1、2022-8-8i2生产计划与排程i2生产计划与排程生产计划与排程i2生产计划与排程Agenda What Is Rhythm Factory Planner(FP)Rhythm FP Architecture Rhythm Factory Planner(FP)Planning Concept Rhythm FP featuresi2生产计划与排程What Is Rhythm Factory Planner(FP)?i2生产计划与排程What Is Rhythm Factory Planner(FP)Factory Planner uses the information from the
2、existing transaction system(ERP)to provide intelligent decision support capability in Planning and Scheduling Factory Planner provides a global integrated view Purchasing Order EntryShippingMRPFactory PlannerFloor ControlDataDecisions&Datai2生产计划与排程What Can Rhythm FP Do?Factory Planner provides a sys
3、tematic and constraint-based planning concept Factory Planner can help to minimize the current ad-hoc planning process Factory Planner can quickly reveal the production constraint,which is almost impossible for traditional planning processi2生产计划与排程Rhythm FP Architecturei2生产计划与排程Rhythm FP Architectur
4、e Client-Server Architecture Both server and client processes can run on Windows NT machines May run server and client on separate machines Use existing data(from Triton and SFCS)Memory Resident Multi-User capabilityi2生产计划与排程Rhythm FP Architecture(cont.)Rhythm FP ClientRhythm FP ClientRhythmFP Clien
5、tData FilesRhythm FP ServerRhythmFP ServerProduction PlannerMaterialPlannerReport ReaderProduction ServerWhat-ifServeri2生产计划与排程Rhythm FP Framework(Input&Output)RhythmFP ServerDemandProduct Structure:Part numberBOMRoutingsFactory Model:ResourcesResource CalendarMaterial Availability:Unassigned Invent
6、oryP.O./Vendor Info.WIPOther Information:Tools.Production Plan:CapacityMateriali2生产计划与排程Rhythm FP Framework(cont.)FP requires ACCURATE and SUFFICIENT data input(garbage in&garbage out)Open loop planning process in the first phase Planners execute the production plan based on FPs suggestioni2生产计划与排程B
7、asic FP Data Objects BOM data Demand order data Part number data Unassigned inventory data Supplier part data Resource data Routing datai2生产计划与排程More FP Data Objects Wip data Operation resource data Resource calendar data Vendor calendar data Variable capacity bucket size datai2生产计划与排程FP Output File
8、s Critical delivery data Purchase order EDC recommendations Manufacturing order data Planned start times Procurement data Procurement by part data etc.i2生产计划与排程FP Data Objects RelationshipDemand Orders&Forecast OrdersBOMUnassignedinventoryRouting dataVendor Info Resource dataResource calendar dataWI
9、P dataFinished GoodsPart NumbersMfg Ordersi2生产计划与排程Rhythm FP Planning Concepti2生产计划与排程FP Planning Concept BTO(Build-to-order)engine:use Demands as the driver to create plan Consider both material and capacity constraints at the same time Consider both Sales Orders and Forecasts as the demand input w
10、ith different priorities Start as an Infinite Capacity Plan and progress to a Finite Capacity Plani2生产计划与排程FP Planning Concept(cont.)Materials are assigned according to the BOM explosion from the finish good level also consider Time factors Raw Materials(Procured Parts)are supplied by on-hand invent
11、ory or P.O.from vendors.Manufactured parts(finish goods and intermediate parts)are supplied by WIP or manufacturing orders(work orders).i2生产计划与排程Process Flow in FPInfinite Capacity PlanningFinite Capacity PlanningCAO(constraint anchor optimization)Detail Scheduling Identify Material and Capacity Pro
12、blems Fix Material Problems Attempt to fix Capacity Problems Create detailed schedulesi2生产计划与排程FP Infinite Capacity Planning(ICP)Build factory model phase Inventory Assignment phase Planned start time phase Capacity utilization phase Presents plan through user interface(client)i2生产计划与排程ICP-Build Fac
13、tory Model Read files into memory and create resident memory model File formats in Spec Files Do consistency checkingi2生产计划与排程ICP-Inventory Assignment Explore Bill of Materials Determines BOM configuration and routing assignments Creates manufacturing orders to satisfy demands Net requirements for r
