柔性生产计划与排产管理

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1Kim“”21Craft2Mass3-aAutomation+Integration+4Lean+Hi-Tech+SCM++3-bTPS-JIT•••••••••+“”••—/IE••+•+•••“”•“”••--•++•+“”•+•TQM+•+“”•+“”+••+••ERP+JIT•TQM+•+OBM+OEM•“”++•“”-BSC•+•--•/-FMS+Robot•/MRP+CIMS•+•+•“”+“”••——1920——502050——802060—702090—21++++……——–——––——–––3……YESNO1.1443/21No.---...5ABC1.2.3.•……1.26()()()1.2.1Vs•–••••––––––•/––––––––7–MTS,Maketostock™™™™™“”•MTS,Maketoorder¾¾¾¾“”1.2.28•ATO‰‰‰‰•ETO¾¾•MTO™™™™OLT/OLTOrderLeadTime)OLTOLTOLT9ProductionLeadTime(PLT)ThroughputTime(TPT)TotalProductionCycleTime(TPCT)DoortoDoorLeadTimeBACABC/ABC2-8——51020100%7090100AA70%70%BB20%20%CC10%10%10123456TOCTheoryofConstraint1.2.4+BOM-BOM+ABC-+-MTSPTSMT0PTOMT0PTOMTSPTS1B/Cor2A/a)b)/12MTOMTSPTOPTSOLT-PLT11DesignforManufacture/Cost•–VRP,VarietyReductionProgram–PDM/–•/•()()()12——•–++–+–MRP+JIT+APS+TOC+Project••••1312a)b34••••••“”•“”141./2.3.4.5.6.2.3.4.1.••••••••••15“”/“”“”“”“”1617-()12342.1••••••18•/•–1–1•––2.2(Annual)AggregatePlan——(ProductionBudget)••–––•19•••••••202.3–––––––––21SOP——1“”23422——****23=(O)+4x(ML)+(P)6=EV-$4941549$-120$-5065%20035%9065%12035%6035%1065%7035%-3065%8024——Ft=Ft-1+(At-1-Ft-1)=+(-)312142153(3)=142+0.20*(153-142)=144.2()314414125——&•––/•–•–•••••26–––––––––––12--/327282930•–––•––––•––•–––•311.2.…1.2.3.4.……1.2.3.……1.2.3.4.……32OEE(OEE)—33•=(OEE)=•==•==•OEE=341246789111213141516171819202122232526272829301002003004005006007008009001000110035123451710.3551580.3842860.2131250.4821330.451321/(/1252861584111581585051.011400.28D41100.22L3900.18M21650.33L1500B2160.72480.16D3720.24M2960.32L1300A(/36OE=85%121483AD1881401629072371110165968*1*21=1688*1*21=1681218*3*21=504321(142.8142.8OE=85%403.2OE=80%-45.24B-19.22B2AM32.23B1B1AL•••••37•••4(MRP)•MPSMPS()•MRPMRP38()39()40M1B1M1B8gB200gM1M1B1M1M1M1B120gB6gB3g1M1B0.5g01234M1000012000110001300014000121001220012300124001310012110121101211012410124201241112421411./2./3.4.5.6.7./8.9.10.11.12.13.14./15./16.17.18.19.20.21.22./23.(MRP)24.(CRP)25.26.27.28.29.30.31.32.33.34.35.36.42ERP‹SAP‹Oracle‹J.d.Edwards‹SSA‹FourthShift‹QAD‹BAAN‹CA‹U.F.SAPOracleJ.D.ECAQADSSAF.S.BaanSchedule&Sequence43—/J5J3J1J2J4J5J3J1J2J4•,•/••44•/,•––•–•••••3.112345•••••……••••……:……CR-criticalRatio–LSO-LeastSlackperoperation––!!!46-3-2-1-D—6M—6L—8TM—8D—15L—2SM—14D—11L—3RD—5M—7L—4QD—2L—12P1.–L1(M)1D)1–2.–173–63.––4.476020T6025S4028R3016Q3014P481/23––––5S¡“”¡“”¡OEE¡¡¡¡¡¡(¡¡¡49…...Month1Month2Month3Month4CFM56CF6-6CF6-80C1000600400Week1Week2Week3Week4CFM56CF6-6CF6-80C250150100250150100250150100250150100Day1Day2Day3Day4CFM56CF6-6CF6-80C5030205030205030205030203.2/“”50“”•(SKU,Pack,SNP)•,Pallet)•TEU)••—~ChangeOverTime)810—EPEIEveryPartEveryInterval)——•••••••……51•••1.--(ABCMOQSQ)2./3.(SQ4.MOQ)(=SQ5.CR6.7.—8.9./LSO10.—/5212345531.2.3.4.31.2.3.4.1.2.3.1.2.3.21.2.3.4.1.2.3.1.2.3.1/5410D6C3B9A121110987654321Mzzzzzzzzz551.2.3.4.41.2.31.2.3.4.21.2.3.4.1No.1.2.3.4.81.2.3.71.2.3.61.2.3.4.5No.56•2060•60⎯80-MRP-JIT•90⎯BACABC3.4.1--ABCABC57)™)™)™)™)™))))58/ROP3.4.2(%)-z500.00750.67800.84901.28941.55951.64961.73982.05992.33--SS=zLT594.5.360(C+C)(L+L)=CL+CL+LC+CLC(L(L()C()T1T2T3T4DD61(C+C)(T+L+L)CT+CL+CL+CT+CL+CLC(L(T(L()C()2+2100+1062“”/BOM63OEMD+?????DD+?D+??D+???D+????/OEM“”“”“”6465•••68VMI)ConsignmentCMIVMRVMIConsignment---CMICo-ManagedInventory)---VMR(VendorManagedReplenishment)---VMI(VendorManagedInventory)---ECR(EfficientCustomerResponse)---69__4.1CustomerFacing™™™™…………InternalFacing¾¾¾¾¾…………704.2-Time•QuotedLeadTime•CustomerLTratioLT•ManufacturingCycleTime1Responsiveness-Reliability•OTDrequest•OTDpromise•Fulfillrate-Flexibility•#ordersperday•Effectivecapacityrange+/-%without+/-resourceImplementationMeasures71•DeliveredPPM•Warranty$•InfantFailure-Quality-Fixed•V-Aperfixed•Unit/squaremeter/2ResourceProductivity-Working•ITO-totalforproductfamily•RawITO•WIPITO•F/GITOImplementationMeasures–-ImplementationMeasures---Human•Total-valueadded/totalheadcount/•Direct-valueadded/direct/•Ratio-salary+indirect/total•Safety-accidentratelossworkingdays-•FTQ-firsttimequality•Scrapandrework%%•COQ-costofquality-InternalQuality72ImplementationMeasures–--Supplier•-LTOTD•-PPM•-%/=================================================KeyPoint-Fewbetterthanmanymax1212-Frommeasuredivisionlevelandplantlevelchangetofocusonproductfamily1.2.3.4.5.6.7.8.9.10.

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