库存管理优化研究与实现

上海交通大学硕士学位论文库存管理优化研究与实现姓名：邢华申请学位级别：硕士专业：@指导教师：张洁;胡安东20080201ISAPSAPSAPII,:SAPIIIINVENTORYOPITIMIZATIONANDIMPROVEMENTSTUDYABSTRACTItisveryimportantfortheinventorycontrolunderthehighcompetitionandfastchangingmarketingsituation.Inventorynotonlyaffectthewarehousecostandcurrencyoccupationbutalsoaffecttheservicelevelandreactionspeedtothecustomers.Therefore,itisakeyquestionforacompanytohaveproperplanandmethodtocontroltheinventory.WetakeCoopertooldivisionasstudyobjecttodiscusstheinventoryproblem.Forsmallvolumeandmultipletypesproductionmodethecomponentsquantityisbigandthecomponentshavesomecommonusing.Thecomponentsleadtimeislongandthefinishgoodsdemandisnotsoclear.Itbringshighrequirementfortheinventorymanagementandmakestheinventoryoptimizeveryimportant.TherehastheSAPsysteminthiscompany.WetryusethebasicdatafromSAPsystemanddeveloptheoptimizingandsalesforecastprogramtohelptheinventoryplanningandorderingprocess.Wetakethesupplierchaintheoryandgrayforecasttheoryasthemethodforthisstudy.Whentheprogramanddatabasearereadyweuseitthedrivetheinventorysetupandcontinuousfollowit.Therearemanyfactsneedtobeconsideredfortheinventoryproblem.Oneisthematerialinventorystrategyoptimizingandtheotheriswhomakeagoodsalesforecast.Thepurposewestudythestrategyandforecastistomakeafitfulinventorylevelandamounttomeetthecustomers’requirementfortheproducts.Ifwecandothatwecanmakegoodinventoryturnsandmeetforthedeliverrequest.Thefirststepissetupaninventoryoptimizemoduleafterstudyeachitemswhichwillaffecttheinventorystrategy.InthismodulewewilltakethedatafromtheSAPsystemasthebasicoftheprogram.Instudywewillconsidertheitemslikeinventoryturnrequirement,unitpurchaseprice,purchasingcost,thepurchaseleadtime,purchasinglotsizelimitation,qualityproblem,etc..Forwilldefinethestrategyforeachitemandputthemintotheprogrambeforeitstarttorun.ItcanIVsaythatthebasicitemsarethecontrollimitationoftheinventorysetup.Second,wewillusethegrayforecastmethodtousethelimitedonhandsalesdatatogivereasonablesalesforecast.Thatwillbethestartinputoftheprogramrunning.PuttheinventoryoptimizemoduleandthegrayforecastmoduletogetheranddeveloptheprogrambaseontheSAPdatawecangettheinventoryrequirementquicklyandeasily.Therehavemanykeyitemswereimprovedafterthisprojectimplement.Thewarehousespacewasdeducedandtheinventoryturnratewereincreased.Theontimedeliverrateandmaterialanalysisprocesswereimproved.Andtheallthecomponentsinventorysetupmeettheirmartialcharacteristic.KEYWORDSinventorymanagement,inventorystrategy,grayforecast,SAP200902231801.11.1.150%1