零配件分销企业库存的控制和改进

上海交通大学硕士学位论文零配件分销企业库存的控制和改进姓名：田之茵申请学位级别：硕士专业：物流工程指导教师：周炳海;邵为民20090101I,KPI,,,,,,,,IIIIITHESTOCKCONTROLANDIMPROVEMENTOFSPAREPARTSDISTRIBUTIONCOMPANYABSTRACTThisthesisisbasedontheCumminsEngineShanghaiCorporationsprojectofSparePartsStockOptimization.Intheviewpointofcombiningboththeoryandtheengineerapplications,theobjectiveofthisthesisistocontrolandoptimizestockforsparepartsDistributionCompany.Afterextensivestudyingfordomestic&foreigninventorycontrolsystem,meanwhile,combingwiththecurrentcharactersofsparepartsdistributionmarket&KPIappliedinsparepartsDistributionCompany,andconcerningtothepracticalproblemcompanymeets,theresearchcontentsarebroughtforward.Intheviewofsparepartsdemandingcharacters,andcombiningcurrentstatusofinventoryandinventorymanagementofthecompany,thethesisanalyzesthekeyreasonsthathighstockamountsaswellaslowcustomerorderfillratelevelPointoutthemethodofstockcontrollingistoimprovesparepartsclassification,inventorystructuremodelandforecastaccuracy.Thethesisanalysis&findoutanewmethodtoclarifythesparepartswhichconsolidatethethreekeyspecificationsofspareparts,suchasdemandfrequency,salesamount,importanceofenginemaintenance.Afterdefinedsparepartsclassification,thethesissetupdifferentinventorymodelbasedondifferentcharactersofeachgroup.Inordertoincreasecustomersatisfactorylevelwealsoneedtoconcernpartsdemandforecastexceptforsettingupsafetystock.Then,thethesisistoidentifythekeyfactorswhichimpactdemandbasedonpeculiarityofpartsdistributionenterprise.Thesekeyfactorsarepartsdamagefrequencyandmarketingactivity.TofindoutthebestforecastmethodandprocessbysettingupdifferentforecastmodulethatimproveforecastaccuracyaswellasinventoryoptimizationandcustomerIVsatisfactionlevel.Finallythethesisevaluatethenewmethodofinventorycontrolbyinventoryturncustomerorderfillrateandlogisticcostandsetupcontinuedimprovementprocess.Accordingtomentionedinventorycontrolmethods,thedeadstocklevelisreducedremarkablyaswellasinventoryoptimizationandcustomersatisfactionlevelimprovement.Thisisagoodexperienceforothersparepartsdistributioncompanies,anditcancreateabetterstockcontrolwayforCummins.KEYWORDS:demandfrequency,importanceofmaintenance,stockmodel,damagefrequency,forecast11.1,,,,1.1.11.1.21.1.3,,,,,21.219112124020061020001231.31.3.1DSCMERP1KPI231.3.241.4,151.2.,3.,4.1Fig.1StudyContent62.1,40%-50%...:abc2.22.2.1A2007150K$BC7D2.2.2,WIPWorkinProcessWIP[1]WIPWIPWIP1823456-292Fig.2StockCreationFlowChart2.33420071032007Fig.3CompanyInventoryValueandInventoryTurnof200742007Fig.4CustomerOrderFillRateTrendChartof20072007918.6M$1014.1M$CPDCInventoryValueM$andTurn0246810121416182000.511.522.533.54Series214.5515.7713.7416.0115.7816.2518.218.118.616.415.314.1Series12.82.42.93.333.13.53.43.13.53.63.5010702070307040705070607070708070907100711071207CPDCMonthlyFPFRTrendReport2007-200801000200030004000500060007000800090000107020703070407050706070707080709071007110712070.00%10.00%20.00%30.00%40.00%50.00%60.00%70.00%80.00%90.00%100.00%FilledOrderLineFailedOrderLineFPFR11520061220078520061220078Fig.5InventoryOnHandByABCAnalysisofDec2006VSAug2007ABCDEF20078A8%C93%CDEF35%41%62007CPDCInventoryOnHandByABCAnalysis(K$)0200040006000020040060080010001200Dec2006AmountAug2007AmountDifferencePercentageDec2006Amount4793115311101296808Aug2007Amount5165178121441660995Difference3726281034364187Percentage8%54%93%28%23%ABCD+EF1262007Fig.6DPartsInventoryTrendChartof20072.4[2]1-23456789,DPartsInventoryTrendChart0.002,000.004,000.006,000.008,000.0010,000.0012,000.00123456789101112ValueRMBK0%2%4%6%8%10%12%14%16%DPartsInventoryPercentage131ISM20071ISM2007A2007233K$,3%,IDDescsalesstatusPNUnitCostQty/EngineTotalSoldTotalSalesAmount4BEARING,THRUS70308489910.3143373,473.3512COMPRESSOR,AI703104324851.3315143,418.0028SENSOR,VISCOS70306972829.28131907.6869MOTOR,STARTIN703103952422.91131,268.723GEAR,CRANKSHA703084445208.591153,128.805LEVER,CAMFOL70341764558.486341,988.3219TUBE,FUELSUP70316161813.67114191.3378ROD,PUSH70307604622.7561613,662.211CRANKSHAFT,EN7030737072554.87125,109.7351INJECTOR704061851506.7263618,241.92XCECISMEngineRecommendedsparepartsList14B7200872008Fig.7NPIPartsAgingInventoryChartOf200820086800K$300K$30085%CDNPIPartsInventoryChart0.00100.00200.00300.00400.00500.00600.00MonthValueK$78%80%82%84%86%88%90%92%94%96%98%100%Over300daysinventoryK$42.3043.8051.20382.50486.30301.10Over300daysw/odemandK$41.1042.5046.20348.60413.90254.90Percentage97%97%90%91%85%85%01080208030804080508060815[3],,200735%,163.1ABC,ABC,ABC,,,,,[4],,,,,,,,,,ABC[5]3.2ABC3.2.1ABCABCABCABCABC1951H.F.A12ABCA10%70%C70%10%B20%173ABCABCABCABCABCABC3.2.2ABC3.2.2.1ABCABCABC,,;,,[6][7]ABCA10%,70%B20%,20%C70%,10%:1.A,C2.A,C3..A,C,,,,,184.A,C5.A,C22007ISM22007ISM3821AC3.2.2.2ABC,ABC,,,,IDDescsalesstatusPNUnitCostQty/EngineTotalSoldDemandIssue4BEARING,THRUS70308489910.3143373812COMPRESSOR,AI703104324851.331511428SENSOR,VISCOS70306972829.281311169MOTOR,STARTIN703103952422.911313GEAR,CRANKSHA703084445208.5911575LEVER,CAMFOL70341764558.486341619TUBE,FUELSUP70316161813.67114878ROD,PUSH70307604622.756161211CRANKSHAFT,EN703073707