高级生产管理培训讲义

,*,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,Welcome,Advanced Manufacturing Training,高级生产培训,Cycle Time, Inc.,Introductions,自我介绍,Name,姓名,Company Product or Service,公司名称及产品,Job or Area of Responsibility,工作岗位,Implementation Status,实施状态,Your Experience Using,Fourth Shift,使用,Fourth Shift,系统的经验,Your Primary Objective for Attending Class,参加本课程的主要目的,Administrative Topics,课程事项,Lunch Facilities,午餐,Breaks and Restrooms,课间休息,Phones and Messages,电话,Smoking,禁止吸烟,Course Objectives,课程目的,(11),1.从管理、计划和执行的角度来更有效地使用,Fourth Shift,系统。,2.集中精力管理订单，稳定计划和减少信息处理。,3.标识如何管理不同的库存策略。,4.完成订单在系统中的处理流程。即从客户订单接收到发货过程。,5.设置加工中心并建立加工中心的能力。,6.制定物料的主生产计划。,7.了解生产信息对财务信息的影响，缩短月结帐周期。,8.运行订单差异分析,(,OVAR,),报告，标识物料的使用差异。,9.运用有效的物料管理概念及操作规程：,提高库存周转率/ 降低库存量,将物料短缺减至最少,10.使用系统获取信息。,11.标识系统实施成功的关键内容。,APICS,American Production Inventory Control Society,-,美国产品库存控制协会,Definition of MRPII,MRP:,M,aterial,R,equirement,P,lanning,使用物料清单，库存数据和主生产计划进行物料需求,计划的方法。,MRPII:,M,anufacturing,R,esource,P,lanning,生产企业使用的对所有制造资源进行有效计划的方法。,Amf P1.3,The Developing Stage History of MRPII/ERP,Amf P1.3,年代,MRP/ERP,40,订货点法,60,时段式,MRP,70,闭环,MRP,80,MRP II,90,ERP,Effective planning of resources,有效的资源计划,Simulation capabilities,模拟能力,Linked functions,衔接功能,Manufacturing output linked to financial,生产信息与财务的集成,APICS,American Production Inventory Control Society,-,美国产品库存控制协会,Definition of MRPII,Amf P1.4,超越 MRPII 范围的集成功能,质量管理,试验室管理,流程作业管理,配方管理,维护管理,产品数据管理,Gartner Group Definition of ERP,(Enterprise Resource Planning),Amf P1.4,Forecast,Forecast/ Cust. Order Demands,销售预测/ 客户订单,Customer Order,近期 远期 长期,MRP,需求,Demands,供应,Supplies,Supply/ Demands System,供需平衡系统,Amf P1.6,MRP,需求,Demands,供应,Supplies,Supply/ Demands System,供需平衡系统,销售预测客户订单,安全库存,库存,采购入库,生产入库,key Elements,关键要素,Customer demands (Forecast, Customer Order),客户需求 (销售预测、客户订单),Master Schedule,主生产计划,Bill of material,物料清单,Inventory,库存,Manufacturing schedule and shop capacity,生产规划及车间能力,Shop calendar,车间日历,Amf P1.5,Manufacturing,生产,Financial,财务,Components,组成部分,FMT P1.4,What Is FOURTH SHIFT,需求,Demand,主生产计划,Master Prod. Schedule,物料清单,Bills,库存,Inventory,物料计划,MRP,当前清单,(生产订单，采购订单),Current Orders,(MO,PO),Amf P1.4,物料主文件,库存,物料清单,主生产计划,销售预测,销售订单,计,划,订货行动,生产订单,采购订单,客户订单,采购接收,物料控制,发货,完工入库,领料,完工入库,供应商,客户,Manufacturing Process,生产过程,FMT P1.6,The Solution,Purchase Order,Inventory,Mfg Order,Customer Order,Accounts Payable,General Ledger,Accounts Receivable,Bills of Material,MRP Planning,Sales Forecast,Master Schedule,Planning,Execution,Reporting,Cash Management,The Solution,采购订单,生产订单,发货计划,应付款,总帐,应收款,销售预测,主生产计划,计划,执行,报告,模块通讯,现金管理,销售订单,物料清单,MRP 计划,库存控制,采购入库,生产领料、完工入库,发货,Closed System,闭环MRPII系统,销售预测,Forecast,计划 Planning,生产 Manufacturing,财务 Finance,Manufacturing System,生产系统,销售预测,Forecast,计划 Planning,生产 Manufacturing,运行检测 Performance,应收,应付,A/R, A/P,现金 Cash,总帐 General Ledger,现金流量 Cash Flow,Finance System,财务系统,MRP,需求,Demands,供应,Supplies,Supply/ Demands System,供需平衡系统修正因素,父项产出率,子项残料率,预测代码,预测阶段,需求时界,计划时界,订货策略,批量订货天数,批量订货数量,最小订货批量,需求时界,计划时界,Production and Stock Strategy,生产和库存策略,面向订单设计,面向订单生产,面向订单装配,面向库存生产,Amf P1.8,Production and Stock Strategy,生产和库存策略,标准产品,面向库存生产,面向订单装配,面向订单生产,面向订单设计,定制产品,Amf P1.8,库存,能力,库存,能力,库存,能力,工程设计,能力,采购,发货,装配,加工,Dependent/Independent Demands,相对需求/ 独立需求,相对需求：,在同一物料系统中，依赖于其他物料需求的需求。,独立需求：,在同一物料系统中，不依赖于其他物料需求的需求。,Dependent/Independent Demands,相对需求/ 独立需求,相对需求：,由,MRP,计算得出。