制造业的目标课件

,*,Slide Title,Body Text,Second Level,Third Level,MFG6.0,77,Day 1,制造业的目标,提高服务水平,降低生产成本,降低库存,需求,供给,闭环通讯,销售员,工厂,采购员,制造业的目标提高服务水平需求供给闭环通讯销售员工厂采购员,1,制造资源计划,管理层,战略层,应收帐,成本,基础,财务,库,存,项目主文件,成本数据,基础,可配置总帐,应付帐,经营计划,资源,BOM,计划,BOM,制造,BOM,部门,工作中心,工艺路线,运行层,性能测试,有限顺排,主生产计划,粗能力计划,物料需求计划,能力需求计划,采购,销售计划,订单,予测,生产计划,录车间,制造资源计划管理层战略层应收帐成本基础项目主文件成本数据基础,2,库 存,成品库,原材料库,子部件库,部件库,库 存 成品库 原材料库 子,3,库存集成,总帐,客户订单处理,予测,促销与另售,分布资源计划,成本,库存,应付帐,物料需求计划,能力计划,主生产计划,车间控制,JIT/ Repetitive,制造数据管理,采购,销售分析,出货后勤,库存集成 总帐 客户订单处理 予测促销与另售,4,项目类型,BPCS 保留项目类型,虚拟件0,可选组合件 3,固定组合件4,计划BOM 5,非余额项目 6,项目类型BPCS 保留项目类型,5,项目/项目类型/项目类别,项目类别,n,01 - 49,成品,01,02,03,n,50 - 69,半成品,50,60,n,70 - 89,原材料,70,80,项目主文件,n,产品,n,部件,n,另件,外购件,半成品,毛坯件,项目类型,n,装配件,n,采购件,n,制造件,外协件,项目/项目类型/项目类别项目类别n 01 - 49,6,计量单位,销售,按支制造,按组销售,采购/库存,采购-桶,库存-瓶,墨水,Ink,替换,替换项目,计量单位销售采购/库存采购-桶墨水Ink替换替换项目,7,替换项目,码,定义,1,总替换,2,基本件不足时替换,3,替换件足够时替换,替换项目 码定义1总替换2基本件不足时替换3替换件足够时,8,可求净,成品,非求净,可,分,配,库,存,非,可,分,配,库,存,样品,待验品,Scrap,在制品,在途品,可求净库存和可分配库存,可求净成品非求净可样品待验品Scrap在制品在途品可求净库存,9,六级库存管理,储位,批,批,批,批,批,仓库,项目,仓库,场所,容 器,储位,储位,储位,批,六级库存管理 储位 批 批 批 批 批 仓库,10,批号,接收批号,空,手工输入,1,YYMMnnnnnn,2,YYnnnnnnnn,3,YYDDDnnnnn,4,用户定义算法,批号 接收批号 空手工输入1YYMMnnnnn,11,批状态,批状态,说明,A,有效,C,有条件通过,E,期满,H,挂起,Q,因质量挂起,R,拒收,V,到达,Z,取消或保留已完成批订单,批状态 批状态说明A有效C有条件通过E期满H挂起,12,批跟踪,仓库,副产品 F,联产品 G,批 D2,批 D1,批 C1,批 B1,批 A3,批 A2,批 A1,批 D3,批 G1,批 F1,批 E1,原料库,产品 A,产品 B,产品 C,产品 D,产品 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 E3,VENDORS,MARKETPLACE,批跟踪仓库 副产品 F联产品 G 批 D2批 D1批,13,事务影响,事务将引起库存状态和库存量的变化,库存事务:,调整,发料,收料,事务影响事务将引起库存状态和库存量的变化,14,库存状态,期初库存,- 发料,+ 收料,+/- 调整,= 现有量,现有量,现有量,- 已分配量,可用量变,可用量,库存状态 期初库存现有量 现有量可用量,15,制造数据管理,粗能力计划,CAP,有限顺排FFS,库存,INV,人员成本会计,CST,物料需求计划MRP,资源BOM,CAP,细能力计划CAP,另部件详情,项目,仓库,在制品,和倒冲物料理,生产成本核算,关键资源,采购,PUR,车间控制,SFC/JIT,BOM,和计划信息,详细工作中心可用能力,关键工作中心可用能力,工艺外协,制造数据管理,MDM,详细工作中心可用能力,制造数据管理粗能力计划有限顺排FFS库存人员成本会计物料,16,物料清单,制造BOM,计划 BOM,BOM,物料清单制造BOM计划 BOMBOM,17,BOM,单级,A,C,B,多级,A,C,B,F,E,D,BOM单级ACB多级ACBFED,18,BOM树结构,父项,状配项,批,成分,成分,制造部件,原材料费,采购件,BOM树结构父项状配项批成分成分制造部件原材料费采购件,19,制造数据维护,BOM 数据处理,组号,子项号,需求数量,废品率,有效/失效日期,工序号,序号,制造数据维护BOM 数据处理组号,20,有效/失效日期,项目号,需求量,有效日期,失效日期,A,B,1,1/1/YY,99/99/99,1,2,1/1/YY,99/99/99,2,1,1/1/YY,5/31/YY,2A,1,6/1/YY,99/99/99,1/1/YY,99/99/99,有效/失效日期项目号需求量有效日期失效日期AB11/1/YY,21,虚拟件,用途：,识别制造产品的固有另件,简化BOM,可以有库存,特点：,提前期为零部件,订货政策为直接批量,虚拟件用途：,22,特征件和可选件 BOM,礼品笔,笔盒,(100%),笔,(100%),皮套(30%),墨水,蓝 = 30%黑 = 50%,红 = 20%,合计,= 100%,红木盒(30%),笔杆,圆珠 = 70%自来水 = 30%,合计,= 100%,标准件,100%,选择 %可以小于 100%,可选件合计 = 100%,特征件和可选件 BOM礼品笔笔盒笔皮套(30%)墨水红木盒,23,部门和,工作中心,场所CH,仓库,AA,场所XX,仓库,CC,仓库BB,部门,100,部门200,部门,300,部门,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,部门和工作中心场所CH仓库场所XX仓库仓库BB部门部门,24,工作中心维护,工作中心,说明,负荷码,部门,能力,效率,每日班次,每班小时数,设备数,负荷百分比,成本 (系数),工作中心维护工作中心说明,25,设备数据维护,设备数据,部门,固定资产标识,从货位,有效期,截止期,平均效率,设备速度,设备数据维护设备数据部门,26,工艺路线,部件库存,工作中心,100,成品库存,20,工作中心,200,工作中心,300,30,40,10,工序,工艺路线 部件库存 工作中心100 成品库存 20,27,工艺路线维护,工艺路线,工序号,状态,工作中心,基本码,小时 (人工, 准备, 机器),工具/备注,有效/截止 