1、生产计划与排程(英文)AgendavWhat Is Rhythm Factory Planner(FP)vRhythm FP ArchitecturevRhythm Factory Planner(FP)Planning ConceptvRhythm FP featuresWhat Is Rhythm Factory Planner(FP)?What Is Rhythm Factory Planner(FP)vFactory Planner uses the information from the existing transaction system(ERP)to provide inte
2、lligent decision support capability in Planning and SchedulingvFactory Planner provides a global integrated view PurchasingOrder EntryShippingMRPFactory PlannerFloor ControlDataDecisions&DataWhat Can Rhythm FP Do?vFactory Planner provides a systematic and constraint-based planning conceptvFactory Pl
3、anner can help to minimize the current ad-hoc planning processvFactory Planner can quickly reveal the production constraint,which is almost impossible for traditional planning processRhythm FP ArchitectureRhythm FP ArchitecturevClient-Server ArchitecturevBoth server and client processes can run on W
4、indows NT machinesvMay run server and client on separate machinesvUse existing data(from Triton and SFCS)vMemory ResidentvMulti-User capabilityRhythm FP Architecture(cont.)Rhythm FP ClientRhythm FP ClientRhythmFP ClientData FilesRhythm FP ServerRhythmFP ServerProduction PlannerMaterialPlannerReport
5、ReaderProduction ServerWhat-ifServerRhythm FP Framework(Input&Output)RhythmFP ServerDemandProduct Structure:Part numberBOMRoutingsFactory Model:ResourcesResource CalendarMaterial Availability:Unassigned InventoryP.O./Vendor Info.WIPOther Information:Tools.Production Plan:CapacityMaterialRhythm FP Fr
6、amework(cont.)vFP requires ACCURATE and SUFFICIENT data input(garbage in&garbage out)vOpen loop planning process in the first phasevPlanners execute the production plan based on FPs suggestionBasic FP Data ObjectsvBOM datavDemand order datavPart number datavUnassigned inventory datavSupplier part da
7、ta vResource datavRouting dataMore FP Data ObjectsvWip datavOperation resource datavResource calendar datavVendor calendar datavVariable capacity bucket size dataFP Output FilesvCritical delivery datavPurchase order EDC recommendationsvManufacturing order datavPlanned start timesvProcurement datavPr
8、ocurement by part datavetc.FP Data Objects RelationshipDemand Orders&Forecast OrdersBOMUnassignedinventoryRouting dataVendor Info Resource dataResource calendar dataWIP dataFinished GoodsPart NumbersMfg OrdersRhythm FP Planning ConceptFP Planning ConceptvBTO(Build-to-order)engine:use Demands as the
9、driver to create planvConsider both material and capacity constraints at the same timevConsider both Sales Orders and Forecasts as the demand input with different prioritiesvStart as an Infinite Capacity Plan and progress to a Finite Capacity PlanFP Planning Concept(cont.)vMaterials are assigned acc
10、ording to the BOM explosion from the finish good levelalso consider Time factorsvRaw Materials(Procured Parts)are supplied by on-hand inventory or P.O.from vendors.vManufactured parts(finish goods and intermediate parts)are supplied by WIP or manufacturing orders(work orders).Process Flow in FPInfin
11、ite Capacity PlanningFinite Capacity PlanningCAO(constraint anchor optimization)Detail Scheduling Identify Material and Capacity Problems Fix Material Problems Attempt to fix Capacity Problems Create detailed schedulesFP Infinite Capacity Planning(ICP)vBuild factory model phasevInventory Assignment
12、phasevPlanned start time phasevCapacity utilization phasevPresents plan through user interface(client)ICP-Build Factory ModelvRead files into memory and create resident memory modelFile formats in Spec FilesvDo consistency checkingICP-Inventory AssignmentvExplore Bill of MaterialsDetermines BOM conf
13、iguration and routing assignmentsCreates manufacturing orders to satisfy demandsvNet requirements for raw materials and sub-assemblies against on-hand inventory and WIP(Work-In-Process)Creates material requirementsICP-Inventory Assignment(cont.)vBackward Schedule Definition:Latest Possible Start Tim
14、e(LPST)-the latest date a 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 performanceICP
15、-Inventory Assignment(cont.)vBackward ScheduleSubassembly 1R.W.#1R.W.#2Sub assembly 2Computer Order Due DateTask Due Date(LPST)LPST LPSTMfg order#1Mfg order#3Mfg order#2ICP-Inventory Assignment(cont.)vInventory AssignmentPrioritize demand orders(due date,priority,quantity)Sort prioritized demand ord
16、ersSort parts from end-item to raw materialsCalculate demandsAllocate supplies ICP-Inventory Assignment(cont.)vForward 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 Ti
17、me)Calculates the EPST for each manufacturing taskEach manufacturing task will have an EPSTHard constraint:production cannot be started without materials availableICP-Inventory Assignment(cont.)Sub assembly 1R.W.#1R.W.#2ComputerOrder CompletionTimeMaterial AvailableTime(EPST)EPSTEPSTMfg order#1Mfg o
18、rder#3Mfg order#2 Forward ScheduleSub assembly 2ICP-Planned Start TimevAssign PST for each taskvDefinition:Planned Start Time(PST)is the expected start date that a task will begin taking material availability into considerationvCalculation:PST=max(EPST,LPST)vEach manufacturing task will have a PSTvP
19、ST values may be overriden through the user interfaceICP-Capacity UtilizationvDetermine bucket(operation time interval)configuration-from variable capacity bucket size datavCalculate capacity for each bucket-from resource calendar datavCalculate work load in each bucket based on PST and run time of
20、each taskFP Finite Capacity PlanningvIdentify the constrained resourcesvBalance and offload loads for constrained resources in a GLOBAL view(Global optimization)vPlan based on flexible strategy options(e.g.Minimize WIP)vRespond quicklyFP Detail SchedulingvSchedule based on flexible strategy options(
21、e.g.FIFO)vAble to specify the scheduling horizonvAble to generate a global optimized production schedulevGenerate the dispatch list for executionvIntelligent scheduling algorithm and resultsHow to make it successfulvUser-own projectvTrust and CooperationvWhat are our game rules?Forecast/Acceptance,S
22、/O,P/O,etc.Thinking of future,reasonable proceduresvData Clean-up Should be started from the very beginningWhere,when,who,how,etc.vetc.Rhythm FP FeaturesList of Some FeaturesvTransfer BatchingvManufacturing Lot Sizing(CMO)vProcurement Lot SizingvWIP ReportingvAdvanced Scheduler(AS)vDue Date Quotingv
23、Batch Client Alternates Alternate Parts Alternate Resources Alternate Routing ECN Effectivity Date effectivity Use-up effectivity Sequence-Dependent Setups Resource ModelingUsing Rhythm FPUsing FP-Basic UI entitiesvProblem windowsvReportsvDemand ordersvDemand order planvMfg orders vMfg order planvPa
24、rt bufferUsing FP-Problem WindowsvFP has the outstanding problem analytical capabilitiesShort order problemLate order problemCapacity shortage problemMaterial shortage problemLate manufacturing parts problemUsing FP-Problem Windows(cont.)Using FP-FP reports vCritical delivery reportvPurchase order EDC reportvProcurement reportvLate material reservationsvMaster schedulevResource loadUsing FP-Demand ordersUsing FP-Demand Order PlanUsing FP-Mfg OrdersUsing FP-Mfg Order PlanUsing FP-Part Buffer
