制造業(yè)的目標(biāo)課件

制造業(yè)的目標(biāo)提高服務(wù)水平降低生產(chǎn)成本降低庫(kù)存需求供給閉環(huán)通訊銷售員工廠采購(gòu)員制造業(yè)的目標(biāo)提高服務(wù)水平需求供給閉環(huán)通訊銷售員工廠采購(gòu)員1制造資源計(jì)劃管理層戰(zhàn)略層應(yīng)收帳成本基礎(chǔ)財(cái)務(wù)庫(kù)存項(xiàng)目主文件成本數(shù)據(jù)基礎(chǔ)可配置

總帳應(yīng)付帳經(jīng)營(yíng)計(jì)劃資源BOM計(jì)劃BOM制造BOM部門工作中心工藝路線運(yùn)行層性能測(cè)試有限順排主生產(chǎn)計(jì)劃粗能力計(jì)劃物料需求計(jì)劃能力需求計(jì)劃采購(gòu)銷售計(jì)劃

訂單予測(cè)生產(chǎn)計(jì)劃錄車間制造資源計(jì)劃管理層戰(zhàn)略層應(yīng)收帳成本基礎(chǔ)項(xiàng)目主文件成本數(shù)據(jù)基礎(chǔ)2庫(kù)存成品庫(kù)原材料庫(kù)子部件庫(kù)部件庫(kù)庫(kù)存成品庫(kù)原材料庫(kù)子3庫(kù)存集成總帳

客戶訂單處理予測(cè)促銷與另售分布資源計(jì)劃成本庫(kù)存應(yīng)付帳物料需求計(jì)劃能力計(jì)劃主生產(chǎn)計(jì)劃車間控制JIT/Repetitive制造數(shù)據(jù)管理采購(gòu)

銷售分析出貨后勤庫(kù)存集成總帳客戶訂單處理予測(cè)促銷與另售4項(xiàng)目類型BPCS保留項(xiàng)目類型虛擬件 0可選組合件 3固定組合件 4計(jì)劃BOM 5非余額項(xiàng)目 6項(xiàng)目類型BPCS保留項(xiàng)目類型5項(xiàng)目/項(xiàng)目類型/項(xiàng)目類別項(xiàng)目類別n

01-49成品010203n

50-69半成品5060n

70-89原材料7080項(xiàng)目主文件

n

產(chǎn)品n部件n另件外購(gòu)件{{半成品毛坯件

項(xiàng)目類型n

裝配件n

采購(gòu)件n制造件外協(xié)件項(xiàng)目/項(xiàng)目類型/項(xiàng)目類別項(xiàng)目類別n01-496計(jì)量單位銷售按支制造

按組銷售采購(gòu)/庫(kù)存采購(gòu)--桶庫(kù)存--瓶墨水Ink替換替換項(xiàng)目

計(jì)量單位銷售采購(gòu)/庫(kù)存采購(gòu)--桶墨水Ink替換替換項(xiàng)目

7替換項(xiàng)目碼定義1總替換2基本件不足時(shí)替換3替換件足夠時(shí)替換替換項(xiàng)目碼定義1總替換2基本件不足時(shí)替換3替換件足夠時(shí)8可求凈成品非求凈可分配庫(kù)存非可分配庫(kù)存樣品待驗(yàn)品Scrap在制品在途品可求凈庫(kù)存和可分配庫(kù)存可求凈成品非求凈可樣品待驗(yàn)品Scrap在制品在途品可求凈庫(kù)存9六級(jí)庫(kù)存管理儲(chǔ)位批批批批批倉(cāng)庫(kù)項(xiàng)目倉(cāng)庫(kù)場(chǎng)所容器儲(chǔ)位儲(chǔ)位儲(chǔ)位批六級(jí)庫(kù)存管理儲(chǔ)位批批批批批倉(cāng)庫(kù)10批號(hào)接收批號(hào)空手工輸入1YYMMnnnnnn2YYnnnnnnnn3YYDDDnnnnn4用戶定義算法批號(hào)接收批號(hào)空手工輸入1YYMMnnnnn11批狀態(tài)

批狀態(tài)說(shuō)明A有效C有條件通過(guò)E期滿H掛起Q

因質(zhì)量掛起R拒收V到達(dá)Z取消或保留已完成批訂單批狀態(tài)批狀態(tài)說(shuō)明A有效C有條件通過(guò)E期滿H掛起12批跟蹤倉(cāng)庫(kù)副產(chǎn)品F聯(lián)產(chǎn)品G批D2批D1批C1批B1批A3批A2批A1批D3批G1批F1批E1原料庫(kù)產(chǎn)品A產(chǎn)品B產(chǎn)品C產(chǎn)品D產(chǎn)品E加工批1批2批3批5批7批4批6成份AB1成份C1成份D1成份D2成份E1成份E2成份E3VENDORSMARKETPLACE批跟蹤倉(cāng)庫(kù)副產(chǎn)品F聯(lián)產(chǎn)品G批D2批D1批13事務(wù)影響事務(wù)將引起庫(kù)存狀態(tài)和庫(kù)存量的變化庫(kù)存事務(wù):調(diào)整發(fā)料收料事務(wù)影響事務(wù)將引起庫(kù)存狀態(tài)和庫(kù)存量的變化14庫(kù)存狀態(tài)

期初庫(kù)存-發(fā)料+收料+/-調(diào)整=現(xiàn)有量現(xiàn)有量

現(xiàn)有量-已分配量可用量變可用量庫(kù)存狀態(tài)期初庫(kù)存現(xiàn)有量現(xiàn)有量可用量15制造數(shù)據(jù)管理粗能力計(jì)劃

