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1、第五章 供应链管理与APS,MRP基本原理逻辑图,潜在客户,物料清单,库存记录,工作中心,工艺路线,关键工作中心 （瓶颈工序）,资源清单,闭环 MRP逻 辑 流 程 图, 自上而下的可行计划 自下而上的执行反馈 实时应变, 约束理论：重点在瓶颈工序 APS技术：MRP/CRP同步运行,库存记录,产品配置,物料系统,财务,MRP II 计划与控制层次,最终成品,￥,产品系列,工 序,1 经 营 规 划,2 销售与运作规划,3 主生产计划( MPS ),4 物料需求计划 ( MRP ),5 生产作业控制 ( SFC/PAC ),决策层,计划层,执行层,工作量,层 次,计划对象,计划期,3=7年,1
2、-3 年,3=18 周,3-18 周,日,复核期,年,月,周=季,日-周,时-日,时段,年,月,周-季,日=周,日,能力,资源计划,企业资源,粗能力计划,能力需求计划 ( CRP ),投入/产出 控制,小,大,流程脱节与解决方案, 需求供应难沟通 需求不明：经销商/客户需求多变 供应不明：供货保障情况不掌握, 产供销严重脱节 销售接下订单，生产做不出来 生产计划排好，原材料供应不上, 财务与业务脱节 费用不清，源出多头 财务报告滞后，处理 / 决策不及时,物料与资金流程脱节,上下游信息流程脱节,主要内容,Buys Ingredients and Components,Makes aProduc
3、t,Moves it to a DistributionCenter,Stores it atDistributionCenters,Stores it in aWarehouse,Moves itto Stores,Stores it in the Store,Sells it toConsumers,Multi Enterprise Supply Chains,Source: I2-Technologies,Enterprise functional silos with conflicting goals,Purchasing,Manufacturing,Distribution,Cus
4、tomer Service/Sales,Few change- oversStable schedulesLong run lengths,High inventoriesHigh service levelsRegional stocks,Low pur-chase priceMultiple vendors,Low invent-oriesLow trans-portation,Overview of SCM - Issues,Overview and targets of SCM,Definition of Supply Chain Management: Supply Chain Ma
5、nagement describes all kind of activities across multiplecompanies or locations to optimize the manufacturing of products. Herebyconcerning all interfaces on operational and strategic level for involvedassociates.,Main focus,Development of heterogeneous global production networks Increased integrati
6、on of advanced technologies,Minimzing costs for inventories and deliveries Long term relationships (customer / supplier binding) Customer satisfaction,By,ERP - BasisSCM - ToolsInternet,Overview and targets of SCM,Integration of suppliers in planning in consideration of.,Suppliers inventories Supplie
7、rs manufacturing capacities Transport times and capacities,Reduction of own inventories,Integrated planning of supply chains leads to Reduction of inventories Cost savings Capability to meet promised delivery datesIncreased customer satisfactionIntensified customer bindingPerspective to extend the s
8、ales market,Overview and targets of SCM,Prerequisites for success,Share information with your suppliers Keep longer relationships with your suppliers Trust as foundation of relationships with suppliers Fundamentals of supply chain planning,SCM Business Processes,Technology helps enable a variety of
9、SCM business processesPush to pullProcess orientationOptimizationPostponementMore frequent planningCollaboration,Move from push to pull manufacturing,Manufacturers,Distributors/ Wholesalers,Consumers,Suppliers,Retailers,Make what we will sell, not sell what we will make!,Features of SCM,Move from fu
