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1、1供應鏈規劃與執行模組世新大學資管系 鄒慶士 副教授2AgendanOverview/Features of SCMnSupply Chain Network DesignnAdvanced Planning and SchedulingnShop Floor ControlnMES/MCS3nEnterprise functional silos with conflicting goalsPurchasingManufacturingDistributionCustomer Service/SalesFew change-oversStable schedulesLong run leng
2、thsHigh inventoriesHigh service levelsRegional stocksSOURCEMAKEDELIVERSELL Low pur-chase priceMultiple vendorsLow invent-oriesLow trans-portationOverview of SCM-Issues4Overview and targets of SCMn Definition of Supply Chain Management:Supply Chain Management describes all kind of activities across m
3、ultiplecompanies 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-ToolsInternet5Overview and targets of SCMBuys Ingredients and ComponentsMakes aProductMoves it to a DistributionCenterStores it atDistributionCentersStores it in aWarehouseMoves it
5、to StoresStores it in the StoreSells it toConsumersMulti Enterprise Supply ChainsSource:I2-Technologies6Overview and targets of SCMn Integration of suppliers in planning in consideration of.n Suppliers inventoriesn Suppliers manufacturing capacitiesn Transport times and capacitiesReduction of own in
6、ventories7n 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 SCM8Prerequisites for successn No mana
7、gement 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 hi
8、gher profit marginsn Short life cycle(typically few month)n Volatile demandn Newness makes demand unpredictablen Importance of early sales9Prerequisites for successPrimarily functional productsn Supply at lowest costs to predictable demandn High utilization rate of capacityn Minimize inventoriesn Sh
9、ort 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 aggres
10、sively 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 supply10Prerequisites for successEfficientResponsiveFunctionalInnovativematchmatchmismatchmismatc
11、hUse of SCM software tools like APO11Prerequisites for success12SCM Business ProcessesnTechnology helps enable a variety of SCM business processesnPush to pullnProcess orientationnOptimizationnPostponementnMore frequent planningnCollaboration13nMove from push to pull manufacturingManufacturersDistri
12、butors/WholesalersConsumersSuppliersRetailersManufacturersDistributors/WholesalersConsumersSuppliersRetailers Make what we will sell,not sell what we will make!Features of SCM14PurchasingManufacturingDistributionCustomer Service/SalesAvailable-to-Promise(ATP)Capable-to-Promise(CTP)nMove from functio
13、nal silos to process-oriented business processes(e.g.,order-to-cash,cash-to-cash)Integrated Sales and Operations Planning(S&OP)SOURCEMAKEDELIVERSELLFeatures of SCM15nOptimization of all supply chain activitiesSupply Chain OptimizationSynchronized,Concurrent PlanningDemandPlanningDistributionPlanning
14、Manufacturing PlanningProcurementPlanningIndependent,Sequential PlanningForecastingDistributionPlanningManufacturing PlanningProcurementPlanningFeatures of SCM16PostponementnMove to MTO,ATO and CTO from MTSnFront-end APS suites support nATP/CTPnProduct configurationnBack-end integration to transacti
15、on systemsInternationalTradeLogisticsWarehouseManagementAdvancedPlanning Scheduling CustomerRelationshipManagementLogisticsManufacturingMaterialsManagementAccounting Human Resources ERPEAIFeatures of SCMSCM17nMore frequent planning means responsive to changing customer needs while decreasing invento
16、riesTimeTimeAverageSupplyAverageSupplyPlanning CyclePlanning CycleFeatures of SCM18ne-Business will enable supply chain collaboration among trading partnersManufacturerDistributors/WholesalersSuppliersRetailersCollaborative Demand PlanningCollaborative Logistics PlanningTransportation servicesDistri
17、bution center servicesSynchronized Production SchedulingCollaborative Product DevelopmentFeatures of SCMLogistics Providers19Components of E-Supply ChainnSupply-chain replenishmentnE-procurementnCollaborative planningnCollaborative product developmentnE-logisticsnSupply webs20Evolution of ITARAPGLPa
