主生产排程

(企管培训资料下载)主生產排程MasterProductionScheduling(MPS)(企管培训资料下载)MPS的目的協調各單位的活動，尤其是產銷之間的配合。驅動其他的計劃，如採購、製造、人力、設備、資金等。衡量各單位的績效。調和客戶需求和工廠能力，提供可靠的客戶訂單交期。評估計畫變更的影響。(企管培训资料下载)MPS和MRPMPS是MRP最主要的輸入資料。MRP把MPS中的完成品生產排程轉變成零組件的需求數量及時間。MPS是否合理可行決定了MRP是不是能發揮作用。(企管培训资料下载)MPS和PP生產規劃(PP)是針對產品群或「平均產品」而作；而MPS是針對個別完成品而作。生產規劃通常以月、而主生產排程通常以週為時段長。生產規劃的計劃期間較主生產排程長。生產規劃視產能為決策變數；主生產排程則視產能為限制條件。(企管培训资料下载)生產規畫(PP),MPS,MRPMPSRCCPMRP資源?NotOKOkPP(企管培训资料下载)Month1234Forecast620800660760ProductionPlan720720720720PAB500600520580540生產規劃Productfamily:X(企管培训资料下载)ItemWeek12345678GR7885869096100120100MPS9090909090909090APAB250262267271271265255225215GR4850465258607055MPS5454545454545454BPAB150156160168170166160144143GR2830323238444036MPS3636363636363636CPAB100108114118122120112108108MPS(企管培训资料下载)MPS的資料來源客戶訂單銷售預測廠際調撥配銷倉庫需求(企管培训资料下载)MPS技術(1)需求時柵(DemandTimeFence,DTF):在DTF之前不能再有新的需求，因為必來不及交貨。因此MPS只考慮訂單不考慮預測。MPS的修改必須經過仔細的分析及授權。計劃時柵(PlanningTimeFence,PTF):在DTF和PTF之間，新的訂單還是會進來，若某期預測大於訂單，表示尚有訂單會進來，MPS考慮預測量；若訂單大於預測，表示預測低估，MPS取訂單量。在PTF之後，MPS只考慮預測量。(企管培训资料下载)時柵NowDTFPTFEndofPlanningHorizonContainsfrozencustomerordersonly.Containsordersandforecasts.Customerordersreplaceforecastquantities.Containsforecastsonly.(企管培训资料下载)TimeFencesDemandTimeFence(DTF)PlanningTimeFence(PTF)Frozen(InsideDTF)•NoschedulechangesallowedwithinthiswindowModeratelyFirm(BetweenDTF&PTF)•SpecificchangesallowedwithinproductgroupsaslongaspartsareavailableFlexible(OutsidePTF)•Significantvariationallowedaslongasoverallcapacityrequirementsremainatthesamelevels(企管培训资料下载)TimeFences81526WeeksFrozenModeratelyFirmFlexibleFirmCustomerOrdersForecastandavailablecapacityCapacityDTFPTF(企管培训资料下载)MPSTimeFencesMPSPlanningHorizonTodayFutureVisibility(3-6Months)ProcurementFabricationAssemblyCumulativeLeadTimeEmergencyChangesMixChangesONLYRateandAnyChangeDTFPTF(企管培训资料下载)MPSTimeFencesProvideaninputtoroughcutcapacityplanning.Procuringlongrangesresources.Givepurchasingmoretimetoworkwithsuppliers.(企管培训资料下载)MPS技術(2)預計可用量(PAB)表示若採行MPS建議的行動訊息及計劃訂單，各期期未的預計庫存量。可答應量(ATP):在庫量、在途量及計劃訂單量中，尚未承諾給客戶的部份。ATP出現在MPS報表中的第一期及有在途訂單或計劃訂單的時段。負的ATP扣抵前期的ATP。(企管培训资料下载)TPOP的技術用在MPS和MRP的計算上。DRP和服務零件需求規劃亦可用。材料主檔(itemmaster)中，某項目定義為MPS項目，則所有上階父件均為MPS項目，均由MPS系統處理。這時通常要用到計劃材料表(planningBOM)，處理邏輯和MRP同。只有在材料主檔中「訂購政策」定為MRP的材料，MRP系統才會計算其材料需求。