Capacity Management产能管理(ppt)
产能管理
(Capacity Management)
Outline
• 生产环境演变与相关管理工具之关系
• 制造环境分类
• 制造规划及控制系统架构
• 产能管理相关概念
• 粗估产能规划(RCCP)
• 产能需求规划(CRP)
• 投入/产出规划及控制(I/O Planning & Control)
• 作业排程(Operation Sequencing)
• 结论
Competitive Priority
• 1950~1960
– Cost 
• 1970~1980
– Quality 
• 1990~2000
– Delivery、Flexibility、Service 
– Global-wise
Competitive Priority
Planning Evolution
MRP-1960’s and 70’s
• Material Requirements Planning
• Master Production Scheduling
• Unconstrained
MRP II-1980’s
• Unconstrained
• Manufacturing Planning and Control, with manual processes to “close the loop”
• Capacity Management
• Financial Integration
ERP- 1990’s
• An accounting-oriented information system for identifying and planning the enterprise-wide resources needed to take, make, ship, and account for customer orders. [APICS dictionary]

信息系统之演进
• MRP I -- 1960~1980
– 生产者导向大量生产
– 产品以价格及功能取胜生产成本降低
– 整合：MPS及BOM
• MRP II -- 1980~1990
– 消费者导向少样多量生产
– 产品以多样化及高质量取胜生产弹性及消除浪废
– 整合：制造、营销、财务、人事、项目
• ERP/SCM -- 1990~
– 消费者导向大量客制化
– 快速反应市场需求
– 跨地区、跨币别的实时、整合信息
信息系统


制造环境分类
• 以制造策略分类
– Job Shop (零工型)
– Repetitive (重复型)
– Batch (批量型)
– Flow Shop (流线型)
• 以产品定位策略分类
– Engineering-to-order
– Make-to-order
– Assemble-to-order
– Make-to-stock
制造环境
Manufacturing System Model
Capacity Management in MPS System
Capacity Planning and Control
Capacity Definition
• The rate at which work is withdraw from the system.
• The highest reasonable output rate which can be achieved with the current product specifications, product mix, work force, plant, and equipment. [APICS dictionary]
Capacity Management
• The function of establishing, measuring, monitoring, and adjusting limits or levels of capacity in order to execute all manufacturing schedules. [APICS dictionary]
• Include
– capacity planning
– capacity control
Work Center and Load
• Work Center
– A specific production facility, consisting of one or more people and/or machines, which can be considered as on unit for purposes of capacity requirements planning and detailed scheduling. [APICS dictionary]
• Load
– The amount of scheduled work ahead of a manufacturing facility, usually expressed in terms of hours of work or units of production. [APICS dictionary]

Wight’s Funnel
Capacity and Load [APICS]
Capacity Planning Terms
Capacity Utilization Scenarios
Determining Capacity Available
• Demonstrated (Measured) Capacity
– the average recent output actually achieved , is figured from historical data
– is defined as average output, not max output
• Rated (Calculated) Capacity
– available hours ×utilization ×efficiency
Utilization
Utilization
Efficiency
• A measure of how closely predetermined standards are achieved.
Efficiency
Capacity Determination
Rough-Cut Capacity Planning
• The need for long planning horizons and the lack of specific, accurate data for many important factors make RCCP techniques more practical than detailed calculations
• A capacity plan should not be deferred; rough-cut approaches are very practical
Bill of Resource (Bill of Labor)
• 资源清单(BOR; BOL)乃针对制造料件或零件群时，所需之主要关键资源的产能需求条列。
• 不是为了作为途程(Routing)用途。
• 只是一种估计特定料项所需产能的方法。
RCCP Procedure
• Converting units of product in the MPS to standard hours of work in individual centers
• To accumulate in each period in the MPS the total hours of work required to produce all products scheduled in that period
– no LT offsetting
– no lot-sizing
– no significant changes in inventories of items
Routing for Product X
Routing for Assy-01

BOM for FG
Item Master Files for FG
Routing Files for FG
Work Center Master Files
MPS for Part 100
RCCP-Process Time Computation
RCCP-BOR Computation
Rough Cut Capacity Requirements
RCCP
RCCP
Backward and Forward Scheduling
Infinite and Finite Loading
CRP Definition
• The function of establishing, measuring, and adjusting limits or level of capacity
• The process of determining in detail the amount of labor and machine resources required to accomplish the tasks of production [APICS Dictionary]
Capacity Requirements Planning
Manufacturing Order and Routing
• Manufacturing Order (Work Order)
– A document, group of documents, or schedule identity conveying authority for the manufacture of specified parts or products in specified quantities. [APICS dictionary]
• Routing
– A set of information detailing the method of manufacture of a particular item. It includes the operations to be performed, their sequence, the various work centers to be involved, and the standards for setup and run (times). [APICS dictionary]