CAP有限順排

FFS庫(kù)存INV人員成本會(huì)計(jì)CST物料需求計(jì)劃

MRP資源BOM

CAP細(xì)能力計(jì)劃

CAP另部件詳情

項(xiàng)目,倉(cāng)庫(kù),

在制品和倒沖物料理生產(chǎn)成本核算關(guān)鍵資源

采購(gòu)PUR車間控制

SFC/JITBOM和計(jì)劃信息

詳細(xì)工作中心可用能力

關(guān)鍵工作中心可用能力

工藝外協(xié)制造數(shù)據(jù)管理

MDM詳細(xì)工作中心可用能力

制造數(shù)據(jù)管理粗能力計(jì)劃

有限順排

FFS庫(kù)存人員成本會(huì)計(jì)物料16物料清單制造BOM計(jì)劃BOMBOM物料清單制造BOM計(jì)劃BOMBOM17BOM單級(jí)ACB多級(jí)ACBFEDBOM單級(jí)ACB多級(jí)ACBFED18BOM樹(shù)結(jié)構(gòu)父項(xiàng)狀配項(xiàng)批成分成分制造部件原材料費(fèi)采購(gòu)件

BOM樹(shù)結(jié)構(gòu)父項(xiàng)狀配項(xiàng)批成分成分制造部件原材料費(fèi)采購(gòu)件

19制造數(shù)據(jù)維護(hù)BOM數(shù)據(jù)處理組號(hào)子項(xiàng)號(hào)需求數(shù)量廢品率有效/失效日期工序號(hào)序號(hào)制造數(shù)據(jù)維護(hù)BOM數(shù)據(jù)處理組號(hào)20有效/失效日期項(xiàng)目號(hào)需求量有效日期失效日期AB11/1/YY99/99/99121/1/YY99/99/99211/1/YY5/31/YY2A16/1/YY99/99/991/1/YY

99/99/99

有效/失效日期項(xiàng)目號(hào)需求量有效日期失效日期AB11/1/YY21虛擬件用途：識(shí)別制造產(chǎn)品的固有另件簡(jiǎn)化BOM可以有庫(kù)存特點(diǎn)：提前期為零部件訂貨政策為直接批量虛擬件用途：22特征件和可選件BOM禮品筆筆盒(100%)筆(100%)皮套

(30%)墨水藍(lán)=30%

黑=50%紅=20%

合計(jì)=100%紅木盒

(30%)筆桿圓珠=70%

自來(lái)水=30%

合計(jì)=100%標(biāo)準(zhǔn)件100%選擇%可以小于

100%可選件

合計(jì)=100%特征件和可選件BOM禮品筆筆盒筆皮套

(30%)墨水紅木盒23部門和工作中心場(chǎng)所

CH倉(cāng)庫(kù)AA場(chǎng)所

XX倉(cāng)庫(kù)CC倉(cāng)庫(kù)

BB部門100部門

200部門300部門400工作中心110工作中心

120工作中心210工作中心310工作中心320工作中心1100部門和工作中心場(chǎng)所

CH倉(cāng)庫(kù)場(chǎng)所

XX倉(cāng)庫(kù)倉(cāng)庫(kù)

BB部門部門24工作中心維護(hù)工作中心

說(shuō)明負(fù)荷碼部門能力效率每日班次每班小時(shí)數(shù)設(shè)備數(shù)負(fù)荷百分比成本(系數(shù))工作中心維護(hù)工作中心

說(shuō)明25設(shè)備數(shù)據(jù)維護(hù)設(shè)備數(shù)據(jù)部門固定資產(chǎn)標(biāo)識(shí)從貨位有效期截止期平均效率設(shè)備速度設(shè)備數(shù)據(jù)維護(hù)設(shè)備數(shù)據(jù)部門26工藝路線部件庫(kù)存

工作中心100成品庫(kù)存

20工作中心200工作中心300304010工序工藝路線部件庫(kù)存工作中心100成品庫(kù)存2027工藝路線維護(hù)工藝路線工序號(hào)狀態(tài)工作中心基本碼小時(shí)(人工,準(zhǔn)備,機(jī)器)工具/備注有效/截止日期操作員工藝路線維護(hù)工藝路線工序號(hào)28工序時(shí)間或非加工時(shí)間天非加工時(shí)間天加工時(shí)間小時(shí)排隊(duì)加工機(jī)器搬運(yùn)準(zhǔn)備}變化固定固定固定工序時(shí)間或非加工時(shí)間29基本碼Blank 小時(shí)/件C 元/件H小時(shí)/件P 件/小時(shí)1 小時(shí)/10件2 小時(shí)/100件3 小時(shí)/1000件4 小時(shí)/10000件5 小時(shí)/100000件6 小時(shí)/1000000件基本碼Blank 小時(shí)/件30替換工藝方法成品貨位工序10工序20工序30工序10工序10工序40工序10工序10工序10原材料貨位生產(chǎn)線1方法L1生產(chǎn)線2方法L2生產(chǎn)線3方法L3貨位1貨位6貨位3貨位2貨位5替換工藝方法成品貨位工序10工序20工序30工序10工序1031物料用途查詢層0層1層2用于的產(chǎn)品AEFBFDC物料用途查詢層0層1層2用于的產(chǎn)品AEFB32生產(chǎn)計(jì)劃MPSActualBacklogForecastInventoryCapacity總需求總需求生產(chǎn)計(jì)劃MPSActualBacklogForecastIn33生產(chǎn)計(jì)劃和MPS/MRP的關(guān)系Daysin

Month生產(chǎn)計(jì)劃

Jan2020,000Feb1919,000Mar2424,000Apr2020,000MasterProductionScheduleWeek產(chǎn)品A產(chǎn)品B

。。。..Total147505,000153005,000165,000175005,000AprilbyWeeks主生產(chǎn)計(jì)劃產(chǎn)品德A500-Week17展開(kāi)需求

500-Week14500-Week12500-Week6SubassemblyComponentRawMaterialPurchPartPurchPart生產(chǎn)計(jì)劃和MPS/MRP的關(guān)系Daysin

