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1、生产计划与排程(英文),Agenda,What Is Rhythm Factory Planner(FP)Rhythm FP ArchitectureRhythm Factory Planner(FP)Planning ConceptRhythm FP features,What Is Rhythm Factory Planner(FP)?,What Is Rhythm Factory Planner(FP),Factory Planner uses the information from the existing transaction system(ERP)to provide inte
2、lligent decision support capability in Planning and SchedulingFactory Planner provides a global integrated view,What Can Rhythm FP Do?,Factory Planner provides a systematic and constraint-based planning conceptFactory Planner can help to minimize the current ad-hoc planning processFactory Planner ca
3、n quickly reveal the production constraint,which is almost impossible for traditional planning process,Rhythm FP Architecture,Rhythm FP Architecture,Client-Server ArchitectureBoth server and client processes can run on Windows NT machinesMay run server and client on separate machinesUse existing dat
4、a(from Triton and SFCS)Memory ResidentMulti-User capability,Rhythm FP Architecture(cont.),Production Planner,MaterialPlanner,Report Reader,Production Server,What-ifServer,Rhythm FP Framework(Input&Output),RhythmFP Server,Demand,Product Structure:Part numberBOMRoutings,Factory Model:ResourcesResource
5、 Calendar,Material Availability:Unassigned InventoryP.O./Vendor Info.WIP,Other Information:Tools.,Production Plan:CapacityMaterial,Rhythm FP Framework(cont.),FP requires ACCURATE and SUFFICIENT data input(garbage in&garbage out)Open loop planning process in the first phasePlanners execute the produc
6、tion plan based on FPs suggestion,Basic FP Data Objects,BOM dataDemand order dataPart number dataUnassigned inventory dataSupplier part data Resource dataRouting data,More FP Data Objects,Wip dataOperation resource dataResource calendar dataVendor calendar dataVariable capacity bucket size data,FP O
7、utput Files,Critical delivery dataPurchase order EDC recommendationsManufacturing order dataPlanned start timesProcurement dataProcurement by part dataetc.,FP Data Objects Relationship,Rhythm FP Planning Concept,FP Planning Concept,BTO(Build-to-order)engine:use Demands as the driver to create planCo
8、nsider both material and capacity constraints at the same timeConsider both Sales Orders and Forecasts as the demand input with different prioritiesStart as an Infinite Capacity Plan and progress to a Finite Capacity Plan,FP Planning Concept(cont.),Materials are assigned according to the BOM explosi
9、on from the finish good levelalso consider Time factorsRaw Materials(Procured Parts)are supplied by on-hand inventory or P.O.from vendors.Manufactured parts(finish goods and intermediate parts)are supplied by WIP or manufacturing orders(work orders).,Process Flow in FP,Infinite Capacity Planning,Fin
10、ite Capacity PlanningCAO(constraint anchor optimization),Detail Scheduling,Identify Material and Capacity ProblemsFix Material Problems,Attempt to fix Capacity Problems,Create detailed schedules,FP Infinite Capacity Planning(ICP),Build factory model phaseInventory Assignment phasePlanned start time
11、phaseCapacity utilization phasePresents plan through user interface(client),ICP-Build Factory Model,Read files into memory and create resident memory modelFile formats in Spec FilesDo consistency checking,ICP-Inventory Assignment,Explore Bill of MaterialsDetermines BOM configuration and routing assi
12、gnmentsCreates manufacturing orders to satisfy demandsNet requirements for raw materials and sub-assemblies against on-hand inventory and WIP(Work-In-Process)Creates material requirements,ICP-Inventory Assignment(cont.),Backward Schedule Definition:Latest Possible Start Time(LPST)-the latest date a
13、manufacturing task can begin and still complete on timeLPST=Task Due Date-Task Processing timeCalculates the LPST for each manufacturing taskEach manufacturing task will have a LPSTSoft constraint:violate LPST constraint will deteriorate the order-fulfillment performance,ICP-Inventory Assignment(con
14、t.),Backward Schedule,Subassembly 1,R.W.#1,R.W.#2,Sub assembly 2,Computer,Order Due Date,Task Due Date(LPST),LPST,LPST,Mfg order#1,Mfg order#3,Mfg order#2,ICP-Inventory Assignment(cont.),Inventory AssignmentPrioritize demand orders(due date,priority,quantity)Sort prioritized demand ordersSort parts
15、from end-item to raw materialsCalculate demandsAllocate supplies,ICP-Inventory Assignment(cont.),Forward ScheduleDefinition:Earliest Possible Start Time(EPST)-the earliest date that a manufacturing task can begin(constrained by materials)EPST=max(Server Start Time,Material Available Time)Calculates
16、the EPST for each manufacturing taskEach manufacturing task will have an EPSTHard constraint:production cannot be started without materials available,ICP-Inventory Assignment(cont.),Sub assembly 1,R.W.#1,R.W.#2,Computer,Order CompletionTime,Material AvailableTime(EPST),EPST,EPST,Mfg order#1,Mfg orde
17、r#3,Mfg order#2,Forward Schedule,Sub assembly 2,ICP-Planned Start Time,Assign PST for each taskDefinition:Planned Start Time(PST)is the expected start date that a task will begin taking material availability into considerationCalculation:PST=max(EPST,LPST)Each manufacturing task will have a PSTPST v
18、alues may be overriden through the user interface,ICP-Capacity Utilization,Determine bucket(operation time interval)configuration-from variable capacity bucket size dataCalculate capacity for each bucket-from resource calendar dataCalculate work load in each bucket based on PST and run time of each
19、task,FP Finite Capacity Planning,Identify the constrained resourcesBalance and offload loads for constrained resources in a GLOBAL view(Global optimization)Plan based on flexible strategy options(e.g.Minimize WIP)Respond quickly,FP Detail Scheduling,Schedule based on flexible strategy options(e.g.FI
20、FO)Able to specify the scheduling horizonAble to generate a global optimized production scheduleGenerate the dispatch list for executionIntelligent scheduling algorithm and results,How to make it successful,User-own projectTrust and CooperationWhat are our game rules?Forecast/Acceptance,S/O,P/O,etc.
21、Thinking of future,reasonable proceduresData Clean-up Should be started from the very beginningWhere,when,who,how,etc.etc.,Rhythm FP Features,List of Some Features,Transfer BatchingManufacturing Lot Sizing(CMO)Procurement Lot SizingWIP ReportingAdvanced Scheduler(AS)Due Date QuotingBatch Client,Alte
22、rnatesAlternate PartsAlternate ResourcesAlternate RoutingECN EffectivityDate effectivityUse-up effectivitySequence-Dependent SetupsResource Modeling,Using Rhythm FP,Using FP-Basic UI entities,Problem windowsReportsDemand ordersDemand order planMfg orders Mfg order planPart buffer,Using FP-Problem Wi
23、ndows,FP has the outstanding problem analytical capabilitiesShort order problemLate order problemCapacity shortage problemMaterial shortage problemLate manufacturing parts problem,Using FP-Problem Windows(cont.),Using FP-FP reports,Critical delivery reportPurchase order EDC reportProcurement reportLate material reservationsMaster scheduleResource load,Using FP-Demand orders,Using FP-Demand Order Plan,Using FP-Mfg Orders,Using FP-Mfg Order Plan,Using FP-Part Buffer,