,独立需求：,销售预测,客户订单,安全库存,Demand/ Supply Difference without MPS,无主生产计划,Demand/,Supply,Demand/ Supply Difference with MPS,有主生产计划,Demand,MPS,A,Ordered,订货对象,Component Types,子项类型,N,Consumed,被消耗,In Stock,有库存,On,Picklist,for A,在,A,的领料单上,R,N,N,N (Normal),普通物料,FMT P2.16,A,Ordered,订货对象,Component Types,子项类型,P,Not Ordered,非订货对象,Not in Inventory,不入库,R,N,On,Picklist,for A,在,A,的领料单上,P (Phantom),虚项,N,Component Types,子项类型,R (Resource),资源项,A,N,WCRXXX,R: Run Time Resource,R：,加工时间资源,N,WCSXXX,S: Set up Resource,S：,准备时间资源,WCRXXX,N,Component Types,子项类型,X (Reference),参考项,A,X,No Cost,不计成本,No Planned,不生成计划,N,R,Component Types,子项类型,B (By-Product),副产品,A,Ordered,订货对象,B,Produced during A made,在制造,A,的过程中产生,N,Picked,已领出,R,Component Types,子项类型,T (Tool),工具,U (Tool Return),可返回工具,A,Ordered,订货对象,N,U,Returned after A made,生产,A,之后返回入库,T,Issued for A,生产,A,之前领出,Component Types,子项类型,D (Document),文档,A,D,No Cost,不计成本,No Planned,不生成计划,N,R,N,N,N,Bill/Component Type 物料清单子项类型,Parent,R,R,C,N,Second,Quality Parent,Consumed,Labor Hrs.,Setup Hrs.,P,T,U,Fixture,Fixture,Return,Non-stocked Sub,R,X,N,B,Material,Valuable,Fall-off,Machine Hrs.,Drawing,Forecast Consumption Logic,预测消耗逻辑,Forecast Code 预测代码 (0,1,2,3,4),Forecast Period 预测阶段 (W-周，M-月),Forecast Consumption Logic,预测消耗逻辑,预测剩余,代码预测,2当需求时界日期移至下一个预测阶段时，调整为零。,3,4当需求时界日期移至下一个预测阶段时，累计该日期,之前的预测。,Amf P2.9,ABC Analysis,ABC,分析,$,#,#,$,A,B,C,Paretto,帕累托定律,Amf P5.2,Order PolicyModifiers,订货策略,Order Policy,订货策略,No Planning,无计划 (0),Order Point Policy,订货点策略 (1),Order Up-to Policy,预定上界订货策略 (2),Period Order Policy,定期订货策略,(3),Fixed Order Policy,定量订货策略,(4),Manual Planning Policy,手工计划订货策略,(5),FMT P4.20,Order Policy 1,订货点策略,Order Policy 1,Time,时间,Quantity,数量,Order Policy 1,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order Policy 1,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order Policy 1,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order Policy 1,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order Policy 1,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order Policy 1,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order Policy 1,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order Policy 1,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order Policy 2,预定上界订货策略,Order Policy 2,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order-up-to Quantity,订货数量,Order Policy 2,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order-up-to Quantity,订货数量,Order Policy 2,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order-up-to Quantity,订货数量,Order Policy 2,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order-up-to Quantity,订货数量,Order Policy 2,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order-up-to Quantity,订货数量,Order Policy 2,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order-up-to Quantity,订货数量,Order Policy 2,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order-up-to Quantity,订货数量,Order Policy 2,Time,时间,Quantity,数量,Order,Point,Quantity,订货点,Order-up-to Quantity,订货数量,Order Policy 3,定期订货策略,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,Scheduled Data,计划开始,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement Daily Requirement 日需求,计划到货,Scheduled Data,计划开始,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25,Projected Available Start Inventory 期初库存,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,Scheduled Data,计划开始,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,Scheduled Data,计划开始,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,? Suggestion,Scheduled Data,计划开始,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,? Suggestion,Scheduled Data,计划开始,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,? Suggestion,Scheduled Data,计划开始,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,40,Scheduled Data,计划开始,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 - 30 5 - -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,40 ?,Scheduled Data,计划开始,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 - 30 5 - -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,40 ?,Scheduled Data,计划开始,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 - 30 5 - -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,40 112,Scheduled Data,计划开始,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 - 30 5 - - 97 75 -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,40 112,Scheduled