14、aw materials and sub-assemblies against on-hand inventory and WIP(Work-In-Process)Creates material requirementsi2生产计划与排程ICP-Inventory Assignment(cont.)Backward Schedule Definition:Latest Possible Start Time(LPST)-the latest date a manufacturing task can begin and still complete on time LPST=Task Due
15、 Date-Task Processing time Calculates the LPST for each manufacturing task Each manufacturing task will have a LPST Soft constraint:violate LPST constraint will deteriorate the order-fulfillment performancei2生产计划与排程ICP-Inventory Assignment(cont.)Backward ScheduleSubassembly 1R.W.#1R.W.#2Sub assembly
16、 2Computer Order Due DateTask Due Date(LPST)LPST LPSTMfg order#1Mfg order#3Mfg order#2i2生产计划与排程ICP-Inventory Assignment(cont.)Inventory Assignment Prioritize demand orders(due date,priority,quantity)Sort prioritized demand orders Sort parts from end-item to raw materials Calculate demands Allocate s
17、upplies i2生产计划与排程ICP-Inventory Assignment(cont.)Forward Schedule Definition: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 the EPST for each manufacturing task Each manufa
18、cturing task will have an EPST Hard constraint:production cannot be started without materials availablei2生产计划与排程ICP-Inventory Assignment(cont.)Sub assembly 1R.W.#1R.W.#2ComputerOrder CompletionTimeMaterial AvailableTime(EPST)EPSTEPSTMfg order#1Mfg order#3Mfg order#2 Forward ScheduleSub assembly 2i2生
19、产计划与排程ICP-Planned Start Time Assign PST for each task Definition:Planned Start Time(PST)is the expected start date that a task will begin taking material availability into consideration Calculation:PST=max(EPST,LPST)Each manufacturing task will have a PST PST values may be overriden through the user
20、 interfacei2生产计划与排程ICP-Capacity Utilization Determine bucket(operation time interval)configuration-from variable capacity bucket size data Calculate capacity for each bucket-from resource calendar data Calculate work load in each bucket based on PST and run time of each taski2生产计划与排程FP Finite Capaci
21、ty Planning Identify the constrained resources Balance and offload loads for constrained resources in a GLOBAL view(Global optimization)Plan based on flexible strategy options(e.g.Minimize WIP)Respond quicklyi2生产计划与排程FP Detail Scheduling Schedule based on flexible strategy options(e.g.FIFO)Able to s
22、pecify the scheduling horizon Able to generate a global optimized production schedule Generate the dispatch list for execution Intelligent scheduling algorithm and resultsi2生产计划与排程How to make it successful User-own project Trust and Cooperation What are our game rules?Forecast/Acceptance,S/O,P/O,etc
23、.Thinking of future,reasonable procedures Data Clean-up Should be started from the very beginning Where,when,who,how,etc.etc.i2生产计划与排程Rhythm FP Featuresi2生产计划与排程List of Some Features Transfer Batching Manufacturing Lot Sizing(CMO)Procurement Lot Sizing WIP Reporting Advanced Scheduler(AS)Due Date Qu
24、oting Batch Client Alternates Alternate Parts Alternate Resources Alternate Routing ECN Effectivity Date effectivity Use-up effectivity Sequence-Dependent Setups Resource Modelingi2生产计划与排程Using Rhythm FPi2生产计划与排程Using FP-Basic UI entities Problem windows Reports Demand orders Demand order plan Mfg o
25、rders Mfg order plan Part bufferi2生产计划与排程Using FP-Problem Windows FP has the outstanding problem analytical capabilities Short order problem Late order problem Capacity shortage problem Material shortage problem Late manufacturing parts problemi2生产计划与排程Using FP-Problem Windows(cont.)i2生产计划与排程Using F
26、P-FP reports Critical delivery report Purchase order EDC report Procurement report Late material reservations Master schedule Resource loadi2生产计划与排程Using FP-Demand ordersi2生产计划与排程Using FP-Demand Order Plani2生产计划与排程Using FP-Mfg Ordersi2生产计划与排程Using FP-Mfg Order Plani2生产计划与排程Using FP-Part Buffer2022-8-8i2生产计划与排程
