產(chǎn)能管理PPT學(xué)習(xí)教案

1、會計學(xué)1產(chǎn)能管理產(chǎn)能管理2第1頁/共83頁3第2頁/共83頁4手工藝時代大量生產(chǎn)豐田生產(chǎn)系統(tǒng)及時生產(chǎn)系統(tǒng)零庫存生產(chǎn)系統(tǒng)世界級制造成本成本質(zhì)量質(zhì)量彈性彈性交期交期192019501960197019801990 2000服務(wù)、創(chuàng)新、全球化服務(wù)、創(chuàng)新、全球化第3頁/共83頁5MRPMRP IIERP1970198019902000APS 第4頁/共83頁6DemandSupply第5頁/共83頁7第6頁/共83頁8第7頁/共83頁9The VisionThe DeliveryMRPMRP IIERPExtended ERPReduced inventory through “infinite” m

2、anufacturing planningReduced inventory, fewer stock-outs and accurate financial records through “infinite” manufacturing planning and periodic transaction processing.Customer focused, dynamically balanced enterprise through asset optimization and real-time transaction processing.Customer focused, dy

3、namically balanced value network through asset optimizationand real-time transaction processing.MRPMRP IIMRP II (plus)Supply ChainThe vision of ERP is Evolving to include the Extended Enterprise第8頁/共83頁10第9頁/共83頁111970 年代1980 年代1990 年代2000 年代企業(yè)應(yīng)用軟體MRPMRP IIERPEERP應(yīng)用範圍部門工廠企業(yè)供應(yīng)鏈資訊系統(tǒng)架構(gòu)MainframeMinicomp

4、uterClient/Server Web Computing需求重點成本品質(zhì)速度(交期)協(xié)同規(guī)劃(彈性)市場特性大眾市場區(qū)隔市場利基市場一對一少樣大量多樣少量多樣大量大量客製生產(chǎn)模式產(chǎn)品供給導(dǎo)向客戶需求導(dǎo)向資料來源: 資策會MIC IT IS計劃第10頁/共83頁12企業(yè)應(yīng)用軟件演變趨勢企業(yè)應(yīng)用軟件演變趨勢E-Business(電子企業(yè)環(huán)境)ESCM(延伸型供應(yīng)鏈管理)EERP(延伸型企業(yè)資源規(guī)畫)E-Commerce(電子商務(wù))SFA(銷售自動化)CRM(客戶關(guān)系管理)SCM(供應(yīng)鏈管理)ERP(企業(yè)資源規(guī)畫)MRP (物料需求規(guī)劃)Payroll (薪資系統(tǒng))GL (總帳會計)AP (應(yīng)

5、收帳款系統(tǒng))AR (應(yīng)付帳款系統(tǒng))197019902000EDI(電子信息交換)Planning (計劃)Scheduling (排程)Distribution (配銷)MRP II(制造需求規(guī)劃)HR(人力資源)FMIS(財務(wù)系統(tǒng))1980資料來源：HP簡報第11頁/共83頁13E-Business Application Architecture=e-commerceE-business+ERP+SCM+MES/MCS+KM+CRMCustomerEmployeeSupplierE-ProcurementCustomer Relationship ManagementEnterprise

6、Applications IntegrationManufacturing ExecutionManufacturing ControlKnowledge ManagementSupply Chain ManagementEnterprise Resource PlanningSelling Chain Management第12頁/共83頁14nto-ordern Make-to-ordern Assemble-to-ordern Make-to-stock種類數(shù)量1234第13頁/共83頁15Repetitive productionProductJob shopFlowshopCusto

7、mLow volume differentiatedHigh volume differentiatedCommoditySpecialty chemicalsand drugsAerospaceIndustrial machineryMachine toolsElectrical and electronicsPaper Containers Brewers AutomobileTire and rubberSteel productsMajor chemicals and drugsOilSteelForest productsProcessSource: Taylor et al., h

8、y the Process Industries Are Different,?Production and Inventory Management Journal, 1981.One-of-a-kindPERT/CPMMRP; CRPMRP; Line BalancingJIT 第14頁/共83頁16Business PlanningSales PlanningProduction PlanningMPSMRPDemand ManagementFinance PlanningResource Requirements PlanningRough-Cut Capacity PlanningC

9、apacity Requirements PlanningPurchasingProductionActivity ControlMid TermLong-TermShort-TermInventory ManagementInput/OutputControl第15頁/共83頁17Resourcerequirements planningRough-cutcapacity planningCapacityrequirements planningPurchasingMaterial requirements planningMessage toBUY or MAKEProduction ac

10、tivity controlMaster production schedulingProductionplanningInput/OutputanalysisOperationSequencing第16頁/共83頁18PriorityCapacityPlanningControlPPMPSMRPRRPRCCPCRPInput/OutputControlOperationSequencing第17頁/共83頁19第18頁/共83頁20n第19頁/共83頁21ahead of a manufacturing facility, usually expressed in terms of hour