Data,计划开始,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 - 30 5 - - 97 75 -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,40 112 ?,Scheduled Data,计划开始,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 - 30 5 - - 97 75 - 10,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,40 112 18,Scheduled Data,计划开始,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 - 30 5 - - 97 75 - 10,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,40 112 18,Scheduled Data,计划开始,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 - 30 5 - - 97 75 - 10,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,40 112 18,Scheduled Data,计划开始,40,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 - 30 5 - - 97 75 - 10,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,40 112 18,Scheduled Data,计划开始,40 112,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 0 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 - 30 5 - - 97 75 - 10,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,40 112 18,Scheduled Data,计划开始,40 112 18,Start Data,Order Policy 3,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 50 最小订货数量,Lot Size Mult = 0批量订货倍数,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,Scheduled Data,计划开始,Start Data,Order Policy 3,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement Daily Requirement 日需求,计划到货,Scheduled Data,计划开始,Start Data,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 50 最小订货数量,Lot Size Mult = 0批量订货倍数,Order Policy 3,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25,Projected Available Start Inventory 期初库存,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,Scheduled Data,计划开始,Start Data,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 50 最小订货数量,Lot Size Mult = 0批量订货倍数,Order Policy 3,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,Scheduled Data,计划开始,Start Data,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 50 最小订货数量,Lot Size Mult = 0批量订货倍数,Order Policy 3,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,? Suggestion,Scheduled Data,计划开始,Start Data,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 50 最小订货数量,Lot Size Mult = 0批量订货倍数,Order Policy 3,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,? Suggestion,Scheduled Data,计划开始,Start Data,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 50 最小订货数量,Lot Size Mult = 0批量订货倍数,Order Policy 3,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,? Suggestion,Scheduled Data,计划开始,Start Data,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 50 最小订货数量,Lot Size Mult = 0批量订货倍数,Order Policy 3,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,40,Scheduled Data,计划开始,Start Data,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 50 最小订货数量,Lot Size Mult = 0批量订货倍数,Order Policy 3,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,40 50,Scheduled Data,计划开始,Start Data,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 50 最小订货数量,Lot Size Mult = 0批量订货倍数,Order Policy 3,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 -,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,50,Scheduled Data,计划开始,Start Data,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 50 最小订货数量,Lot Size Mult = 0批量订货倍数,Order Policy 3,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 - 40 15 10 10,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,50 ?,Scheduled Data,计划开始,Start Data,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 50 最小订货数量,Lot Size Mult = 0批量订货倍数,Order Policy 3,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 - 40 15 10 10,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,Gross Requirement,计划到货,50 ?,Scheduled Data,计划开始,Start Data,Lead Time = 2 订货提前期,Lot size Day 3 批量订货天数,Minimum = 50 最小订货数量,Lot Size Mult = 0批量订货倍数,Order Policy 3,1 2 3 4 5 6 7 8 9 10 11 12,计划可用量,25 10 5 - 40 15 10 10,Projected Available,毛需求,15 5 5 10 25 5 - 15 22 75 8 10,