MPS技術(3)(企管培训资料下载)配銷需求規劃(DRP)決定各地區倉庫何時補充多少庫存的功能用TPOP將地區倉庫的計劃訂單展開成供應來源的總需求量在多階配銷網的情況下，一階一階展開至工廠MPS項目的獨立需求為止各階雖為相同完成品，但以不同項目視之(企管培训资料下载)CustomersDCADCBCentralSupplyFactoryDCC配銷系統(企管培训资料下载)ParentComponentQty-PerX-DCAX-CS1X-DCBX-CS1X-CSX1BOMforDistributionSystem(企管培训资料下载)Part#=XPastOH=50TT=2SS=0AL=0LS=100PeriodsDue123456789101112FcsSale253055503040504030405030InTransit100POH259540-106020-30300-4010-20PAB25954090602070300601080NetReq.00010000100001000100PORcpt.00010000100001000100POR001000010000100010000Part#=XPastOH=100TT=1SS=0AL=0LS=200PeriodsDue123456789101112FcsSale95851007050607075851009075InTransit0POH5-8020-5010040-309510-9020-55PAB51202015010040170951011020145NetReq.0200020000200002000200PORcpt.0200020000200002000200POR02000200002000020002000DRPforDC(企管培训资料下载)Part#=XPastOH=400LT=2SS=0AL=0LS=500PeriodsDue123456789101112Indep.D.GR200100200010020001002001002000SR0POH200100-1004003001001000-20020000PAB200100400400300100100030020000NetReq.0010000000200000PORcpt.0050000000500000POR05000000050000000DRPforCentralSupply(企管培训资料下载)回應客戶訂單的方式訂單生產(Make-to-Order,MTO)：在收到顧客的訂單後，才進行產品的生產。最終產品通常包含標準項目和針對顧客需求特別設計的項目。接單設計(Engineer-to-Order,ETO)：接到客戶訂單後才展開設計的工作，每張客戶訂單都會產生一套新的件號、材料表、和途程表。接單組裝(Assemble-to-Order,ATO)：關鍵零組件根據客戶需求預測，事先計劃、採購、生產、並儲存在倉庫中，在接到客戶訂單時，領出客戶指定的關鍵零組件，組裝成最終完成品。計劃生產(Make-to-Stock,MTS)：在客戶訂單抵達前，產品就已事前生產完成，接到客戶訂單後直接從倉庫出貨。(企管培训资料下载)MPSApproachesMTOATOMTSApproachControlpointMPSunitBacklogFASForecastCustordersOptionsEnditemsProductlevelEndprod.EndtoIntrm.Endprod.CustorderpromisingHighrequirementLowrequirementForecastaccuracyLowrequirementHighrequirementUseofPlanningBillYesYesNoCopewithdesignandprocessuncertaintyHighneedLowneedBasesofdeliveryMaketoCOontimeMaketoCOontimeMaketorepl.Orderorcustcall-offschl.(企管培训资料下载)MPSItemSelectionbasedonManufacturingStrategyMaketoStockAssembletoOrderMaketoOrderNumberofFinishedProductsNumberofSubassembliesNumberofRawMaterialsTypicalLevelforMPS(企管培训资料下载)MPS,FAS,BOMMTSATOMTOFASFASMPSMPS/FASMPSMPS/FAS:BuildfinisheditemstoforecastMPS:BuildcomponentsandsubassembliesFAS:FinalassemblyofexactconfigurationsFAS:Buildonlytocustomerorders(企管培训资料下载)最終組裝排程(FAS)FAS在接到客戶訂單後才安排，考慮到材料及產能限制。FAS安排從在庫的MPS項目到最終完成品的生產。MPS安排完成品組件的生產；FAS安排可出貨之完成品的生產。MPS含蓋數月；FAS只含蓋數天或週。MPS根據客戶需求預測；FAS根據實際客戶訂單