Month生產(chǎn)34主生產(chǎn)計(jì)劃項(xiàng)目類型MPSMake-to-StockMPSCombination/

Assemble-to-OrderMake-to-OrderMPSEngineer-to-OrderMPS主生產(chǎn)計(jì)劃項(xiàng)目類型MPSMake-to-StockMPSCo35獨(dú)立需求與相關(guān)需求DependentDemandSubassembly(alsosoldasservicepart)FinishedGoodsPurchaseComponentPurchaseComponentRawMaterialDependentDemandDependentDemandIndependentDemandDependentandIndependentDemand獨(dú)立需求與相關(guān)需求DependentDemandSubass36生產(chǎn)計(jì)劃舉例PlanningStart

Date 11/15SystemDate 11/18Proration YesCalculation:16daysleftinperiodTotalof30daysinperiodX Forecastquantityof3000 = 1600PeriodQuantityStartDateEndDateDemandDateDemandQuantity1200010/110/31nonenochange2300011/111/3011/1516003200012/112/3112/1nochangePeriodQuantityStartDateEndDateDemandDateDemandQuantity2300011/111/3011/181300Demandtoon-lineinquirieswillchangedynamicallywithsystemdatechange.生產(chǎn)計(jì)劃舉例PlanningStart

Date 11/37累計(jì)提前期YABCXY關(guān)鍵路徑CumulativeLeadTime = 2+3+5 = 1010987654321CXB產(chǎn)品A53226StartEndCumulativeLeadTime

forParentA累計(jì)提前期YABCXY關(guān)鍵路徑CumulativeLead38MPS展望期月/年 PlanningStartDate+ MPSHorizonDays= MPSHorizonDateStartdate 6thHorizondays 15Horizondate 21stMPS展望期月/年 PlanningStartDate39誰(shuí)來(lái)改變MPS?GeneralManagerMaterialsManagerMasterSchedulerMasterScheduler

cannotchange

withoutapproval

ofhigherlevel

authoritySalescannot

promiseordersSchedulercan

trytoaddIfScheduler

cannotadd,

salesmust

maketradeoffScheduler

limitedto

authorization

overplanningWeek工程改變管理改變改變限制改變能力0481216CumulativeLeadTime誰(shuí)來(lái)改變MPS?GeneralMaterialsMaster40需求控制EngineertoOrderMaketoStock裝配制造采購(gòu)生產(chǎn)計(jì)劃成本ForecastOnlyCustomerOrdersOnlyCumulativeLeadTimeMPSHorizonDemandTimeFenceCustomerOrdersOnlyGreaterofForecastandCustomerOrdersDemandTimeFenceMaketoOrderCustomerOrdersOnlyGreaterofForecastandCustomerOrdersAssembletoOrderDemandTimeFenceToday需求控制EngineertoOrderMaketoSt41訂貨政策A 直接批量F 最新成本G 周期批量H 批量以上直接批量I IncrementAboveLotSizeJ MultipleofLotSizeK PeriodOrderQuantityBlank ReorderPoint訂貨政策A 直接批量42和主生產(chǎn)計(jì)劃有關(guān)的量GrossRequirementsCustomerOrdersand

ManufacturingAllocationsScheduledReceiptsProjectedOn-HandNetRequirementsPlannedOrderReceipts

andReleasesAvailable-to-Promise和主生產(chǎn)計(jì)劃有關(guān)的量GrossRequirements43MPS計(jì)算PeriodOn-hand123456789GrossRequirements75300CustomerOrdersandManufacturingAllocations7550100ScheduledReceiptsProjectedOn-hand17510050-50-50-50-350-350-350-350NetRequirements2550100300PlannedOrderReceipts2550100300PlannedOrderReleases2550100300Available-to-Promise-50MPS計(jì)算PeriodOn-hand123456789Gr44計(jì)劃重排Period123456Required202020101020ScheduledReceipts404040ProjectedOn-Hand2545255-52545Period123456Required202020101020ScheduledReceipts4040ProjectedOn-Hand25525535255x計(jì)劃重排Period123456Required20202045訂貨應(yīng)允量CustomercallstoordermarkersCheckwhatisAvailable-to-PromisePromisemarkers

tocustomerCustomerisgiven

honest,reliabledate

Thiscustomerwill

callagain訂貨應(yīng)允量Customercallstoorderm46重訂貨點(diǎn)Leadtime= 2periodsDemand= 12.50pcs./

periodonavg.ReorderPoint= 50pcs.SafetyStock= 25pcs.Lotsize= 50pcs.QUANTITYTIME提前期安全庫(kù)存2550750123456789101112ReorderPoint重訂貨點(diǎn)Leadtime= 2periodsQUA47MRP做為庫(kù)存管理Leadtime = 2periodsSafetyStock = 25pcs.OrderPolicyCode= A(Discrete)1234567891011120255075TIMEQUANTITY計(jì)劃量

安全庫(kù)存提前期計(jì)劃下達(dá)計(jì)劃接收MRP做為庫(kù)存管理Leadtime = 2pe48廢品率與產(chǎn)出率AYieldof90%C(1)NoScrapB(1)Scrapfactorof1.11111needed

