第五章供應(yīng)鏈管理與APS,MRP基本原理邏輯圖,潛在客戶,物料清單,庫存記錄,工作中心,工藝路線,關(guān)鍵工作中心（瓶頸工序）,資源清單,閉環(huán)MRP邏輯流程圖,自上而下的可行計劃自下而上的執(zhí)行反饋實時應(yīng)變,約束理論：重點在瓶頸工序APS技術(shù)：MRP/CRP同步運行,庫存記錄,產(chǎn)品配置,物料系統(tǒng),財務(wù),MRPII計劃與控制層次,最終成品,￥,產(chǎn)品系列,工序,1經(jīng)營規(guī)劃,2銷售與運作規(guī)劃,3主生產(chǎn)計劃(MPS),4物料需求計劃(MRP),5生產(chǎn)作業(yè)控制(SFC/PAC),決策層,計劃層,執(zhí)行層,工作量,層次,計劃對象,計劃期,3=7年,1-3年,3=18周,3-18周,日,復(fù)核期,年,月,周=季,日-周,時-日,時段,年,月,周-季,日=周,日,能力,資源計劃,企業(yè)資源,粗能力計劃,能力需求計劃(CRP),投入/產(chǎn)出控制,小,大,流程脫節(jié)與解決方案,需求供應(yīng)難溝通需求不明：經(jīng)銷商/客戶需求多變供應(yīng)不明：供貨保障情況不掌握,產(chǎn)供銷嚴(yán)重脫節(jié)銷售接下訂單，生產(chǎn)做不出來生產(chǎn)計劃排好，原材料供應(yīng)不上,財務(wù)與業(yè)務(wù)脫節(jié)費用不清，源出多頭財務(wù)報告滯后，處理/決策不及時,物料與資金流程脫節(jié),上下游信息流程脫節(jié),主要內(nèi)容,BuysIngredientsandComponents,MakesaProduct,MovesittoaDistributionCenter,StoresitatDistributionCenters,StoresitinaWarehouse,MovesittoStores,StoresitintheStore,SellsittoConsumers,MultiEnterpriseSupplyChains,Source:I2-Technologies,Enterprisefunctionalsiloswithconflictinggoals,Purchasing,Manufacturing,Distribution,CustomerService/Sales,Fewchange-oversStableschedulesLongrunlengths,HighinventoriesHighservicelevelsRegionalstocks,Lowpur-chasepriceMultiplevendors,Lowinvent-oriesLowtrans-portation,OverviewofSCM-Issues,OverviewandtargetsofSCM,DefinitionofSupplyChainManagement:SupplyChainManagementdescribesallkindofactivitiesacrossmultiplecompaniesorlocationstooptimizethemanufacturingofproducts.Herebyconcerningallinterfacesonoperationalandstrategiclevelforinvolvedassociates.,Mainfocus,DevelopmentofheterogeneousglobalproductionnetworksIncreasedintegrationofadvancedtechnologies,MinimzingcostsforinventoriesanddeliveriesLongtermrelationships(customer/supplierbinding)Customersatisfaction,By,ERP-BasisSCM-ToolsInternet,OverviewandtargetsofSCM,Integrationofsuppliersinplanninginconsiderationof.,SuppliersinventoriesSuppliersmanufacturingcapacitiesTransporttimesandcapacities,Reductionofowninventories,IntegratedplanningofsupplychainsleadstoReductionofinventoriesCostsavingsCapabilitytomeetpromiseddeliverydatesIncreasedcustomersatisfactionIntensifiedcustomerbindingPerspectivetoextendthesalesmarket,OverviewandtargetsofSCM,Prerequisitesforsuccess,ShareinformationwithyoursuppliersKeeplongerrelationshipswithyoursuppliersTrustasfoundationofrelationshipswithsuppliersFundamentalsofsupplychainplanning,SCMBusinessProcesses,TechnologyhelpsenableavarietyofSCMbusinessprocessesPushtopullProcessorientationOptimizationPostponementMorefrequentplanningCollaboration,Movefrompushtopullmanufacturing,Manufacturers,Distributors/Wholesalers,Consumers,Suppliers,Retailers,Makewhatwewillsell,notsellwhatwewillmake!,FeaturesofSCM,Movefromfunctionalsilostoprocess-orientedbusinessprocesses(e.g.,order-to-cash,cash-to-cash),FeaturesofSCM,Optimizationofallsupplychainactivities,Independent,SequentialPlanning,FeaturesofSCM,Purchasing,SupplyPlan,Scheduling,Logistics,Planning,OrderMgmt,DemandPlan,Supply,Distribution,Production,ProcessControl,ManufacturingExecutionSystem,Infrastructures,SCMStrategicPlan,Real-timeDispatching,VirtualFactoryPlanning,Sales,FrequencyMonth/QuarterWeek/MonthDay/HourMinute,SCMArchitecture,Strategy,Plan,Execution,SupplyChainManagement,供應(yīng)鏈管理構(gòu)架,倉庫補貨運輸計劃,實物配送結(jié)構(gòu),原材料計劃供應(yīng)商選擇合作,產(chǎn)品規(guī)劃戰(zhàn)略銷售規(guī)劃,二、APS產(chǎn)生背景,高級計劃排程（AdvancedPlanningandScheduling,APS）復(fù)雜制造系統(tǒng)環(huán)境現(xiàn)有管理軟件缺陷,復(fù)雜制造環(huán)境,緊急插單/訂單Cancel可選加工路線生產(chǎn)線產(chǎn)能調(diào)整(加班,機器故障.)設(shè)計修改,生產(chǎn)管理現(xiàn)狀（1）,Lackofsupplychainvisibility供應(yīng)鏈透明度低Inefficientproduction/distributionplanningandexecution低效率生產(chǎn)/分銷計劃和執(zhí)行LongresponsivenessTPT客戶響應(yīng)速度慢Lackofflexibility生產(chǎn)計劃柔性差,生產(chǎn)管理現(xiàn)狀（2）,Lackofoptimization生產(chǎn)計劃優(yōu)化程度差Pooron-timedelivery低及時交貨率Highinventory,lowturnover高庫存、低周轉(zhuǎn)率Competingmanagementobjectives相互矛盾的生產(chǎn)管理目標(biāo),ERP軟件缺陷,固定工藝路線假定提前期無限生產(chǎn)能力排程運算時間長敏捷性差,三、APS基本原理（1）,APS綜合:供應(yīng)鏈的實際狀況實體的運籌配置(工廠，分銷中心)；物料結(jié)構(gòu)BOM；生產(chǎn)工藝路徑；分銷路徑和提前期；成本(生產(chǎn)，分銷，庫存等)市場需求信息銷售預(yù)測；客戶訂單；補貨訂單原料供應(yīng)信息現(xiàn)有庫存；在途量，在制量，調(diào)撥量流動資金可用量信息預(yù)計收款量；預(yù)計付款量,三、APS基本原理（2）,利用約束條件（產(chǎn)能約束、原料供應(yīng)約束、運輸?shù)募s束）與商業(yè)規(guī)則（客戶或區(qū)域的優(yōu)先順序、安全庫存、批量）,通過APS引擎,提供以下功能:在市場需求、約束條件、原料供應(yīng)、生產(chǎn)能力無法同步平衡時，及時警告問題的原因；計劃人員交互調(diào)控；手動或自動的，實時重新計算保持供應(yīng)鏈的同步平衡。來達到可行的、優(yōu)化的生產(chǎn)計劃、采購計劃、分銷計劃與排程。,三、APS基本原理（3）,約束理論（TheoryofConstraints）先進算法(LP、GA)基于計算機內(nèi)存的計算,數(shù)據(jù)存儲,Aps運算器,APS系統(tǒng),計劃,長期,中期,日/周調(diào)整,排程,調(diào)度,四、APS體系結(jié)構(gòu),五、FeaturesofAPS,SynchronizedconcurrentplanningConstraint-basedplanningOptimizedplanningReal-timeplanningDecisionsupportcapabilityWhat-ifsimulationPeggingbetweendemandandsupplySpeedandperformance,SynchronizedPlanning,客戶,銷售代表,訂單承諾,生產(chǎn)計劃,庫存管理,采購管理,可允諾能力查詢,訂單請求,庫存情況查詢,庫存情況,采購信息查詢,采購信息,資源使用計劃查詢,資源使用計劃,訂單承諾計算,交貨數(shù)量、交貨期,交貨數(shù)量、交貨期,原材料采購計劃,資源使用計劃,需求,供給,AvailabletoPromise,Constraint-basedPlanning,APS,Constraint,Supply,Demand,Output,Time:PurchaseLTMfg.LTTrasf.LTDueDate,Capacity:ResourceloadRouting,Material:AlternatePartsECNPartsSourcingRule,Demand:ForecastSalesOrder,SupplyData:On-handWIPPurchasingOrder,OptimalPlan,OptimizedTechnologiesinAPS,DemandPlanningExponentialSmoothingSystemDynamicsMultipleLinearRegressionProductionPlanning&SchedulingLinearProgramming/MixedIntegerLPGeneticAlgorithmsSimulationAnnealingHeuristicMethodsDistributionPlanning&DeploymentFlowAlgorithmsBranch-and-BoundAlgorithm,六、APS主要內(nèi)容,基于訂單任務(wù)(Job-based)訂單優(yōu)先級計劃基于事件(Event-based)資源利用率最大化計劃基于資源(Resource-based，TOC)瓶頸約束計劃基于物料約束的可行的計劃基于歷史、現(xiàn)在、未來的需求計劃基于供應(yīng)資源優(yōu)化的分銷配置計劃基于運輸資源優(yōu)化運輸計劃,基于訂單任務(wù)(Job-based),基于訂單的優(yōu)先級決定下一個訂單的加工。