10、nctional silos to process-oriented business processes (e.g., order-to-cash, cash-to-cash),Features of SCM,Optimization of all supply chain activities,Independent, Sequential Planning,Features of SCM,Purchasing,Supply Plan,Scheduling,Logistics,Planning,Order Mgmt,Demand Plan,Supply,Distribution,Produ
11、ction,Process Control,Manufacturing Execution System,Infrastructures,SCM Strategic Plan,Real-time Dispatching,Virtual Factory Planning,Sales,FrequencyMonth/QuarterWeek/MonthDay/HourMinute,SCM Architecture,Strategy,Plan,Execution,Supply Chain Management,供应链管理构架,仓库补货运输计划,实物配送结构,原材料计划供应商选择合作,产品规划战略销售规划
12、,二、APS产生背景,高级计划排程（Advanced Planning and Scheduling, APS）复杂制造系统环境现有管理软件缺陷,复杂制造环境,紧急插单 / 订单Cancel可选加工路线生产线产能调整 (加班,机器故障.)设计修改,生产管理现状（1）,Lack of supply chain visibility 供应链透明度低Inefficient production/distribution planning and execution低效率生产/分销计划和执行Long responsiveness TPT 客户响应速度慢Lack of flexibility生产计划柔性
13、差,生产管理现状（2）,Lack of optimization生产计划优化程度差Poor on-time delivery 低及时交货率High inventory, low turnover高库存、低周转率Competing management objectives相互矛盾的生产管理目标,ERP软件缺陷,固定工艺路线假定提前期无限生产能力排程运算时间长敏捷性差,三、APS基本原理（1）,APS综合:供应链的实际状况实体的运筹配置(工厂，分销中心)；物料结构BOM；生产工艺路径；分销路径和提前期；成本(生产，分销，库存等)市场需求信息销售预测；客户订单；补货订单原料供应信息现有库存；在途量
14、，在制量，调拨量流动资金可用量信息预计收款量；预计付款量,三、APS基本原理（2）,利用约束条件（产能约束、原料供应约束、运输的约束）与商业规则（客户或区域的优先顺序、安全库存、批量）,通过APS引擎,提供以下功能:在市场需求、约束条件、原料供应、生产能力无法同步平衡时，及时警告问题的原因；计划人员交互调控；手动或自动的，实时重新计算保持供应链的同步平衡。来达到可行的、优化的生产计划、采购计划、分销计划与排程。,三、APS基本原理（3）,约束理论（Theory of Constraints）先进算法(LP、GA)基于计算机内存的计算,数据存储,Aps运算器,APS 系统,计划,长期,中期,日/
15、周调整,排程,调度,四、APS体系结构,五、Features of APS,Synchronized concurrent planningConstraint-based planningOptimized planningReal-time planningDecision support capabilityWhat-if simulationPegging between demand and supplySpeed and performance,Synchronized Planning,客户,销售代表,订单承诺,生产计划,库存管理,采购管理,可允诺能力查询,订单请求,库存情况查询
16、,库存情况,采购信息查询,采购信息,资源使用计划查询,资源使用计划,订单承诺计算,交货数量、交货期,交货数量、交货期,原材料采购计划,资源使用计划,需求,供给,Available to Promise,Constraint-based Planning,APS,Constraint,Supply,Demand,Output,Time:Purchase LTMfg.LTTrasf.LTDue Date,Capacity:Resource loadRouting,Material:Alternate PartsECN PartsSourcing Rule,Demand:ForecastSales
17、Order,Supply Data:On-handWIPPurchasing Order,Optimal Plan,Optimized Technologies in APS,Demand PlanningExponential SmoothingSystem DynamicsMultiple Linear RegressionProduction Planning & SchedulingLinear Programming/Mixed Integer LPGenetic AlgorithmsSimulation AnnealingHeuristic MethodsDistribution
18、Planning & DeploymentFlow AlgorithmsBranch-and-Bound Algorithm,六、APS主要内容,基于订单任务(Job-based)订单优先级计划基于事件(Event-based)资源利用率最大化计划基于资源(Resource-based，TOC)瓶颈约束计划基于物料约束的可行的计划基于历史、现在、未来的需求计划基于供应资源优化的分销配置计划基于运输资源优化运输计划,基于订单任务(Job-based),基于订单的优先级决定下一个订单的加工。如:工作中心WC A 有两个资源 工作中心WC B 有一个资源订单MO-1 最高优先级。订单MO-2 次优先
19、级,基于事件(Event-based),基于资源高利用率的方法,基于资源(Resource-based，TOC),基于资源的约束来优化计划，对定义的约束资源建模进行大量的模拟，来实现实际的详细计划。对所有资源可以模拟不同的批量来分析对库存或完成日期的影响。,七、APS软件主要模块,需求计划模块生产计划和排程模块分销计划模块运输计划模块企业或供应链分析,需求计划模块,用统计工具、因果要素和层次分析等手段进行更为精确的预测。用包括Internet和协同引擎（collaboration engines）在内的通讯技术帮助生成企业间的最新和实时的协作预测。,生产计划和排程模块,分析企业内部和供应商生产