日期,操作员,工艺路线维护工艺路线工序号,28,工序时间或,非加工时间,天,非加工时间,天,加工时间,小时,排队,加工,机器,搬运,准备,变化,固定,固定,固定,工序时间或 非加工时间,29,基本码,Blank,小时/件,C,元/件,H,小时/件,P,件/小时,1,小时/10件,2,小时/100件,3,小时/1000件,4,小时/10000件,5,小时/100000件,6,小时/1000000件,基本码Blank小时/件,30,替换工艺方法,成品货位,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,原材料货位,生产线 1,方法 L1,生产线 2,方法 L2,生产线 3,方法 L3,货位1,货位6,货位3,货位2,货位5,替换工艺方法成品货位工序10工序20工序30工序10工序10,31,物料用途查询,层 0,层 1,层 2,用于的产品,A,E,F,B,F,D,C,物料用途查询层 0层 1层 2用于的产品AEFB,32,生产计划,MPS,Actual,Backlog,Forecast,Inventory,Capacity,总,需求,总,需求,生产计划MPSActualBacklogForecastIn,33,生产计划和MPS/MRP的关系,Days inMonth,生产计划,Jan,20,20,000,Feb,19,19,000,Mar,24,24,000,Apr,20,20,000,Master Production Schedule,Week,产品 A,产品B。.,Total,14,750,5,000,15,300,5,000,16,5,000,17,500,5,000,April by Weeks,主生产计划,产品德 A,500 - Week 17,展开需求,500 - Week 14,500 - Week 12,500 - Week 6,Subassembly,Component,Raw Material,Purch Part,Purch Part,生产计划和MPS/MRP的关系Days inMonth生产,34,主生产计划项目类型,MPS,Make-to-Stock,MPS,Combination/Assemble-to-Order,Make-to-Order,MPS,Engineer-to-Order,MPS,主生产计划项目类型MPSMake-to-StockMPSCo,35,独立需求与相关需求,Dependent,Demand,Subassembly,(also sold as,service part),Finished,Goods,Purchase,Component,Purchase,Component,Raw,Material,Dependent,Demand,Dependent,Demand,Independent,Demand,Dependent and,Independent,Demand,独立需求与相关需求DependentDemandSubass,36,生产计划举例,Planning StartDate 11/15,System Date11/18,ProrationYes,Calculation:,16 days left in period,Total of 30 days in period,XForecast quantity of 3000=1600,Period,Quantity,Start,Date,End,Date,Demand,Date,Demand,Quantity,1,2000,10/1,10/31,none,no change,2,3000,11/1,11/30,11/15,1600,3,2000,12/1,12/31,12/1,no change,Period,Quantity,Start,Date,End,Date,Demand,Date,Demand,Quantity,2,3000,11/1,11/30,11/18,1300,Demand to on-line inquiries will change dynamically with system date change.,生产计划举例Planning StartDate 11/,37,累计提前期,Y,A,B,C,X,Y,关键路径,Cumulative Lead Time=2 + 3 + 5 =10,10,9,8,7,6,5,4,3,2,1,C,X,B,产品 A,5,3,2,2,6,Start,End,Cumulative Lead Timefor Parent A,累计提前期YABCXY关键路径Cumulative Lead,38,MPS展望期,月/年,Planning Start Date,+MPS Horizon Days,=MPS Horizon Date,Start date6th,Horizon days15,Horizon date21st,MPS展望期月/年Planning Start Date,39,谁来改变MPS?,General,Manager,Materials,Manager,Master,Scheduler,Master Schedulercannot changewithout approvalof higher levelauthority,Sales cannotpromise orders,Scheduler cantry to add,If Schedulercannot add,sales mustmake trade off,Schedulerlimited toauthorizationover planning,Week,工程改变,管理改变,改变限制,改变能力,0,4,8,12,16,Cumulative Lead Time,谁来改变MPS?GeneralMaterialsMaster,40,需求控制,Engineer,to Order,Make to,Stock,装配,制造,采购,生产计划成本,Forecast Only,Customer Orders Only,Cumulative Lead Time,MPS Horizon,Demand Time Fence,Customer Orders Only,Greater of Forecast and,Customer Orders,Demand Time Fence,Make to,Order,Customer,Orders Only,Greater of Forecast and,Customer Orders,Assemble,to Order,Demand Time Fence,Today,需求控制Engineerto OrderMake