toyield1000(Yieldof90%)1111neededtomake1111(NoScrap)1222neededtomake1111(Scrapfactorof1.1)Example廢品率與產(chǎn)出率AC(1)B(1)1111needed49和MRP有關(guān)的量毛需求予計(jì)接收予計(jì)庫(kù)存凈需求計(jì)劃接收計(jì)劃下達(dá)和MRP有關(guān)的量毛需求50物料需求計(jì)劃GrossRequirementsScheduledReceiptsProjectedOn-HandPlannedOrderReceiptPlannedOrderReleaseAllocationsNetRequirementsGrossRequirementsScheduledReceiptsProjectedOn-HandPlannedOrderReceiptPlannedOrderReleaseAllocationsNetRequirementsDemandSupplyDifferencePlanDemandSupplyDifferencePlanPartAPeriod:12345505050303030301010-10-60105010501050PartBPeriod:12345SparePartsForecastforPartB(IndependentDemand)10201001020704020-80-80-9080100100(Assumesminimumbalance=0)A2BPartALeadTime=2PeriodsOrderPolicy:Discrete(lotforlot)PartBLeadTime=1PeriodOrderPolicy:Lotsize=100pcs.物料需求計(jì)劃GrossRequirementsSchedu51計(jì)劃反查A12MPSItemAPO10011/10-11/18PO10011/21-11/23B23MPSItemBFPO7511/16-11/19PO5011/17-11/20CommonItem2PO10011/9FPO7511/15PO5011/16PO10011/20PO=PlannedOrdersFPO=FirmPlannedOrders計(jì)劃反查A12MPSItemAPO10011/1052粗能力與細(xì)能力RoughCutDetailMPSOnlyMPSandMRPBillofResourcesRoutingCriticalWorkCentersAllWorkCentersMasterScheduledItemsAllManufacturedItemsPlannedOrdersPlannedOrdersFirmPlannedOrdersFirmPlannedOrdersReleasedProductionOrders粗能力與細(xì)能力RoughCutDetailMPSOnly53工作中心負(fù)荷圖HoursTimePeriodsCurrentCapacityPlannedLoad工作中心負(fù)荷圖HoursTimePeriodsCurre54交叉排序交叉排序55可用能力Releasable?ReleaseShortNoNoYesYesYesManufacturingSchedulePre-ProductionReleaseMRP510ScheduleAdjustmentNoOn-handElsewhereNoteChangesSFC350MaterialAvailabilityMRP250ReleasableOrdersReportMaterialOK?CapacityOK?NoYesProductionMeetingAlternateItem可用能力Releasable?ReleaseShortNoN56計(jì)劃下達(dá)計(jì)劃下達(dá)57車間定單打包分配例外領(lǐng)料單匯總領(lǐng)料單工藝卡工票車間定單打包分配例外58Just-In-Time/Repetitive流程圖Work

FileJIT620ProductionUpdateProduction

UpdateProduction

Release/PrintJIT610ProductionDataListJIT600ProductionReportingJust-In-Time/Repetitive流程圖Wor59物料發(fā)放GatewayWorkCenterOperationSingleIssueIJMultipleIssueKitScheduleInstructionsSFC560OrderPickListSFC521SummarizedPickListLOCALOCBLOCDLOCCWarehouse物料發(fā)放GatewayWorkCenterOperatio60計(jì)劃短缺INV500IssueMaterialSFC400MassAllocationsMaterial

Received

ShortWarehouseSFC560ShopPacketReprintSFC720Lot/LocationAllocation計(jì)劃短缺INV500IssueMaterialSFC400M61數(shù)據(jù)收集OrderNumberItemNumberScheduledStartDateOperationNumberWorkCenterDepartmentEmployeeNumberQuantityGoodQuantityRejectStartTimeStopTime數(shù)據(jù)收集OrderNumber62工單反沖WarehouseMaterialIssueMaterialReceiptWorkcenter100Workcenter200Workcenter300Operation10Operation20Operation30RunMoveQueueSetupRunMoveQueueMachineREPORTINGPOINTQuantityHours工單反沖WarehouseMaterialIssueMat63退料接收退料接收64質(zhì)量/實(shí)驗(yàn)室產(chǎn)品集成質(zhì)量管理系統(tǒng)QMSCapacityPlanningCAPCIMPathCIMAdvancedProcessIndustriesAPIJustinTime/RepetitiveJITInventoryINVLaboratoryManagementSystemLMSMRP/MPSProductionActivityControlPACSystemSYSPurchasingPUR質(zhì)量/實(shí)驗(yàn)室產(chǎn)品集成質(zhì)量管理系統(tǒng)QMSCapaci65QMS處理流程質(zhì)量檢驗(yàn)書采樣測(cè)試結(jié)果材料性能QMS處理流程質(zhì)量檢驗(yàn)書采樣測(cè)試結(jié)果材料性能66ISO9000系列ISO9000ISO9001ISO9002ISO9003ISO9004ISO9004ISO9004ISO9000系列ISO9000ISO9001ISO90067ISO9004指南ManagementandSystemsQualityCostsMarketingDesignandSpecificationsPurchasingandProcessesVerificationCalibrationNonconformingCorrectiveActionPostproductionQualityRecordsPersonnelSafetyStatisticalMethodsISO9004導(dǎo)向ISO9004ManagementQualityDesign68QMSAPISFCMDMJITPURORDINV

BPCS執(zhí)行指南ISO9001ISO9002ISO9003BASISImplementation換uality,intheISOmodel,isnotanisolatedbusinessfunction換uality,intheBPCSframework,isnotanisolatedbusinessfunctionBPCS和ISO質(zhì)量模型QMSAPISFCMDMJITPURORDINV69QMSBPCSQualityManagementSystemTheWorldofISOTheWorldofBPCSIntegratedintotheMRPIIenvironmentQualityactivitiesoccurinrealtimeCompletespecificationmanagementsystemUserdefinedsamplelevelsandtypesUserdefinedsamplingplans,i.e.Mil-StdUserdefinedtestplansUserdefinedprocesscontrolsCompletecalibrationsystemExtensivecontrolsfornonconformingproductDatabaseaccessforstatisticalanalysisBPCS質(zhì)量管理系統(tǒng)QMSBPCSQualityManagementSys70計(jì)劃BOMPenGift

SetPackaging(100%)Pen

(100%)LeatherCase

(30%)Ink

Blue=30%

Black=50%Red=20%

Total=100%Mahogany

Case

(30%)Cartridge

Rollerball=70%

Fountain=30%

Total=100%Standard

Component100%Option%canbe

lessthan100%FeatureGroup

Total=100%計(jì)劃BOMPenGift

SetPackagingPen

71裝配計(jì)劃下達(dá)FASPacketPrint訂單輸入

計(jì)劃BOMBOM600PickListMRP530FASOrderNotReleasedInstructionsScheduleandDispatch訂貨書材料足夠

OK?FAS500FAS下達(dá)