11、s of work or units of production. APICS dictionary第20頁/共83頁22CAPACITYLOADOUTPUT第21頁/共83頁23CapacityLoad(每一作業(yè)之每一作業(yè)之Setup 及及 run times)工程研發(fā)工單工程研發(fā)工單PM重工工單重工工單計劃工單計劃工單已發(fā)放工單已發(fā)放工單加班及外包加班及外包考慮人員考慮人員, 設(shè)施設(shè)施,之之a(chǎn)vailable hours及及Time Efficiency Rate減項減項 Breaks, Downtime, Rework Absenteeism, Daily, Maintenance, O

12、ther第22頁/共83頁第23頁/共83頁第24頁/共83頁26nefficiency第25頁/共83頁276%6%62%13%13%BreaksR. MaintenanceRun TimeUn-utilized butscheduled timeSetup TimeActual time used (run and setup) Scheduled time intended for productionUtilization =A measure of how intensively a resourceis being used.第26頁/共83頁28Example:Breaks: 2

13、0 minutes per shiftRoutine maintenance: 10 minutes per shiftRun time charged: 6 hoursSetup time: 0.5 hourUtilization = 第27頁/共83頁29Actual output (standard hours earned)Standard output expected (scheduled)efficiency =第28頁/共83頁30Example:Work center: 3 machines, two 8-hrs shifts, five days a weekBreakdo

14、wn: 12 hrs per weekUtilization = records indicate that the work center produced an average of 250.8 sta. Hours of output.Efficiency =Capacity = 第29頁/共83頁31Shift per Day Machines or Work StationsHours per ShiftDays per WeekUtilizationEfficiency= Standard Hours per WeekEx: Shifts = 3Shift Length = 8 h

15、rs5 Days per WeekNumber of Machines = 6Machine Utilization = .8Efficiency = .9第30頁/共83頁32第31頁/共83頁33第32頁/共83頁34nno significant changes in inventories of items第33頁/共83頁35Product X12438765PERIODSPlanned Order ReleasedProduct X100 50 80 100 40 60 90第34頁/共83頁36Assy-0112438765PERIODSPlanned Order Release

16、dAssy-01100 50 80 200 180 40 60 90第35頁/共83頁37Resource Load ProfileWork Center 205010015020025012345678PeriodLoadOthersAssy-01Pro XCapacity第36頁/共83頁38階層零件數(shù)量/母項說明 0 1 2 210011012112212610FGsubassemblycomponent Acomponent B第37頁/共83頁39ItemOrderQuantityOn HandOn OrderDueDateLead Time Allocated10011012112

17、2L4L40024006000050015002500250400240060007/37/107/107/101 week2 weeks3 weeks4 weeks0000第38頁/共83頁40PartsWorkCenterSetup Time/LotRun Time/Piece100130 min2.5 min1102110 min15 min0.75 min0.50 min12131215 min25 min15 min0.30 min0.25 min0.25 min122231325 min30 min75 min30 min0.75 min0.15 min0.50 min0.75 m

18、in第39頁/共83頁41WorkCenterAvailable(min)Utilization Efficiency PlannedQueue1232,4002,4002,400100%100%100%100%100%100%4 days4 days4 days第40頁/共83頁42Week123456789101112Quantity 250 200 250 150 200 300 150 250 200 200 250 200第41頁/共83頁43PartOpn.LSSURunProcessQty/FGTotalWC1001200302.502.65012.65011101400100.

19、750.77521.55021102400150.500.53821.076112112400150.300.30661.836312122400250.250.26061.560112132400150.250.25661.536212216000250.750.754107.540212226000300.150.155101.550312236000750.500.513105.130112246000300.750.755107.5503第42頁/共83頁44PartLSSUPrcessRunQty/FGTotalWCWCtotal100400150.50.53821.07611226

20、000750.50.513105.13011212400250.250.26061.5601100200302.52.65012.650110.4161212400150.250.25661.5362110400100.750.77521.55021226000250.750.754107.540210.6261226000300.150.155101.55031226000300.750.755107.55031212400150.30.30661.836310.936第43頁/共83頁45WeekWork Center1234567平均123260426572734208321252187

21、260426572734156215941640208321252187312531883281156215941640223222772343第44頁/共83頁460 05005001000100015001500200020002500250030003000350035001 12 23 34 45 56 67 7WC1WC1WC2WC2WC3WC3第45頁/共83頁47A11A12A22A21WC1WC2P1P2B11B12B22B21P1P2M1M2C11C12C22C21WC1WC2M1M2RCCPMPSBOR第46頁/共83頁48OP NOP N-1OP 1Forward sch

22、edulingBackward schedulingOrder Due DateOrder Start DateOP N-1第47頁/共83頁49InfiniteFiniteCapacityCapacity050100150200PeriodLoadLoad1041201801309712511015012345678050100150200PeriodLoadLoad11012012012010512011012012345678第48頁/共83頁50Dictionary第49頁/共83頁51CapacityRequirementsPlanningPlanned orders Release