20、设施的物料和能力的约束，编制满足物料和能力约束的生产进度计划，并且还可以按照给定条件进行优化。各软件供应商根据不同的生产环境应用不同的算法和技术，提供各有特色的软件。,生产计划和排程基本流程,触发事件（紧急订单、机器故障）生产过程建模参数模型：常量、变量计算法则：数学模型、统计模型、作业研究、约束规则假定生产状况排程优化算法（运算能力、存储能力）生成初始级生产作业计划排程作业交互仿真分析排程方案选择,i2工厂计划模型,分销计划模块,帮助管理分销中心并保证产品可订货、可盈利、能力可用。分销计划帮助企业分析原始信息。然后企业能够确定如何优化分销成本或者根据生产能力和成本提高客户服务水平。,运输计划
21、模块,帮助确定将产品送达客户的最好途径。运输计划模型的时标是短期的和战术的。运输计划模块对交付进行成组并充分利用运输能力。,企业或供应链分析,通过用整个企业或供应链的可视化模型，帮助企业从战略功能上对工厂和销售中心进行调整。有可能对贯穿整个供应链的一个或多个产品进行分析、发掘问题,Scope of APS,Supply chain strategic planningSupply chain network planningDemand planning and forecastingInventory planningSupply chain planningSupply planningD
22、istribution planningTransportation planningShop floor operation schedulingShipment scheduling,APS是使用現存Transaction系統(ERP)的信息，以提供快速規劃及排程的智能决策支持系统。,Purchasing,Order Entry,Manufacturing,Logistics/Shipping,ERP,Current Situation,FinalPlan,Supply Chain Planner,Input DataDemandCapacityMaterials,OutputProduc
23、tion PlanShipping PlanPromise Plan,APS and ERP,Multi-Site Planning,Complex multi-site manufacturing refers to the environment where there are multiple sites that are dependent upon each other for material and assemblies.Supply Planning for a complex multi-site manufacturing environment involves the
24、consolidation of data from the individual sites into a corporate consolidation database.,Multi-Site Planning,Global APS Engine,Demand Planning Engine,Order Promising Engine,APSEngine,APSEngine,APSEngine,Master Plan,Master Plan,Master Plan,Supply Plan,Supply Plan,Supply Plan,Demand Plan,Supply Plan,S
25、CM Information System,Leading provider of B2B and Supply Chain solutions,Provides planning, execution and collaborative optimisation. iSC uses: SCP, DP, CP-DC, CP-PC, TM and TO,ERP solution provider with large install base across many industries,Provides transaction backbone,Commonly used DB platfor
26、m across industries,Provides database platform,Solution provider of collaborative design and change order management,Provides collaborative design solutions supporting New Product Introduction and Design Change Management scenarios,Overview,Use in iSC,Solution provider for e-business software applic
27、ation,Pure ECommerce provides order management and monitoring solution supporting Supply Chain Responsiveness scenarios,埃森哲方案 Leading Technology,Constrained BasedSupply Planning,Demand Planning,CollaborativeForecasts Mgt,CollaborativeSupplier Mgt,OrderManagement,TransportationExecution,Carrier &Route Mgt,TransportationPlanning,Track &Trace,Available ToPromise,New ProductIntroduction,OrderExecution,Design ChangeManagement,Suppliers,Customers,埃森哲方案,APS与其它企业信息化系统间的关系,主要APS软件厂商,I2 technologySAP APOOracleAxander,Click to edit company slogan .,Thank You !,