YesNoToShippingFAS510裝配計(jì)劃下達(dá)FASPacketPrint訂單輸入72配置管理流程的改進(jìn)OrderFulfillmentOrderEntryConfigurationManagementQuoteEntrySalesandMarketingEngineeringAccountingTimeTimeTimeFlowwithoutConfigurationManagementFlowwithConfigurationManagement配置管理流程的改進(jìn)OrderOrderConfigurati73配置管理主文件設(shè)置ManufacturingDataManagementBOM500RoutingMaintenanceSFC100ConfigurationStructureCFG550RulesMasterCFG130InheritedDataInheritedDataItemMasterINV100AttributeMasterCFG110VariableMasterCFG560配置管理主文件設(shè)置ManufacturingDataBOM74在線銷售定單配置StartSystempreparesCustomConfiguredOrderDoyouwantastandardsize?Whatwidthdoyouwant?Whatlengthdoyouwant?Wantwoodormetalmodel?Powerassistedoption?Systemautomaticallyspecifiesheavy-dutymotorSystemcalculatesareaandweightCalculatedweightmorethan

40Kg?YesNoYesNoDoyou

wantlight

orheavy

motor?在線銷售定單配置StartSystemprepare75工程改變控制CustomersMarketingChangeControlEngineeringQualityControlFinanceManufacturingHumanResourcesPurchasingResearchandDevelopmentNeedsDesiresProposalsContractsOptimizeproduct,processandcostsAssesstechnicalfeasibility,developconcepts,process,andprototypeDefine,testandrefineproductrequirements,communicatecustomerreactionandproductpotentialDeterminecostandavailabilityofpurchasesJudgeeconomicopportunityandfeasibility,establishcostandinvestmentlimitsCanwedoit?Whatdoweneedtodoit?Assessskillsandheadcount,availability,andneedsDocurrentcontrolsapply?Whatmoreisneeded?Communicate,managetimeframe工程改變控制CustomersMarketingChange76工程改變YesBOM110EngineeringChangeControlledItemsBOM100EngineeringChangeOrderMaintenanceInternalProgramBOMMassUpdateProcessingBOM550ApprovalProcessingBOM190ManufacturingNotesMaintenanceBOM100ECODetailLineMaintenanceOrderClosedClosedECOInquiryBOM350EngineeringChangeOrderReportBOM205NoBOM620StockBasedEffectivityProcessingStatusComplete?工程改變YesBOM110EngineeringBOM10077制造業(yè)的目標(biāo)提高服務(wù)水平降低生產(chǎn)成本降低庫(kù)存需求供給閉環(huán)通訊銷售員工廠采購(gòu)員制造業(yè)的目標(biāo)提高服務(wù)水平需求供給閉環(huán)通訊銷售員工廠采購(gòu)員78制造資源計(jì)劃管理層戰(zhàn)略層應(yīng)收帳成本基礎(chǔ)財(cái)務(wù)庫(kù)存項(xiàng)目主文件成本數(shù)據(jù)基礎(chǔ)可配置

總帳應(yīng)付帳經(jīng)營(yíng)計(jì)劃資源BOM計(jì)劃BOM制造BOM部門工作中心工藝路線運(yùn)行層性能測(cè)試有限順排主生產(chǎn)計(jì)劃粗能力計(jì)劃物料需求計(jì)劃能力需求計(jì)劃采購(gòu)銷售計(jì)劃

訂單予測(cè)生產(chǎn)計(jì)劃錄車間制造資源計(jì)劃管理層戰(zhàn)略層應(yīng)收帳成本基礎(chǔ)項(xiàng)目主文件成本數(shù)據(jù)基礎(chǔ)79庫(kù)存成品庫(kù)原材料庫(kù)子部件庫(kù)部件庫(kù)庫(kù)存成品庫(kù)原材料庫(kù)子80庫(kù)存集成總帳

客戶訂單處理予測(cè)促銷與另售分布資源計(jì)劃成本庫(kù)存應(yīng)付帳物料需求計(jì)劃能力計(jì)劃主生產(chǎn)計(jì)劃車間控制JIT/Repetitive制造數(shù)據(jù)管理采購(gòu)

銷售分析出貨后勤庫(kù)存集成總帳客戶訂單處理予測(cè)促銷與另售81項(xiàng)目類型BPCS保留項(xiàng)目類型虛擬件 0可選組合件 3固定組合件 4計(jì)劃BOM 5非余額項(xiàng)目 6項(xiàng)目類型BPCS保留項(xiàng)目類型82項(xiàng)目/項(xiàng)目類型/項(xiàng)目類別項(xiàng)目類別n

01-49成品010203n

50-69半成品5060n

70-89原材料7080項(xiàng)目主文件

n

產(chǎn)品n部件n另件外購(gòu)件{{半成品毛坯件

項(xiàng)目類型n

裝配件n

采購(gòu)件n制造件外協(xié)件項(xiàng)目/項(xiàng)目類型/項(xiàng)目類別項(xiàng)目類別n01-4983計(jì)量單位銷售按支制造

按組銷售采購(gòu)/庫(kù)存采購(gòu)--桶庫(kù)存--瓶墨水Ink替換替換項(xiàng)目

計(jì)量單位銷售采購(gòu)/庫(kù)存采購(gòu)--桶墨水Ink替換替換項(xiàng)目

84替換項(xiàng)目碼定義1總替換2基本件不足時(shí)替換3替換件足夠時(shí)替換替換項(xiàng)目碼定義1總替換2基本件不足時(shí)替換3替換件足夠時(shí)85可求凈成品非求凈可分配庫(kù)存非可分配庫(kù)存樣品待驗(yàn)品Scrap在制品在途品可求凈庫(kù)存和可分配庫(kù)存可求凈成品非求凈可樣品待驗(yàn)品Scrap在制品在途品可求凈庫(kù)存86六級(jí)庫(kù)存管理儲(chǔ)位批批批批批倉(cāng)庫(kù)項(xiàng)目倉(cāng)庫(kù)場(chǎng)所容器儲(chǔ)位儲(chǔ)位儲(chǔ)位批六級(jí)庫(kù)存管理儲(chǔ)位批批批批批倉(cāng)庫(kù)87批號(hào)接收批號(hào)空手工輸入1YYMMnnnnnn2YYnnnnnnnn3YYDDDnnnnn4用戶定義算法批號(hào)接收批號(hào)空手工輸入1YYMMnnnnn88批狀態(tài)

