i2生产计划与排程(1)

IntroductiontoRhythmFactoryPlannerKwokPoonMay17,2000Agenda•WhatIsRhythmFactoryPlanner(FP)•RhythmFPArchitecture•RhythmFactoryPlanner(FP)PlanningConcept•RhythmFPfeaturesWhatIsRhythmFactoryPlanner(FP)?WhatIsRhythmFactoryPlanner(FP)•FactoryPlannerusestheinformationfromtheexistingtransactionsystem(ERP)toprovideintelligentdecisionsupportcapabilityinPlanningandScheduling•FactoryPlannerprovidesaglobalintegratedviewPurchasingOrderEntryShippingMRPFactoryPlannerFloorControlDataDecisions&DataWhatCanRhythmFPDo?•FactoryPlannerprovidesasystematicandconstraint-basedplanningconcept•FactoryPlannercanhelptominimizethecurrentad-hocplanningprocess•FactoryPlannercanquicklyrevealtheproductionconstraint,whichisalmostimpossiblefortraditionalplanningprocessRhythmFPArchitectureRhythmFPArchitecture•Client-ServerArchitecture•BothserverandclientprocessescanrunonWindowsNTmachines•Mayrunserverandclientonseparatemachines•Useexistingdata(fromTritonandSFCS)•MemoryResident•Multi-UsercapabilityRhythmFPArchitecture(cont.)RhythmFPClientRhythmFPClientRhythmFPClientDataFilesRhythmFPServerRhythmFPServerProductionPlannerMaterialPlannerReportReaderProductionServerWhat-ifServerRhythmFPFramework(Input&Output)RhythmFPServerDemandProductStructure:•Partnumber•BOM•RoutingsFactoryModel:•Resources•ResourceCalendarMaterialAvailability:•UnassignedInventory•P.O./VendorInfo.•WIPOtherInformation:•Tools•...ProductionPlan:•Capacity•MaterialRhythmFPFramework(cont.)•FPrequiresACCURATEandSUFFICIENTdatainput(garbagein&garbageout)•Openloopplanningprocessinthefirstphase•PlannersexecutetheproductionplanbasedonFP’ssuggestionBasicFPDataObjects•BOMdata•Demandorderdata•Partnumberdata•Unassignedinventorydata•Supplierpartdata•Resourcedata•RoutingdataMoreFPDataObjects•Wipdata•Operationresourcedata•Resourcecalendardata•Vendorcalendardata•VariablecapacitybucketsizedataFPOutputFiles•Criticaldeliverydata•PurchaseorderEDCrecommendations•Manufacturingorderdata•Plannedstarttimes•Procurementdata•Procurementbypartdata•etc.FPDataObjectsRelationshipDemandOrders&ForecastOrdersBOMUnassignedinventoryRoutingdataVendorInfoResourcedataResourcecalendardataWIPdataFinishedGoodsPartNumbersMfgOrdersRhythmFPPlanningConceptFPPlanningConcept•BTO(Build-to-order)engine:useDemandsasthedrivertocreateplan•Considerbothmaterialandcapacityconstraintsatthesametime•ConsiderbothSalesOrdersandForecastsasthedemandinputwithdifferentpriorities•StartasanInfiniteCapacityPlanandprogresstoaFiniteCapacityPlanFPPlanningConcept(cont.)•MaterialsareassignedaccordingtotheBOMexplosionfromthefinishgoodlevel–alsoconsiderTimefactors•RawMaterials(ProcuredParts)aresuppliedbyon-handinventoryorP.O.fromvendors.•Manufacturedparts(finishgoodsandintermediateparts)aresuppliedbyWIPormanufacturingorders(workorders).ProcessFlowinFPInfiniteCapacityPlanningFiniteCapacityPlanningCAO(constraintanchoroptimization)DetailScheduling•IdentifyMaterialandCapacityProblems•FixMaterialProblems•AttempttofixCapacityProblems•CreatedetailedschedulesFPInfiniteCapacityPlanning(ICP)•Buildfactorymodelphase•InventoryAssignmentphase•Plannedstarttimephase•Capacityutilizationphase•Presentsplanthroughuserinterface(client)ICP--BuildFactoryModel•Readfilesintomemoryandcreateresidentmemorymodel–FileformatsinSpecFiles•DoconsistencycheckingICP--InventoryAssignment•ExploreBillofMaterials–DeterminesBOMconfigurationandroutingassignments–Createsmanufacturingorderstosatisfydemands•Netrequirementsforrawmaterialsandsub-assembliesagainston-handinventoryandWIP(Work-In-Process)–CreatesmaterialrequirementsICP--InventoryAssignment(cont.)•BackwardSchedule–Definition:LatestPossibleStartTime(LPST)-thelatestdateamanufacturingtaskcanbeginandstillcompleteontime–LPST=TaskDueDate-TaskProcessingtime–CalculatestheLPSTforeachmanufacturingtask–EachmanufacturingtaskwillhaveaLPST–Softconstraint:violateLPSTconstraintwilldeterioratetheorder-fulfillmentperformanceICP--InventoryAssignment(cont.)•BackwardScheduleSubassembly1R.W.#1R.W.#2Subassembly2ComputerOrderDueDateTaskDueDate(LPST)LPSTLPSTMfgorder#1Mfgorder#3Mfgorder#2ICP--InventoryAssignment(cont.)•InventoryAssignment–Prioritizedemandorders(duedate,priority,quantity)–Sortprioritizeddemandorders–Sortpartsfromend-itemtorawmaterials–Calculatedemands–AllocatesuppliesICP--InventoryAssignment(cont.)•ForwardSchedule–Definition:EarliestPossibleStartTime(EPST)-theearliestdatethatamanufacturingtaskcanbegin(constrainedbymaterials)–EPST=max(ServerStartTime,MaterialAvailableTime)–CalculatestheEPSTforeachmanufacturingtask–EachmanufacturingtaskwillhaveanEPST–Hardconstraint:productioncannotbestartedwithoutmaterialsavailableICP--InventoryAssignment(cont.)Subassembly1R.W.#1R.W.#2ComputerOrderCompletionTimeMaterialAvailableTime(EPST)EPSTEPSTMfgorder#1Mfgorder#3Mfgorder#2•ForwardScheduleSubassembly2ICP--PlannedStartTime•AssignPSTforeachtask•Definition:PlannedStartTime(PST)istheexpectedstartdatethatataskwillbegintakingmaterialavailabilityintoconsideration•Calculation:PST=max(EPST,LPST)•EachmanufacturingtaskwillhaveaPST•PSTvaluesmaybeoverridenthroughtheuserinterfaceICP--Cap