A公司备品备件库存管理系统研究

华中科技大学硕士学位论文A公司备品备件库存管理系统研究姓名：綦海军申请学位级别：硕士专业：工商管理指导教师：崔南方20061024IASSAPA20068AA2007AAAAIIAbstractSparepartsarenotintermediateorfinalproductstobesoldtoacustomer,andthepoliciesthatgovernsparepartsinventoryaredifferentfromthosethatgovernrawmaterial,semi-finishedgoodsandfinishedgoods.Asapartofthecompany’sinventoryandassetmanagement,thesparepartsinventorymanagementsupportstheequipmentmaintenanceandplantalteration.Italsoensuresthesuccessfulstart-upofthecompany’snewfacilityandthesmoothoperationoftheexistedplant.Thefunctionofsparepartsinventoryistoassistamaintenancestaffinkeepingequipmentinagoodoperatingcondition.Forthepetrochemicalandothercapitalcentralizedindustries,agoodsparepartsinventorymanagementsystemwillensurethesmoothoperationofequipment,reducecosts,lowerlinedownlostandincreaseoperatingprofit.CompanyAisanewlyoperatedpetrochemicalcomplex.ItadoptedtheexperiencedandadvancedsparepartsinventorymanagementsystemofCompanySbyapplyingthebestpractice.ItalsousesSAPmanagementinformationsystemtomanagethesparepartsandotherbusinessofthecompany.Thispaperstudiesthesparepartsbusinessprocess,sparepartsclassificationmanagement,sparepartsmanagementintheprojectstage,sparepartsmaterialrequirementplanning,physicalinventoryandsparepartsmanagementinformationsysteminCompanyA.ThesparepartsinventoryperformanceismeasuredbasedontheoperationdatainAug2006inCompanyA.ThispapercomparesthephysicalperformanceinAug2006withthebestperformanceinthepetrochemicalindustryandtheyear2007sparepartsinventoryperformancegoalinCompanyA.BasedonthecurrentstatusofthesparepartsinventorymanagementinCompanyA,thispaperalsoanalyzesthesparepartsinventorymanagementproblemsandreasons.ImprovementsuggestionsandstepsforthesparepartsinventorymanagementinCompanyAareputforward.Theimprovementofsparepartsinventorymanagementshallbeacontinuousandprogressionalprocess.ThispaperwillassistCompanyAtoimproveitssparepartsinventorymanagementsystemandperformances.Thispapercouldalsobeareferenceforcompaniesinthepetrochemicalorothercapitalcentralizedindustries.KeywordsSparepartsInventorymanagementManagementinformationsystem20061024?_____?v“v”2006102420061024111.1ASSAPSAA1.2“”InventoryStock[1][2]2[3][4][5][6][7]3A1.32050[8]BP1234456vendorconsignmentstock7[9]8SAP1.45SAPA622.12.1.1[10]7[11]2.1.2A42313AA////23025A2-1[12]82-1A()800,000430,000165,000/450,000250,000//200,000240,000/320,000550,000/250,000135,000/60,0002.1.3A2-192-12.22.2.11Itemcosts2Orderingandset-upcosts3Carryingcosts4Stockoutcosts[13]2.2.2A10[14]2.32.3.112-22-2211SAPMRPSAP2-3122-32.3.21DirectChargeReceiptsStockReceipts13Non-stockitemsSAPSAPSAP2-42-4short-shippedOver-shippeddamaged14SAPMESC2SAP2.3.31ConsumptionIssue2SAP(Workorder)ReservationPickTicket15PrioritiesFirstInFirstOutRuleSAP3SAP2.3.4A2-5162-52.3.5SAPSAPSAP2-6MRPOpenpurchaseorder172-62.4A18A2.4.1EPC,Engineering-Procurement-ConstructionContractorEPCEPCAEPCEPCA2.4.21BoltNutGasketValveFlangeTubefittingBlind21AEPCEPCMESCMESCMaterialandEquipmentStandardCodeMESC19BP2MESCAMESC34567SAP2.4.312201ESPIR2000ESPIR20002ESPIR-20003MESCMESC4[15]5MESCA[16]216789102.4.41Surplusspareparts2SurplusstocksparepartsSurplusprojectsparepartsSurplusdirect-chargesparepartsDeadstockExcessstock3ObsoletestockStockanalystSAP2245[17]6Unduedeterioration237A“””ideal”specification83624AssetWithdrawalCertificateMESCA2.4.51Salvage2MESC3[18]25AMESC2.4.61Scrap[19]232.52.5.1262.5.2AAEPC,Engineering-Procurement-ConstructionContractorPMC,ProjectManagementContractorEPCHSEEPCEPCEPCAEPCEPCABULKAESPIR27[20]ASAPAAESPIR2000AA2.62.6.1MaterialRequirementsPlanning,MRP2060“”MRP[21]28[22][23]2.6.2ALotsizeReorderpointMaximumstocklevelSafetystock2-72-7MRP0,MRP29MRPASAPSAPMRPMaterialrequirementlistPlannedorderPurchasingrequisition2.6.3MRPMRPAMRPMRPMRP1MRPMRPtypeNDNoplanningVBManualreorderpointplanningMRP2MRPMRPgroupNPLDNoplanningPLNDalwaysgenerateplannedorderMRP3MRPW01MRPAMRP4LotsizeHBreplenishtomaxstocklevel5Reorderpointandmaximumstocklevel6Roundingvalue2.7302.7.1(VendorConsignmentStock)[24]GiovanniValentiniLucioZavanella2003EDI[25]FerrozziShapiro2000[26][27]312.7.2AAAAAA[28]AItemcategory“K”A2-82-8322.7.3AASwagelock2002.8Physicalinventory2.8.1PeriodicCycleCountingSamplingABC2.8.2UnrestrictedUseQualityInspectionBlockedStock332.8.3AERPAERP[29]A2-9SAPSAPSAP342-93533.13.1.1AE-SPIR2000E-SPIRElectronicSparePartsandInterchangeabilityRecordE-SPIR2000E-SPIR2000ERPE-SPIR2000SAPPacerCMTCatalogueManagementToolSAPBOM3.1.2E-SPIR2000E-SPIRE-SPIR2000SAPE-SPIR2000know-how363.1.3PurchaseRequisitionStockProposal[30]3.1.41ASAP2ESPIR2000SAPAESPIR2000SAPSAPSAPBOMSAP3.2SAP(ERP)ERPERPMAXIMOSAPERP50080%SAP[31]SAP37“”SAP[32]ASAPSAPR/34.6CSAPR/34.6CInventorymanagement“--”SAPSAPWarehousemanagement3-13-1//ABC//.SAPEAM.:,2005.145-157SAPSAP383.3SAP3.3.1SAP/3-23-2,,12,1,21,2,,1393.3.2“”SAP150“Y”“Z”3-33-3////.SAPEAM.:,2005.145-157403.3.31GoodsReceipt2IncomingQualityInspection3StockTransfer4GoodsIssue415PhysicalInventorySAP6GoodsReturn7ValueDataManagementMovingAveragePriceStandardPriceERP[33]“ValueClass”“”“”“”8InventorySAPSAP42SAP[34]9WarehouseManagementInvent