批狀態(tài)說(shuō)明A有效C有條件通過(guò)E期滿H掛起Q

因質(zhì)量掛起R拒收V到達(dá)Z取消或保留已完成批訂單批狀態(tài)批狀態(tài)說(shuō)明A有效C有條件通過(guò)E期滿H掛起89批跟蹤倉(cāng)庫(kù)副產(chǎn)品F聯(lián)產(chǎn)品G批D2批D1批C1批B1批A3批A2批A1批D3批G1批F1批E1原料庫(kù)產(chǎn)品A產(chǎn)品B產(chǎn)品C產(chǎn)品D產(chǎn)品E加工批1批2批3批5批7批4批6成份AB1成份C1成份D1成份D2成份E1成份E2成份E3VENDORSMARKETPLACE批跟蹤倉(cāng)庫(kù)副產(chǎn)品F聯(lián)產(chǎn)品G批D2批D1批90事務(wù)影響事務(wù)將引起庫(kù)存狀態(tài)和庫(kù)存量的變化庫(kù)存事務(wù):調(diào)整發(fā)料收料事務(wù)影響事務(wù)將引起庫(kù)存狀態(tài)和庫(kù)存量的變化91庫(kù)存狀態(tài)

期初庫(kù)存-發(fā)料+收料+/-調(diào)整=現(xiàn)有量現(xiàn)有量

現(xiàn)有量-已分配量可用量變可用量庫(kù)存狀態(tài)期初庫(kù)存現(xiàn)有量現(xiàn)有量可用量92制造數(shù)據(jù)管理粗能力計(jì)劃

CAP有限順排

FFS庫(kù)存INV人員成本會(huì)計(jì)CST物料需求計(jì)劃

MRP資源BOM

CAP細(xì)能力計(jì)劃

CAP另部件詳情

項(xiàng)目,倉(cāng)庫(kù),

在制品和倒沖物料理生產(chǎn)成本核算關(guān)鍵資源

采購(gòu)PUR車間控制

SFC/JITBOM和計(jì)劃信息

詳細(xì)工作中心可用能力

關(guān)鍵工作中心可用能力

工藝外協(xié)制造數(shù)據(jù)管理

MDM詳細(xì)工作中心可用能力

制造數(shù)據(jù)管理粗能力計(jì)劃

有限順排

FFS庫(kù)存人員成本會(huì)計(jì)物料93物料清單制造BOM計(jì)劃BOMBOM物料清單制造BOM計(jì)劃BOMBOM94BOM單級(jí)ACB多級(jí)ACBFEDBOM單級(jí)ACB多級(jí)ACBFED95BOM樹(shù)結(jié)構(gòu)父項(xiàng)狀配項(xiàng)批成分成分制造部件原材料費(fèi)采購(gòu)件

BOM樹(shù)結(jié)構(gòu)父項(xiàng)狀配項(xiàng)批成分成分制造部件原材料費(fèi)采購(gòu)件

96制造數(shù)據(jù)維護(hù)BOM數(shù)據(jù)處理組號(hào)子項(xiàng)號(hào)需求數(shù)量廢品率有效/失效日期工序號(hào)序號(hào)制造數(shù)據(jù)維護(hù)BOM數(shù)據(jù)處理組號(hào)97有效/失效日期項(xiàng)目號(hào)需求量有效日期失效日期AB11/1/YY99/99/99121/1/YY99/99/99211/1/YY5/31/YY2A16/1/YY99/99/991/1/YY

99/99/99

有效/失效日期項(xiàng)目號(hào)需求量有效日期失效日期AB11/1/YY98虛擬件用途：識(shí)別制造產(chǎn)品的固有另件簡(jiǎn)化BOM可以有庫(kù)存特點(diǎn)：提前期為零部件訂貨政策為直接批量虛擬件用途：99特征件和可選件BOM禮品筆筆盒(100%)筆(100%)皮套

(30%)墨水藍(lán)=30%

黑=50%紅=20%

合計(jì)=100%紅木盒

(30%)筆桿圓珠=70%

自來(lái)水=30%

合計(jì)=100%標(biāo)準(zhǔn)件100%選擇%可以小于

100%可選件

合計(jì)=100%特征件和可選件BOM禮品筆筆盒筆皮套

(30%)墨水紅木盒100部門和工作中心場(chǎng)所

CH倉(cāng)庫(kù)AA場(chǎng)所

XX倉(cāng)庫(kù)CC倉(cāng)庫(kù)

BB部門100部門

200部門300部門400工作中心110工作中心

120工作中心210工作中心310工作中心320工作中心1100部門和工作中心場(chǎng)所

CH倉(cāng)庫(kù)場(chǎng)所

XX倉(cāng)庫(kù)倉(cāng)庫(kù)

BB部門部門101工作中心維護(hù)工作中心

說(shuō)明負(fù)荷碼部門能力效率每日班次每班小時(shí)數(shù)設(shè)備數(shù)負(fù)荷百分比成本(系數(shù))工作中心維護(hù)工作中心

說(shuō)明102設(shè)備數(shù)據(jù)維護(hù)設(shè)備數(shù)據(jù)部門固定資產(chǎn)標(biāo)識(shí)從貨位有效期截止期平均效率設(shè)備速度設(shè)備數(shù)據(jù)維護(hù)設(shè)備數(shù)據(jù)部門103工藝路線部件庫(kù)存