to St,41,订货政策,A直接批量,F最新成本,G周期批量,H批量以上直接批量,IIncrement Above Lot Size,JMultiple of Lot Size,KPeriod Order Quantity,BlankReorder Point,订货政策A直接批量,42,和主生产计划有关的量,Gross Requirements,Customer Orders andManufacturing Allocations,Scheduled Receipts,Projected On-Hand,Net Requirements,Planned Order Receiptsand Releases,Available-to-Promise,和主生产计划有关的量Gross Requirements,43,MPS 计算,Period,On-hand,1,2,3,4,5,6,7,8,9,Gross,Requirements,75,300,Customer Orders,and Manufacturing,Allocations,75,50,100,Scheduled Receipts,Projected On-hand,175,100,50,-50,-50,-50,-350,-350,-350,-350,Net Requirements,25,50,100,300,Planned Order,Receipts,25,50,100,300,Planned Order,Releases,25,50,100,300,Available-to-,Promise,-50,MPS 计算PeriodOn-hand123456789Gr,44,计划重排,Period,1,2,3,4,5,6,Required,20,20,20,10,10,20,Scheduled,Receipts,40,40,40,Projected,On-Hand,25,45,25,5,-5,25,45,Period,1,2,3,4,5,6,Required,20,20,20,10,10,20,Scheduled,Receipts,40,40,Projected,On-Hand,25,5,25,5,35,25,5,x,计划重排Period123456Required202020,45,订货应允量,Customer calls to order markers,Check what is,Available-to-Promise,Promise markersto customer,Customer is givenhonest, reliable dateThis customer willcall again,订货应允量Customer calls to order m,46,重订货点,Lead time = 2 periods,Demand = 12.50 pcs./period on avg.,Reorder Point = 50 pcs.,Safety Stock = 25 pcs.,Lot size = 50 pcs.,QUANTITY,TIME,提前期,安全库存,25,50,75,0,1,2,3,4,5,6,7,8,9,10,11,12,Reorder Point,重订货点Lead time = 2 periodsQUA,47,MRP 做为库存管理,Lead time = 2 periods,Safety Stock = 25 pcs.,Order Policy Code = A (Discrete),1,2,3,4,5,6,7,8,9,10,11,12,0,25,50,75,TIME,QUANTITY,计划量,安全库存,提前期,计划下达,计划接收,MRP 做为库存管理Lead time = 2 pe,48,废品率与产出率,A,Yield of 90%,C (1),No Scrap,B (1),Scrap factor of 1.1,1111 needed to yield 1000,(Yield of 90%),1111 needed to,make 1111,(No Scrap),1222 needed to,make 1111,(Scrap factor of 1.1),Example,废品率与产出率AC (1)B (1)1111 needed,49,和MRP有关的量,毛需求,予计接收,予计库存,净需求,计划接收,计划下达,和MRP有关的量毛需求,50,物料需求计划,Gross Requirements,Scheduled Receipts,Projected On-Hand,Planned Order Receipt,Planned Order Release,Allocations,Net Requirements,Gross Requirements,Scheduled Receipts,Projected On-Hand,Planned Order Receipt,Planned Order Release,Allocations,Net Requirements,Demand,Supply,Difference,Plan,Demand,Supply,Difference,Plan,Part A,Period:,1,2,3,4,5,50,50,50,30,30,30,30,10,10,-10,-60,10,50,10,50,10,50,Part B,Period:,1,2,3,4,5,Spare Parts Forecast,for Part B,(Independent Demand),10,20,100,10,20,70,40,20,-80,-80,-90,80,100,100,(Assumes minimum,balance = 0),A,2B,Part A,Lead Time = 2 Periods,Order Policy: Discrete (lot for lot),Part B,Lead Time = 1 Period,Order Policy: Lot size = 100 pcs.,物料需求计划Gross RequirementsSchedu,51,计划反查,A,1,2,MPS Item A,PO 100 11/10 - 11/18,PO 100 11/21 - 11/23,B,2,3,MPS Item B,FPO 75 11/16 - 11/19,PO 50 11/17 - 11/20,Common Item 2,PO 100 11/9,FPO 75 11/15,PO 50 11/16,PO 100 11/20,PO=Planned Orders,FPO=Firm Planned Orders,计划反查A12MPS Item