18、yrollMRPFMISHRMRPIISchedulingplanningDistributionERPAPS/SCMEISEDIE-CommerceBICRME-Business21Agenda.22ManufacturersWholesale DistributorsSuppliersCustomers Information FlowsGoods FlowSupply Chain Network DesignSupplier ExchangesCustomer ExchangesLogisticsExchangesContract ManufacturersLogistics Provi
19、dersVirtual ManufacturersRetailersnLocation decisionnCapacity decisionnAssignment decision23Strategic 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
20、are capacity requirements for plants/distribution centers?nWhat is the cost situation within the supply chain?24Planning MethodnPlanning of location assignment and transportation lanesnLocation assignment based on geographical distancenCost optimal location assignmentnStructural Network ChangesnPlac
21、ement of a given number of locations based on geographical distance and costsnCost optimal selection of locations25Planning ParametersnCostnTransportation costsnProduction costsnStorage costsnHandling costsnProcurement costsnLocation costs/Location proceedsnFix maintenance costsnCosts for opening an
22、d closure of locationsnPublic subsidiesnPenalty costs for delayed or non-fulfilled demand26Planning ParametersnCapacitiesnHandling capacities for plants and distribution centersnProduction capacities of plantsnDemandnCalculation of demand via Demand PlanningnSupported by forecast methodsnSimulation
23、of demand scenariosnVariation of demand27Planning ResultsnSupply Chain NetworknAssignment of locationsnTransportation lanesnAllocation of products to locationsnNew locations with geographic positionnSelected/not selected locationsnProposal for opening or closure of locations28Planning ResultsnQuanti
24、tiesnProduction,transport,handling,storage and procurementnCostsnProduction,transport,handling,storage and procurementnLocation costsnOpening costs,maintenance costs,subsidies,etc.nCapacity RequirementsnProduction,transport,handling und storage29OutlooknProfit-oriented planningnConsideration of piec
25、e-wise linear costs for transport and productionnConsideration of storage capacitiesnIntegration of GIS applicationsnautomatic calculation of transportation duration and transportation costsnexpanded geographic display30AgendanOverview/Features of SCMnSupply Chain Network DesignnAdvanced Planning an
26、d SchedulingnShop Floor ControlnMES/MCS31Production LogisticsForecastCustomer order administrationPrimary requirements planningRequirements planningPurchasingCapacity schedulingCapacity adjustmentOrder releaseReservationSequencingDetailed schedulingExecutionFactory data entryShop floor controlPlanni
27、ngPlanning/schedulingInitiation of implementation functions32Typical Planning ProcessSupply/DemandMeetingMRP/ERPManual AdjustmentRelease POReceiving/ReceiptChange Production PlannCan not deliver on timenLong promise timenDead items&shortagenCustomer unsatisfied33MRP II Planning ProcessnTop-down proc
28、essnIterative processMaster PlanningRCCPMRPCRPSFC34Problem 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35Problem 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S
29、uppliern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 Time36Drawbacks in Traditional Production PlanningnSequential planningnProblem in scheduling logicnIndependent demand and supply planningnLack of integrationnBatch processnSingle point planningnLack of simulation capability37SCM Infor
30、mation System38Definition 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 creat
31、e a detailed 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 abi
32、lity to deliver on time.(Forrest Research,1996)39Features of APSnSynchronized concurrent planningnConstraint-based planningnOptimized planningnReal-time planningnDecision support capabilitynWhat-if simulationnPegging between demand and supplynSpeed and performance40Synchronized Planning41Constraint-
33、based PlanningAPSConstraintSupplyDemandOutputTime:Purchase LTMfg.LTTrasf.LTDue DateCapacity:Resource loadRoutingMaterial:Alternate PartsECN PartsSourcing RuleDemand:ForecastSales OrderSupply Data:On-handWIPPurchasing OrderOptimal Plan42Optimized Technologies in APSnDemand PlanningnExponential Smooth