工作中心100成品庫(kù)存

20工作中心200工作中心300304010工序工藝路線部件庫(kù)存工作中心100成品庫(kù)存20104工藝路線維護(hù)工藝路線工序號(hào)狀態(tài)工作中心基本碼小時(shí)(人工,準(zhǔn)備,機(jī)器)工具/備注有效/截止日期操作員工藝路線維護(hù)工藝路線工序號(hào)105工序時(shí)間或非加工時(shí)間天非加工時(shí)間天加工時(shí)間小時(shí)排隊(duì)加工機(jī)器搬運(yùn)準(zhǔn)備}變化固定固定固定工序時(shí)間或非加工時(shí)間106基本碼Blank 小時(shí)/件C 元/件H小時(shí)/件P 件/小時(shí)1 小時(shí)/10件2 小時(shí)/100件3 小時(shí)/1000件4 小時(shí)/10000件5 小時(shí)/100000件6 小時(shí)/1000000件基本碼Blank 小時(shí)/件107替換工藝方法成品貨位工序10工序20工序30工序10工序10工序40工序10工序10工序10原材料貨位生產(chǎn)線1方法L1生產(chǎn)線2方法L2生產(chǎn)線3方法L3貨位1貨位6貨位3貨位2貨位5替換工藝方法成品貨位工序10工序20工序30工序10工序10108物料用途查詢層0層1層2用于的產(chǎn)品AEFBFDC物料用途查詢層0層1層2用于的產(chǎn)品AEFB109生產(chǎn)計(jì)劃MPSActualBacklogForecastInventoryCapacity總需求總需求生產(chǎn)計(jì)劃MPSActualBacklogForecastIn110生產(chǎn)計(jì)劃和MPS/MRP的關(guān)系Daysin

Month生產(chǎn)計(jì)劃

Jan2020,000Feb1919,000Mar2424,000Apr2020,000MasterProductionScheduleWeek產(chǎn)品A產(chǎn)品B

。。。..Total147505,000153005,000165,000175005,000AprilbyWeeks主生產(chǎn)計(jì)劃產(chǎn)品德A500-Week17展開(kāi)需求

500-Week14500-Week12500-Week6SubassemblyComponentRawMaterialPurchPartPurchPart生產(chǎn)計(jì)劃和MPS/MRP的關(guān)系Daysin

Month生產(chǎn)111主生產(chǎn)計(jì)劃項(xiàng)目類型MPSMake-to-StockMPSCombination/

Assemble-to-OrderMake-to-OrderMPSEngineer-to-OrderMPS主生產(chǎn)計(jì)劃項(xiàng)目類型MPSMake-to-StockMPSCo112獨(dú)立需求與相關(guān)需求DependentDemandSubassembly(alsosoldasservicepart)FinishedGoodsPurchaseComponentPurchaseComponentRawMaterialDependentDemandDependentDemandIndependentDemandDependentandIndependentDemand獨(dú)立需求與相關(guān)需求DependentDemandSubass113生產(chǎn)計(jì)劃舉例PlanningStart

Date 11/15SystemDate 11/18Proration YesCalculation:16daysleftinperiodTotalof30daysinperiodX Forecastquantityof3000 = 1600PeriodQuantityStartDateEndDateDemandDateDemandQuantity1200010/110/31nonenochange2300011/111/3011/1516003200012/112/3112/1nochangePeriodQuantityStartDateEndDateDemandDateDemandQuantity2300011/111/3011/181300Demandtoon-lineinquirieswillchangedynamicallywithsystemdatechange.生產(chǎn)計(jì)劃舉例PlanningStart

Date 11/114累計(jì)提前期YABCXY關(guān)鍵路徑CumulativeLeadTime = 2+3+5 = 1010987654321CXB產(chǎn)品A53226StartEndCumulativeLeadTime

forParentA累計(jì)提前期YABCXY關(guān)鍵路徑CumulativeLead115MPS展望期月/年 PlanningStartDate+ MPSHorizonDays= MPSHorizonDateStartdate 6thHorizondays 15Horizondate 21stMPS展望期月/年 PlanningStartDate116誰(shuí)來(lái)改變MPS?GeneralManagerMaterialsManagerMasterSchedulerMasterScheduler

cannotchange

withoutapproval

ofhigherlevel

authoritySalescannot

promiseordersSchedulercan

trytoaddIfScheduler

cannotadd,

salesmust

maketradeoffScheduler

limitedto

authorization

overplanningWeek工程改變管理改變改變限制改變能力0481216CumulativeLeadTime誰(shuí)來(lái)改變MPS?GeneralMaterialsMaster117需求控制EngineertoOrderMaketoStock裝配制造采購(gòu)生產(chǎn)計(jì)劃成本ForecastOnlyCustomerOrdersOnlyCumulativeLeadTimeMPSHorizonDemandTimeFenceCustomerOrdersOnlyGreaterofForecastandCustomerOrdersDemandTimeFenceMaketoOrderCustomerOrdersOnlyGreaterofForecastandCustomerOrdersAssembletoOrderDemandTimeFenceToday需求控制EngineertoOrderMaketoSt118訂貨政策A 直接批量F 最新成本G 周期批量H 批量以上直接批量I IncrementAboveLotSizeJ MultipleofLotSizeK PeriodOrderQuantityBlank ReorderPoint訂貨政策A 直接批量119和主生產(chǎn)計(jì)劃有關(guān)的量GrossRequirementsCustomerOrdersand

ManufacturingAllocationsScheduledReceiptsProjectedOn-HandNetRequirementsPlannedOrderReceipts

andReleasesAvailable-to-Promise和主生產(chǎn)計(jì)劃有關(guān)的量GrossRequirements120MPS計(jì)算PeriodOn-hand123456789GrossRequirements75300CustomerOrdersandManufacturingAllocations7550100ScheduledReceiptsProjectedOn-hand17510050-50-50-50-350-350-350-350NetRequirements2550100300PlannedOrderReceipts2550100300PlannedOrderReleases2550100300Available-to-Promise-50MPS計(jì)算PeriodOn-hand123456789Gr121計(jì)劃重排Period123456Required202020101020ScheduledReceipts404040ProjectedOn-Hand2545255-52545Period123456Required202020101020ScheduledReceipts4040ProjectedOn-Hand25525535255x計(jì)劃重排Period123456Required202020122訂貨應(yīng)允量CustomercallstoordermarkersCheckwhatisAvailable-to-PromisePromisemarkers

tocustomerCustomerisgiven

honest,reliabledate

Thiscustomerwill

callagain訂貨應(yīng)允量Customercallstoorderm123重訂貨點(diǎn)Leadtime= 2periodsDemand= 12.50pcs./

periodonavg.ReorderPoint= 50pcs.SafetyStock= 25pcs.Lotsize= 50pcs.QUANTITYTIME提前期安全庫(kù)存2550750123456789101112ReorderPoint重訂貨點(diǎn)Leadtime= 2periodsQUA124MRP做為庫(kù)存管理Leadtime = 2periodsSafetyStock = 25pcs.OrderPolicyCode= A(Discrete)1234567891011120255075TIMEQUANTITY計(jì)劃量