APO 100 11/10,52,粗能力与细能力,Rough Cut,Detail,MPS Only,MPS and MRP,Bill of Resources,Routing,Critical Work Centers,All Work Centers,Master Scheduled Items,All Manufactured Items,Planned Orders,Planned Orders,Firm Planned Orders,Firm Planned Orders,Released Production Orders,粗能力与细能力Rough CutDetailMPS Only,53,工作中心负荷图,Hours,Time Periods,Current Capacity,Planned Load,工作中心负荷图Hours Time PeriodsCurre,54,交叉排序,交叉排序,55,可用能力,Releasable?,Release,Short,No,No,Yes,Yes,Yes,Manufacturing,Schedule,Pre-Production Release,MRP510,Schedule,Adjustment,No,On-hand,Elsewhere,Note,Changes,SFC350,Material,Availability,MRP250,Releasable,Orders Report,Material,OK?,Capacity,OK?,No,Yes,Production,Meeting,Alternate,Item,可用能力Releasable?ReleaseShortNoN,56,计划下达,计划下达,57,车间定单打包,分配例外,领料单,汇总领料单,工艺卡,工票,车间定单打包分配例外,58,Just-In-Time/Repetitive 流程图,WorkFile,JIT620,Production,Update,ProductionUpdate,ProductionRelease / Print,JIT610,Production,Data List,JIT600,Production,Reporting,Just-In-Time/Repetitive 流程图Wor,59,物料发放,Gateway,Work Center,Operation,Single,Issue,I,J,Multiple,Issue,Kit,Schedule,Instructions,SFC560,Order,Pick List,SFC521,Summarized,Pick List,LOC A,LOC B,LOC D,LOC C,Warehouse,物料发放GatewayWork CenterOperatio,60,计划短缺,INV500,Issue,Material,SFC400,Mass,Allocations,MaterialReceivedShort,Warehouse,SFC560,Shop Packet,Reprint,SFC720,Lot/,Location,Allocation,计划短缺INV500IssueMaterialSFC400M,61,数据收集,Order Number,Item Number,Scheduled Start Date,Operation Number,Work Center,Department,Employee Number,Quantity Good,Quantity Reject,Start Time,Stop Time,数据收集Order Number,62,工单反冲,Warehouse,Material Issue,Material Receipt,Workcenter 100,Workcenter 200,Workcenter 300,Operation 10,Operation 20,Operation 30,Run,Move,Queue,Setup,Run,Move,Queue,Machine,REPORTING,POINT,Quantity,Hours,工单反冲WarehouseMaterial IssueMat,63,退料接收,退料接收,64,质量/实验室产品集成,质量,管理,系统,QMS,Capacity Planning,CAP,CIMPath,CIM,Advanced,Process,Industries,API,Just in Time,/Repetitive,JIT,Inventory,INV,Laboratory,Management,System,LMS,MRP/MPS,Production,Activity,Control,PAC,System,SYS,Purchasing,PUR,质量/实验室产品集成质量 管理系统QMSCapaci,65,QMS 处理流程,质量检验书,采样,测试,结果,材料性能,QMS 处理流程质量检验书采样测试结果材料性能,66,ISO9000 系列,ISO9000,ISO9001,ISO9002,ISO9003,ISO9004,ISO9004,ISO9004,ISO9000 系列ISO9000ISO9001ISO900,67,ISO9004,指南,Management,and Systems,Quality,Costs,Marketing,Design,and,Specifications,Purchasing,and Processes,Verification,Calibration,Nonconforming,Corrective,Action,Postproduction,Quality,Records,Personnel,Safety,Statistical,Methods,ISO9004导向,ISO9004ManagementQualityDesign,68,QMS,API,SFC,MDM,JIT,PUR,ORD,INV,BPCS,执行指南,ISO9001,ISO9002,ISO9003,BASIS,Implementation,換uality, in the ISO model, is not an isolated business function,換uality, in the BPCS framework, is not an isolated business function,BPCS 和ISO 质量模型,QMSAPISFCMDMJITPURORDINV,69,QMS,BPCS Quality Management System,The World of ISO,The World of BPCS,Integrated into the MRPII environment,Quality