23、d ordersRoutingWork centerWork center load reportRevised schedule 第50頁/共83頁52operations to be performed, their sequence, the various work centers to be involved, and the standards for setup and run (times). APICS dictionary第51頁/共83頁53timenShop Calendar第52頁/共83頁54queuesetupprocesswaitmove12nW/C.WIP第5

24、3頁/共83頁55ActivationQueueingTimeAssumption: M/M/1queueing systemE(Q) = a/s(a-s) ; a: ave. arrival rate ; s: ave. service rateActivation = a/s第54頁/共83頁56UTILIZATION第55頁/共83頁57on planned and open orders第56頁/共83頁58第57頁/共83頁59第58頁/共83頁60料件 100固定期間訂購; 訂購期間: 1; 前置時間: 1期間 0 1 2 3 4 5 6 7毛需求排程到貨預(yù)估在手量計劃核發(fā) 250

25、 200 250 150 200 300 150 250 料件 110固定數(shù)量訂購; 訂購數(shù)量: 400; 前置時間: 2期間 0 1 2 3 4 5 6 7毛需求排程到貨預(yù)估在手量計劃核發(fā) 400 料件 121固定數(shù)量訂購; 訂購數(shù)量: 2400; 前置時間: 3期間 0 1 2 3 4 5 6 7毛需求排程到貨預(yù)估在手量計劃核發(fā) 2400料件 122固定數(shù)量訂購; 訂購數(shù)量: 6000; 前置時間: 4期間 0 1 2 3 4 5 6 7毛需求排程到貨預(yù)估在手量計劃核發(fā) 6000第59頁/共83頁61ordernCRP load report第60頁/共83頁62WeekPart12345

26、6710011012112220040024006000250400001505002400020040006000300400240001504002400025040000第61頁/共83頁63週零件1234567WC1100110121122合計300003030152507030150751203015250703015004530152575145301525070WC2100110121122合計010025350100010010150250100253501015025010001001015025WC3100110121122合計00150150003030001501500

27、030300015304500150150003030第62頁/共83頁64週零件1234567WC1100110121122合計5000005006252006000142537520003000357550025060001350750200009503752006003000417562520060001425WC2100110121122合計03000450048000300003000375600097503000450048000300600090003000030003006000900WC3100110121122合計006000600000900900006000600000

28、2100210000600900150000600060000021002100第63頁/共83頁65週1234567WC153014953695142099543201495WC2483531010004835925310925WC3615930615213015456152130第64頁/共83頁66partWorkcenterweek Setup timeRun timecalculationRun timeTotal time10011011012112112212212112131121212301015251575302502.54000.754000.524000.2524000

29、.2560000.560000.756253002006006003000450065531021562561530754530第65頁/共83頁67週1234567WC1 4885 1710 36951495WC2 51459251000 4835925310925WC36155460615213066頁/共83頁680 01000100020002000300030004000400050005000600060001 12 23 34 45 56 67 7WC1WC1WC2WC2WC3WC3第67頁/共83頁69additional m

30、aterial requirements nSome of the load must remain in the center to provide the planned standard queue第68頁/共83頁70Input RateControlOutput RateControlQueue(WIP, Load)第69頁/共83頁71Week Ending: 06/06 06/13 06/20 06/27 07/03 07/10 07/17InputPlanned 182 203 172 178 193 205 208Actual 197 180 168 191 189Cum D

31、eviation 15 -8 -12 1 -3Output Planned 207 207 207 207 207 207 207Actual 213 202 206 210 212Cum Deviation 6 1 0 3 8QueueBegging: 300 hrsPlanned 275 271 236 207 193 191 192 Actual 284 262 224 205 182第70頁/共83頁72nmake capacity available第71頁/共83頁73time period, same unit of measurenobtained from reporting

32、 systems or manual logsnaffected by releases to shop, flow from prior operations第72頁/共83頁74nfrom reporting systems or manual logsnaffected by resources, efficiency, workload第73頁/共83頁75nnactual output vs. actual inputnactual input vs. planned input第74頁/共83頁76ninputnmay run out of worknfeeding w/c beh

33、ind schedule, late order 第75頁/共83頁77nout of worknfeeding w/c behind schedule, idle capacity, late order第76頁/共83頁第77頁/共83頁79Dispatching RuleJobProcessTime(days)ArrivalDateDueDateOperationDue DateFCFS EDD ODDSPTA42232452332413B12242422393221C52312402404134D22192432421342第78頁/共83頁80PlanningHorizonExten

34、tTimePeriodsDecisionsTechniquesResourceplanning(long range)Beyondone yearMonthlyQuarterlyYearlyPlant constructionEquipment Proc.Manpower planningGrosscalculationBOLOperatinghorizon plan(medium range)Up toone yearWeeklyManpower transfersWork plan adjustmentsAlternate routingMake/BuySubcontractingCapacity