安全庫(kù)存提前期計(jì)劃下達(dá)計(jì)劃接收MRP做為庫(kù)存管理Leadtime = 2pe125廢品率與產(chǎn)出率AYieldof90%C(1)NoScrapB(1)Scrapfactorof1.11111needed

toyield1000(Yieldof90%)1111neededtomake1111(NoScrap)1222neededtomake1111(Scrapfactorof1.1)Example廢品率與產(chǎn)出率AC(1)B(1)1111needed126和MRP有關(guān)的量毛需求予計(jì)接收予計(jì)庫(kù)存凈需求計(jì)劃接收計(jì)劃下達(dá)和MRP有關(guān)的量毛需求127物料需求計(jì)劃GrossRequirementsScheduledReceiptsProjectedOn-HandPlannedOrderReceiptPlannedOrderReleaseAllocationsNetRequirementsGrossRequirementsScheduledReceiptsProjectedOn-HandPlannedOrderReceiptPlannedOrderReleaseAllocationsNetRequirementsDemandSupplyDifferencePlanDemandSupplyDifferencePlanPartAPeriod:12345505050303030301010-10-60105010501050PartBPeriod:12345SparePartsForecastforPartB(IndependentDemand)10201001020704020-80-80-9080100100(Assumesminimumbalance=0)A2BPartALeadTime=2PeriodsOrderPolicy:Discrete(lotforlot)PartBLeadTime=1PeriodOrderPolicy:Lotsize=100pcs.物料需求計(jì)劃GrossRequirementsSchedu128計(jì)劃反查A12MPSItemAPO10011/10-11/18PO10011/21-11/23B23MPSItemBFPO7511/16-11/19PO5011/17-11/20CommonItem2PO10011/9FPO7511/15PO5011/16PO10011/20PO=PlannedOrdersFPO=FirmPlannedOrders計(jì)劃反查A12MPSItemAPO10011/10129粗能力與細(xì)能力RoughCutDetailMPSOnlyMPSandMRPBillofResourcesRoutingCriticalWorkCentersAllWorkCentersMasterScheduledItemsAllManufacturedItemsPlannedOrdersPlannedOrdersFirmPlannedOrdersFirmPlannedOrdersReleasedProductionOrders粗能力與細(xì)能力RoughCutDetailMPSOnly130工作中心負(fù)荷圖HoursTimePeriodsCurrentCapacityPlannedLoad工作中心負(fù)荷圖HoursTimePeriodsCurre131交叉排序交叉排序132可用能力Releasable?ReleaseShortNoNoYesYesYesManufacturingSchedulePre-ProductionReleaseMRP510ScheduleAdjustmentNoOn-handElsewhereNoteChangesSFC350MaterialAvailabilityMRP250ReleasableOrdersReportMaterialOK?CapacityOK?NoYesProductionMeetingAlternateItem可用能力Releasable?ReleaseShortNoN133計(jì)劃下達(dá)計(jì)劃下達(dá)134車間定單打包分配例外領(lǐng)料單匯總領(lǐng)料單工藝卡工票車間定單打包分配例外135Just-In-Time/Repetitive流程圖Work

FileJIT620ProductionUpdateProduction

UpdateProduction

Release/PrintJIT610ProductionDataListJIT600ProductionReportingJust-In-Time/Repetitive流程圖Wor136物料發(fā)放GatewayWorkCenterOperationSingleIssueIJMultipleIssueKitScheduleInstructionsSFC560OrderPickListSFC521SummarizedPickListLOCALOCBLOCDLOCCWarehouse物料發(fā)放GatewayWorkCenterOperatio137計(jì)劃短缺INV500IssueMaterialSFC400MassAllocationsMaterial

Received

ShortWarehouseSFC560ShopPacketReprintSFC720Lot/LocationAllocation計(jì)劃短缺INV500IssueMaterialSFC400M138數(shù)據(jù)收集OrderNumberItemNumberScheduledStartDateOperationNumberWorkCenterDepartmentEmployeeNumberQuantityGoodQuantityRejectStartTimeStopTime數(shù)據(jù)收集OrderNumber139工單反沖WarehouseMaterialIssueMaterialReceiptWorkcenter100Workcenter200Workcenter300Operation10Operation20Operation30RunMoveQueueSetupRunMoveQueueMachineREPORTINGPOINTQuantityHours工單反沖WarehouseMaterialIssueMat140退料接收退料接收141質(zhì)量/實(shí)驗(yàn)室產(chǎn)品集成質(zhì)量管理系統(tǒng)QMSCapacityPlanningCAPCIMPathCIMAdvancedProcessIndustriesAPIJustinTime/RepetitiveJITInventoryINVLaboratoryManagementSystemLMSMRP/MPSProductionActivityControlPACSystemSYSPurchasingPUR質(zhì)量/實(shí)驗(yàn)室產(chǎn)品集成質(zhì)量管理系統(tǒng)QMSCapaci142QMS處理流程質(zhì)量檢驗(yàn)書采樣測(cè)試結(jié)果材料性能QMS處理流程質(zhì)量檢驗(yàn)書采樣測(cè)試結(jié)果材料性能143ISO9000系列ISO9000ISO9001ISO9002ISO9003ISO9004ISO9004ISO9004ISO9000系列ISO9000ISO9001ISO900144ISO9004指南ManagementandSystemsQualityCostsMarketingDesignandSpecificationsPurchasingandProcessesVerificationCalibrationNonconf