activities occur in real time,Complete specification management system,User defined sample levels and types,User defined sampling plans, i.e. Mil-Std,User defined test plans,User defined process controls,Complete calibration system,Extensive controls for nonconforming product,Database access for statistical analysis,BPCS 质量管理系统,QMSBPCS Quality Management Sys,70,计划BOM,Pen GiftSet,Packaging,(100%),Pen(100%),Leather Case(30%),Ink,Blue = 30%Black = 50%,Red = 20%,Total = 100%,Mahogany Case(30%),Cartridge,Rollerball = 70%Fountain = 30%,Total = 100%,Standard Component 100%,Option % can be less than 100%,Feature GroupTotal = 100%,计划BOMPen GiftSetPackagingPen,71,装配 计划下达,FAS Packet,Print,订单输入,计划BOM,BOM600,Pick,List,MRP530,FAS Order,Not Released,Instructions,Schedule,and Dispatch,订货书,材料足够,OK?,FAS500,FAS,下达,Yes,No,To Shipping,FAS510,装配 计划下达FAS PacketPrint订单输入,72,配置管理流程的改进,Order,Fulfillment,Order,Entry,Configuration,Management,Quote,Entry,Sales and,Marketing,Engineering,Accounting,Time,Time,Time,Flow without Configuration Management,Flow with Configuration Management,配置管理流程的改进OrderOrderConfigurati,73,配置管理主文件设置,Manufacturing Data,Management,BOM500,Routing,Maintenance,SFC100,Configuration,Structure,CFG550,Rules,Master,CFG130,Inherited,Data,Inherited,Data,Item,Master,INV100,Attribute,Master,CFG110,Variable,Master,CFG560,配置管理主文件设置Manufacturing DataBOM,74,在线销售定单配置,Start,System prepares,Custom Configured,Order,Do you,want a,standard,size?,What,width do,you want?,What,length do,you want?,Want wood,or metal,model?,Power,assisted,option?,System,automatically,specifies,heavy-duty,motor,System,calculates,area and,weight,Calculated,weight,more than40Kg?,Yes,No,Yes,No,Do youwant lightor heavymotor?,在线销售定单配置Start System prepare,75,工程改变控制,Customers,Marketing,Change,Control,Engineering,Quality,Control,Finance,Manufacturing,Human,Resources,Purchasing,Research and,Development,Needs,Desires,Proposals,Contracts,Optimize product,process and costs,Assess technical feasibility,develop concepts, process,and prototype,Define, test and refine product,requirements, communicate customer,reaction and product potential,Determine cost,and availability,of purchases,Judge economic opportunity,and feasibility, establish,cost and investment limits,Can we do it?,What do we need to do it?,Assess skills and head count,availability, and needs,Do current,controls apply?,What more is,needed?,Communicate,manage time frame,工程改变控制CustomersMarketingChange,76,工程改变,Yes,BOM110,Engineering,Change,Controlled Items,BOM100,Engineering,Change Order,Maintenance,Internal Program,BOM Mass,Update,Processing,BOM550,Approval,Processing,BOM190,Manufacturing,Notes,Maintenance,BOM100,ECO Detail,Line,Maintenance,Order Closed,Closed ECO,Inquiry,BOM350,Engineering,Change Order,Report,BOM205,No,BOM620,Stock Based,Effectivity,Processing,Status,Complete?,工程改变YesBOM110EngineeringBOM100,77,