34、ingnSystem DynamicsnMultiple Linear RegressionnProduction Planning&SchedulingnLinear Programming/Mixed Integer LPnGenetic AlgorithmsnSimulation AnnealingnHeuristic MethodsnDistribution Planning&DeploymentnFlow AlgorithmsnBranch-and-Bound Algorithm43Scope of APSnSupply chain strategic planningnSupply
35、 chain network planningnDemand planning and forecastingnInventory planningnSupply chain planningnSupply planningnDistribution planningnTransportation planningnShop floor operation schedulingnShipment scheduling44Functions of APS45nAPS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 En
36、tryManufacturingLogistics/ShippingERPCurrent SituationFinalPlanSupply Chain PlannerInput DataDemandCapacityMaterialsOutputProduction PlanShipping PlanPromise PlanAPS and ERP46Multi-Site PlanningnComplex multi-site manufacturing refers to the environment where there are multiple sites that are depend
37、ent upon 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.47Multi-Site PlanningGlobal APS EngineDemand Planning EngineOrder Promising EngineA
38、PSEngineAPSEngineAPSEngineMaster PlanMaster PlanMaster PlanSupply PlanSupply PlanSupply PlanDemand PlanSupply Plan48*Source:AMR,1996Performance ResultsLate Order25-50%ImprovementOrder Lead Time10-40%ImprovementPlanning Cycle95%ImprovementProduction Lead Time10-50%ImprovementInventory10-60%Improvemen
39、tOperating Expense10-50%ImprovementThroughput2-5%Improvement49AgendanOverview/Features of SCMnSupply Chain Network DesignnAdvanced Planning and SchedulingnShop Floor ControlnMES/MCS50Purpose 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51Shop Floor Control System52Functions of Shop Floor Co
40、ntrolnOrder review/releasenDetailed shop floor operations schedulingnData collection/monitoringnControl/feedbacknOrder disposition53Order Review and Releasen扮演一個過濾機制，控制訂單進入現場的流量54Focus of OR/RnAvailability of materialsnRequired capacitynRequired machines and toolingsnReal-time production statusnVeri
41、fy MRP plansnConfirm/modify BOM structurenConfirm/modify routingnEvaluate production loads in shop floornCriteria of performance evaluation55Operations SchedulingnWork center oriented schedulingnWork order oriented schedulingnBackward schedulingnForward schedulingnFinite schedulingnDispatching56Data
42、 Collection and MonitornBarcodenOptical character recognitionnMagnetic stripenVoice recognitionnRadio frequency identificationnMachine vision systemnBlue tooth57Control and FeedbacknOrder problems vs.Resources problemsnIs it solvable?What is the solution?nAdjust and improvenInformation feedback 58Or
43、der DispositionnOrder completionnAS plannednOrder cancellationnMaterials shortagenRelease previously assigned resourcesnEvaluate production performancenDefine and explain specific unexpected conditions/solutions59Shop Floor Control System-Another view60AgendanOverview/Features of SCMnSupply Chain Ne
44、twork DesignnAdvanced Planning and SchedulingnShop Floor ControlnMES/MCS61Relationships of ERP/APS/MES/MCSERPAPSMCSMES62Interactions Between ERP/APS and MES63Definition 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
45、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。64Functions of MES65Order&Operations ManagementnSelect ordernAssign routingnDispatchingnTrace WIPnOrder progress66Material&Resource ManagementnMonitor materials supplynDeploy resourcesnManage operatorsnToolings(e.g.Fixtures,Jigs)controlnEquipments maintenancenTrace e
46、quipment statusnControl scrapes67Quality ManagementnInternal vs.External QCnPerformance analysisnQC for raw materials and finished goodsnSPCnSQCnEngineering data analysis68Reporting&Documents ManagementnWork instructionsnQC reportsnSOPnMachining codenWork order recordnLot documentsnEngineering chang
47、e noticesnISO documents69Manufacturing Control SystemnMan machine interface(MMI)nSupervisory control and data acquisition(SCADA)nDistributed control system(DCS)nManual process control70*Source:PRTM Integrated Supply Chain Benchmarking Study,1997Typical Quantified Benefits from Integrated the Supply
48、Chain Delivery 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%Improvement71ConclusionsnAPS can enhance ERPnMatch of Business Needs and APS SoftwarenIntegration with ERP and MESnAccurate datanSCM is more like a philosophynEnabler-IT 72References.