Inputs Needed for CRP
• Open Order File
• Planned Order Releases
• Routing File
– operations to be performed
– sequence of operations
– work centers to be used
– possible alternate work centers
– tooling needed at each operation
– standard times: setup times, run times
• Work Center File
– move time, wait time, queue time
• Shop Calendar
Lead Time
• Manufacturing LT
– queue, setup, process, wait, move


• Average Q
– (SU+RT)1+(SU+RT)2+…+(SU+RT)n

Expected Queueing Time
A Revised Definition of Capacity Available
• Capacity available = Time available  Efficiency  Availability  Activation

• Availability
– 1- the fraction of time down due to machine breakdown and/or absenteeism
• Activation
– 1- the fraction of down due to lack of work
How Load Is Determined?
• The production plan
– long range rate of production
• The MPS drive MRP
– MRP generate planned orders
– released (open) orders
• CRP (capacity requirements planning)
– calculates std hours required, by W/C, by time period, based on planned and open orders
Load Determination
• Open Orders (from order file status file maintained by
production control)
– order due date
– order quantity
– operations completed
– operation remaining
• MRP-planned Order Releases ( from MRP’s output)
– planned order release date
– planned order receipt date
– planned quantity
Data Requirements for CRP
• Valid due dates on all released and planned orders
• Up-to-date routings and processing information
• Accurate standards for setup and processing time
• A scheduling program to handle all operations
• A loading program to assign work to time periods
• Standard queue allowances for all work centers
• Estimates of load due to unplanned occurrences
MRP for FG
CRP Computation
• Setup time computation for planned order
• Run time computation for planned order
• Setup time computation for open order
• Run time computation for open order
• CRP load report

Planned Order Releases
Setup Time Matrices for FG
Run Time Matrices for FG
Capacity Req. of Planned Releases
Capacity Req. by Released Orders
Capacity Requirements Plan for FG
CRP
W/C Capacity vs. Average Load
• The formal plan does not include all the load it will be necessary to handle
– new products not in the current MPS
– use of alternate routings and processing
– scrap replenishment and rework operations
– additional processing needed for any reason
– record errors resulting in additional material requirements
• Some of the load must remain in the center to provide the planned standard queue
Input/Output Control
Input/Output Control
• Input/Output control is a method to manage queues and work-in-process lead times
• Input/Output Control Report
Definition
• Planned Input
– Work expected to arrive by time period
• based on CRP constraints
• expressed in standard hours or other common unit of measure
• Planned Output
– Work to be reduced by time period
• to reduce queue, plan output greater than input
• make capacity available

Definition
• Planned Queue
– Beginning queue + planned input - planned output
• week ending 06/06 : 300 + 182 - 207 = 275
• week ending 06/13 : 275 + 203 - 207 = 271
• continuing for each succeeding week
• Actual Input
– Work arriving at work center by time period, same unit of measure
• obtained from reporting systems or manual logs
• affected by releases to shop, flow from prior operations
Definition
• Actual Input
– Work arriving at work center by time period, same unit of measure
• obtained from reporting systems or manual logs
• affected by releases to shop, flow from prior operations
• Actual Output
– Standard hours produced during each period
• from reporting systems or manual logs
• affected by resources, efficiency, workload

Definition
• Actual Queue
– Begging (or prior period) queue + actual input - actual output
• week ending 06/06: 300 + 197 -213 = 284
• verified periodically to confirm accuracy of input and output data
• Control
– measure actual to plan
• actual output vs. planned output
• actual output vs. actual input
• actual input vs. planned input
Input/Output Comparisons
• Actual output  planned output
– Queues, LT 
– not enough input? Insufficient capacity?
• Actual output  planned output
– may run out of work, excess capacity
• Actual input  planned input
– may run out of work
– feeding w/c behind schedule, late order
Input/Output Comparisons
• Actual input  planned input
– work released early, queue & LT 
– feeding w/c ahead of schedule
• Actual output  actual input
– work released early, queue & LT 
– not enough capacity
• Actual output  actual input
– work released late, may run out of work
– feeding w/c behind schedule, idle capacity, late order
Dispatching Rules
• First come, first served (FCFS)
• Earliest Job Due Date (EDD)
• Earliest Operation Due Date (ODD)
• Operation start dates
• Critical ratios (CR)
• Shortest process time (SPT)
• Other methods
Dispatching Rules
Capacity Management
制造环境特性

Conclusions
• Managing order LTs requires managing both priority and capacity
• Capacity plans should use the broadest possible product groups that go through similar manufacturing operations
• Capacity must be adequate to support the MPS and handle additional unplanned demands



Capacity Management产能管理(ppt)