternationalTradeLogisticsWarehouseManagementAdvancedPlanning Scheduling CustomerRelationshipManagementLogisticsManufacturingMaterialsManagementAccounting Human Resources Features of SCM16培训专用nMore frequent planning means responsiv
16、e to changing customer needs while decreasing inventoriesTimeTimeAverageSupplyAverageSupplyPlanning CyclePlanning CycleFeatures of SCM17培训专用ne-Business will enable supply chain collaboration among trading partnersManufacturerDistributors/WholesalersSuppliersRetailersCollaborative Demand PlanningColl
17、aborative Logistics PlanningTransportation servicesDistribution center servicesSynchronized Production SchedulingCollaborative Product DevelopmentFeatures of SCMLogistics Providers18培训专用Components of E-Supply ChainnSupply-chain replenishmentnE-procurementnCollaborative planningnCollaborative product
18、 developmentnE-logisticsnSupply webs19培训专用Evolution of ITARAPGLPayrollMRPFMISHRMRPIISchedulingplanningDistributionERPAPS/SCMEISEDIE-CommerceBICRME-Business20培训专用Agenda21培训专用ManufacturersWholesale DistributorsSuppliersCustomers Information FlowsGoods FlowSupply Chain Network DesignSupplier ExchangesC
19、ustomer ExchangesLogisticsExchangesContract ManufacturersLogistics ProvidersVirtual ManufacturersRetailersnLocation decisionnCapacity decisionnAssignment decision22培训专用Strategic Planning ProblemsnWhich products shall be produced at which locations?nHow are customers assigned to distribution centers?
20、nWhere shall new locations be opened?nWhich locations shall be closed?nWhat are capacity requirements for plants/distribution centers?nWhat is the cost situation within the supply chain?23培训专用Planning MethodnPlanning of location assignment and transportation lanesnLocation assignment based on geogra
21、phical distancenCost optimal location assignmentnStructural Network ChangesnPlacement of a given number of locations based on geographical distance and costsnCost optimal selection of locations24培训专用Planning ParametersnCostnTransportation costsnProduction costsnStorage costsnHandling costsnProcureme
22、nt costsnLocation costs/Location proceedsnFix maintenance costsnCosts for opening and closure of locationsnPublic subsidiesnPenalty costs for delayed or non-fulfilled demand25培训专用Planning ParametersnCapacitiesnHandling capacities for plants and distribution centersnProduction capacities of plantsnDe
23、mandnCalculation of demand via Demand PlanningnSupported by forecast methodsnSimulation of demand scenariosnVariation of demand26培训专用Planning ResultsnSupply Chain NetworknAssignment of locationsnTransportation lanesnAllocation of products to locationsnNew locations with geographic positionnSelected/
24、not selected locationsnProposal for opening or closure of locations27培训专用Planning ResultsnQuantitiesnProduction,transport,handling,storage and procurementnCostsnProduction,transport,handling,storage and procurementnLocation costsnOpening costs,maintenance costs,subsidies,etc.nCapacity RequirementsnP
25、roduction,transport,handling und storage28培训专用OutlooknProfit-oriented planningnConsideration of piece-wise linear costs for transport and productionnConsideration of storage capacitiesnIntegration of GIS applicationsnautomatic calculation of transportation duration and transportation costsnexpanded
26、geographic display29培训专用AgendanOverview/Features of SCMnSupply Chain Network DesignnAdvanced Planning and SchedulingnShop Floor ControlnMES/MCS30培训专用Production LogisticsForecastCustomer order administrationPrimary requirements planningRequirements planningPurchasingCapacity schedulingCapacity adjust
27、mentOrder releaseReservationSequencingDetailed schedulingExecutionFactory data entryShop floor controlPlanningPlanning/schedulingInitiation of implementation functions31培训专用Typical Planning ProcessSupply/DemandMeetingMRP/ERPManual AdjustmentRelease POReceiving/ReceiptChange Production PlannCan not d
28、eliver on timenLong promise timenDead items&shortagenCustomer unsatisfied32培训专用MRP II Planning ProcessnTop-down processnIterative processMaster PlanningRCCPMRPCRPSFC33培训专用Problem 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
29、無法掌控nECN頻繁，易產生呆料34培训专用Problem 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Suppliern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 Time35培训专用Drawbacks in Traditional Production PlanningnSequential planningnProblem in scheduling logicnIndepen
30、dent demand and supply planningnLack of integrationnBatch processnSingle point planningnLack of simulation capability36培训专用SCM Information System37培训专用Definition of APSntheres no precise definition of APS systems,but it is quite intuitive to say that the APS systems resolve the shortcomings of the E
31、RP systems as a planning tool.APS systems consider material requirements and plant capacity 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 appl
32、y profound advanced technologies to achieve improved plans that take into account most of the factors and constraints that limit the ability to deliver on time.(Forrest Research,1996)38培训专用Features of APSnSynchronized concurrent planningnConstraint-based planningnOptimized planningnReal-time plannin