.1.2z6z95%z5%z2~3.1.1.32804~68~970%1.1.4z,z,z,zSAP1.21.2.1,,,:IPT(/):3%,A/S():7%:1.2.3.3~43801.2.2,1.2.2.1ERPERP(BOM),,(ERP),SAP(ERP)ERPGartnersgroupsInc.90ERPSCM(SupplyChainManagement)JIT(JustInTime)ERPMRPIIMRPII1.2.2.2ERPzMRPII/ERP20MRPIIERPERPERPERPzERPERP(90)90ERP863CIMSMRPII/ERP200CIMSMRPIIERPMRPII/ERPCIMSzERPERP(21)2000“”“”863ERP10ERPERPERP1.2.2.31.2.2.3.1-MRPMRP4801.2.2.3.2JITJUST-IN-TIMEJIT1.2.2.3.3JITMRPMRPMRPIIManufacturingResourcePlanningERPEnterpriseResourcePlanningMRPII/ERPMRPII/ERPMRPII/ERP“”“”“”MRPII/ERPJIT“”JITzJITzzMRPII/ERPMRPII/ERPJITJITMRII/ERP580JITMRPII/ERPJITMRPII/ERPJIT1.2.2.4CMISMConcurrentEngineering(IntegrateSCM)(LeanManagement)1.31.3.1CIMS,1.3.21.3.2.1SAP1.3.2.2,,1.3.2.31.3.2.3.1SAP6801.3.2.3.2,,,,CIMS,CIMSBusinessProcessReengineeringBPR,BPR,,,1.3.2.3.3JITABC1.4:1),;2),3)SAP,,;1.57801-1Fig.1-1Structureofthethesis:1234568801.69802.11980-1990“”“”20001788GDP20%1%1782.1.1:2.1.1.1:;::2.1.1.1.1zzzzzzz2.1.1.1.210802.1.1.2zzz„„„„2.1.22.1.2.1zzzzz:„„(EOQMRPJIT……)„()„„„2.1.32.1.3.1zz:„„„1180„„2.1.3.2.zzzz2.1.3.3.2.1.3.4.zzz2.1.3.5.zz()zz2.1.42.14.1(EOQ):a;b;c;d:;;;:1280;;;;;2.1.4.2(MRP)2.1.5=/=/X100%=(1-/)X100%=+/2=/X100%=/X100%/=///X100%=/X100%2.1.62.1.6.1zzzzz2.1.6.2zzzzz1380zz2.1.7.32.1.82.1.8.1zzzz2.1.8.2:2.1.8.3zzzz(ManagementStyle)zz1480zzzzzzzz2.2zzz2.2.1z/MTOz/MTSz2-115802-1Fig.2-1Pullproductionmode2-22-2Fig.2-2Pullproductionmodeprocess2-3MMTTOO16802-3Fig.2-3Pushproductionmode2-42-4Fig.2-4Pushproductionmodeprocess2-5MMTTSS17802-5Fig.2-5Orderandforecastmixedproductionmode2-62-6Fig.2-6Orderandforecastmixedproductionprocessfigure2.2.2----/MMTTOOMMTTSS1880()Internet(ATPAble-To-Promise)MRP35/(DistributionRequirementPlanningDRP)OIS(OperationinformationSystem)DCSPID(DynamicMatrixControlDMC)198012SQP----()()()2.2.3----AMRResearchInc535--------12.3;2080:(1)(2)(3)(4)(5)2.3.1:A:;B://R&D;2180C://;D:R&D;E:2.3.2()()2.3.32.3.3.1(GreySystemTheory)2080(W.R.Ashby)(BlackBox)2280I2.3.3.2:2050151615162.42-7:1.,,,2380,2.3.2-7Fig.2-7Configureofthestudyproject2.524803.1.3.2.SAPERPz6z95%z5%z2~38~970%z,z,z,z25803.3SAPSAPSAPSAPSAP3-13-1Fig.3-1InventorymodulestructurefigureSAPSAP26803.4SAP3.4.1SAPEXCEL3-2:3-2Fig.3-2Salesorderdata3.4.2SAP3-327803-3Fig.3-3Productbillofmaterial3.4.3SAP3-43-4Fig.3-4Materialinventorydata28803.4.4SAP3-53-5Fig.3-5Purchaseorder3.53.5.1→→→→“”,;N,M,S=M/N298063-6PTInventoryChart050100150200250300350400450500JanFebMarAprMayJunJulAugSepOctNovDecJanFebMarAprMayJunJulAugSepOctNovDecMonth$K0.02.04.06.08.010.012.0TimesInventoryBudgetIventoryTurnsBu