如:工作中心WCA有兩個資源工作中心WCB有一個資源訂單MO-1最高優(yōu)先級。訂單MO-2次優(yōu)先級,基于事件(Event-based),基于資源高利用率的方法,基于資源(Resource-based，TOC),基于資源的約束來優(yōu)化計劃，對定義的約束資源建模進行大量的模擬，來實現(xiàn)實際的詳細(xì)計劃。對所有資源可以模擬不同的批量來分析對庫存或完成日期的影響。,七、APS軟件主要模塊,需求計劃模塊生產(chǎn)計劃和排程模塊分銷計劃模塊運輸計劃模塊企業(yè)或供應(yīng)鏈分析,需求計劃模塊,用統(tǒng)計工具、因果要素和層次分析等手段進行更為精確的預(yù)測。用包括Internet和協(xié)同引擎（collaborationengines）在內(nèi)的通訊技術(shù)幫助生成企業(yè)間的最新和實時的協(xié)作預(yù)測。,生產(chǎn)計劃和排程模塊,分析企業(yè)內(nèi)部和供應(yīng)商生產(chǎn)設(shè)施的物料和能力的約束，編制滿足物料和能力約束的生產(chǎn)進度計劃，并且還可以按照給定條件進行優(yōu)化。各軟件供應(yīng)商根據(jù)不同的生產(chǎn)環(huán)境應(yīng)用不同的算法和技術(shù)，提供各有特色的軟件。,生產(chǎn)計劃和排程基本流程,觸發(fā)事件（緊急訂單、機器故障）生產(chǎn)過程建模參數(shù)模型：常量、變量計算法則：數(shù)學(xué)模型、統(tǒng)計模型、作業(yè)研究、約束規(guī)則假定生產(chǎn)狀況排程優(yōu)化算法（運算能力、存儲能力）生成初始級生產(chǎn)作業(yè)計劃排程作業(yè)交互仿真分析排程方案選擇,i2工廠計劃模型,分銷計劃模塊,幫助管理分銷中心并保證產(chǎn)品可訂貨、可盈利、能力可用。分銷計劃幫助企業(yè)分析原始信息。然后企業(yè)能夠確定如何優(yōu)化分銷成本或者根據(jù)生產(chǎn)能力和成本提高客戶服務(wù)水平。,運輸計劃模塊,幫助確定將產(chǎn)品送達客戶的最好途徑。運輸計劃模型的時標(biāo)是短期的和戰(zhàn)術(shù)的。運輸計劃模塊對交付進行成組并充分利用運輸能力。,企業(yè)或供應(yīng)鏈分析,通過用整個企業(yè)或供應(yīng)鏈的可視化模型，幫助企業(yè)從戰(zhàn)略功能上對工廠和銷售中心進行調(diào)整。有可能對貫穿整個供應(yīng)鏈的一個或多個產(chǎn)品進行分析、發(fā)掘問題,ScopeofAPS,SupplychainstrategicplanningSupplychainnetworkplanningDemandplanningandforecastingInventoryplanningSupplychainplanningSupplyplanningDistributionplanningTransportationplanningShopflooroperationschedulingShipmentscheduling,APS是使用現(xiàn)存Transaction系統(tǒng)(ERP)的信息，以提供快速規(guī)劃及排程的智能決策支持系統(tǒng)。,Purchasing,OrderEntry,Manufacturing,Logistics/Shipping,ERP,CurrentSituation,FinalPlan,SupplyChainPlanner,InputDataDemandCapacityMaterials,OutputProductionPlanShippingPlanPromisePlan,APSandERP,Multi-SitePlanning,Complexmulti-sitemanufacturingreferstotheenvironmentwheretherearemultiplesitesthataredependentuponeachotherformaterialandassemblies.SupplyPlanningforacomplexmulti-sitemanufacturingenvironmentinvolvestheconsolidationofdatafromtheindividualsitesintoacorporateconsolidationdatabase.,Multi-SitePlanning,GlobalAPSEngine,DemandPlanningEngine,OrderPromisingEngine,APSEngine,APSEngine,APSEngine,MasterPlan,MasterPlan,MasterPlan,SupplyPlan,SupplyPlan,SupplyPlan,DemandPlan,SupplyPlan,SCMInformationSystem,LeadingproviderofB2BandSupplyChainsolutions,Providesplanning,executionandcollaborativeoptimisation.iSCuses:SCP,DP,CP-DC,CP-PC,TMandTO,ERPsolutionproviderwithlargeinstallbaseacrossmanyindustries,Providestransactionbackbone,CommonlyusedDBplatformacrossindustri