33、gnDecision support capabilitynWhat-if simulationnPegging between demand and supplynSpeed and performance39培训专用Synchronized Planning40培训专用Constraint-based PlanningAPSConstraintSupplyDemandOutputTime:Purchase LTMfg.LTTrasf.LTDue DateCapacity:Resource loadRoutingMaterial:Alternate PartsECN PartsSourcin
34、g RuleDemand:ForecastSales OrderSupply Data:On-handWIPPurchasing OrderOptimal Plan41培训专用Optimized Technologies in APSnDemand PlanningnExponential SmoothingnSystem DynamicsnMultiple Linear RegressionnProduction Planning&SchedulingnLinear Programming/Mixed Integer LPnGenetic AlgorithmsnSimulation Anne
35、alingnHeuristic MethodsnDistribution Planning&DeploymentnFlow AlgorithmsnBranch-and-Bound Algorithm42培训专用Scope of APSnSupply chain strategic planningnSupply chain network planningnDemand planning and forecastingnInventory planningnSupply chain planningnSupply planningnDistribution planningnTransport
36、ation planningnShop floor operation schedulingnShipment scheduling43培训专用Functions of APS44培训专用nAPS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 EntryManufacturingLogistics/ShippingERPCurrent SituationFinalPlanSupply Chain PlannerInput DataDemandCapacityMaterialsOutputProduction Pla
37、nShipping PlanPromise PlanAPS and ERP45培训专用Multi-Site PlanningnComplex multi-site manufacturing refers 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 con
38、solidation of data from the individual sites into a corporate consolidation database.46培训专用Multi-Site PlanningGlobal APS EngineDemand Planning EngineOrder Promising EngineAPSEngineAPSEngineAPSEngineMaster PlanMaster PlanMaster PlanSupply PlanSupply PlanSupply PlanDemand PlanSupply Plan47培训专用*Source:
39、AMR,1996Performance ResultsLate Order25-50%ImprovementOrder Lead Time10-40%ImprovementPlanning Cycle95%ImprovementProduction Lead Time10-50%ImprovementInventory10-60%ImprovementOperating Expense10-50%ImprovementThroughput2-5%Improvement48培训专用AgendanOverview/Features of SCMnSupply Chain Network Desig
40、nnAdvanced Planning and SchedulingnShop Floor ControlnMES/MCS49培训专用Purpose 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50培训专用Shop Floor Control System51培训专用Functions of Shop Floor ControlnOrder review/releasenDetailed shop floor operations schedulingnData collection/monitoringnControl/feed
41、backnOrder disposition52培训专用Order Review and Releasen扮演一個過濾機制，控制訂單進入現場的流量53培训专用Focus of OR/RnAvailability of materialsnRequired capacitynRequired machines and toolingsnReal-time production statusnVerify MRP plansnConfirm/modify BOM structurenConfirm/modify routingnEvaluate production loads in shop f
42、loornCriteria of performance evaluation54培训专用Operations SchedulingnWork center oriented schedulingnWork order oriented schedulingnBackward schedulingnForward schedulingnFinite schedulingnDispatching55培训专用Data Collection and MonitornBarcodenOptical character recognitionnMagnetic stripenVoice recognit
43、ionnRadio frequency identificationnMachine vision systemnBlue tooth56培训专用Control and FeedbacknOrder problems vs.Resources problemsnIs it solvable?What is the solution?nAdjust and improvenInformation feedback 57培训专用Order DispositionnOrder completionnAS plannednOrder cancellationnMaterials shortagenRe
44、lease previously assigned resourcesnEvaluate production performancenDefine and explain specific unexpected conditions/solutions58培训专用Shop Floor Control System-Another view59培训专用AgendanOverview/Features of SCMnSupply Chain Network DesignnAdvanced Planning and SchedulingnShop Floor ControlnMES/MCS60培训
45、专用Relationships of ERP/APS/MES/MCSERPAPSMCSMES61培训专用Interactions Between ERP/APS and MES62培训专用Definition 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，根據派工結果控制設備進行實際加工生產，並即時收集與回饋現場生產資訊。63培训专用Functions of MES64培训专用Ord
46、er&Operations ManagementnSelect ordernAssign routingnDispatchingnTrace WIPnOrder progress65培训专用Material&Resource ManagementnMonitor materials supplynDeploy resourcesnManage operatorsnToolings(e.g.Fixtures,Jigs)controlnEquipments maintenancenTrace equipment statusnControl scrapes66培训专用Quality Managem
47、entnInternal vs.External QCnPerformance analysisnQC for raw materials and finished goodsnSPCnSQCnEngineering data analysis67培训专用Reporting&Documents ManagementnWork instructionsnQC reportsnSOPnMachining codenWork order recordnLot documentsnEngineering change noticesnISO documents68培训专用Manufacturing C
48、ontrol SystemnMan machine interface(MMI)nSupervisory control and data acquisition(SCADA)nDistributed control system(DCS)nManual process control69培训专用*Source:PRTM Integrated Supply Chain Benchmarking Study,1997Typical Quantified Benefits from Integrated the Supply Chain Delivery Performance16%-28%Imp
49、rovementInventory Reduction25%-60%ImprovementFulfillment Cycle Time30%-50%ImprovementForecast Accuracy25%-80%ImprovementOverall Productivity10%-16%ImprovementLower Supply-Chain Costs25%-50%ImprovementFill Rates20%-30%ImprovementImproved Capacity Realization10%-20%Improvement70培训专用ConclusionsnAPS can
50、 enhance ERPnMatch of Business Needs and APS SoftwarenIntegration with ERP and MESnAccurate datanSCM is more like a philosophynEnabler-IT 71培训专用References72培训专用Questions and CommentsE-MAIL:73培训专用演讲完毕，谢谢观看！培训专用内容总结供應鏈規劃與執行模組。Overview/Features of SCM。Overview/Features of SCM。Few change-overs。SCM-Tools