1、i2生產計劃與排程2022/7/23i2生產計劃與排程AgendaWhat Is Rhythm Factory Planner (FP)Rhythm FP ArchitectureRhythm Factory Planner (FP) Planning ConceptRhythm FP featuresi2生產計劃與排程What Is Rhythm Factory Planner (FP) ?i2生產計劃與排程What Is Rhythm Factory Planner (FP)Factory Planner uses the information from the existing tra

2、nsaction system (ERP) to provide intelligent decision support capability in Planning and SchedulingFactory Planner provides a global integrated view PurchasingOrder EntryShippingMRPFactory PlannerFloor ControlDataDecisions & Datai2生產計劃與排程What Can Rhythm FP Do?Factory Planner provides a systematic an

3、d constraint-based planning conceptFactory Planner can help to minimize the current ad-hoc planning processFactory Planner can quickly reveal the production constraint, which is almost impossible for traditional planning processi2生產計劃與排程Rhythm FP Architecturei2生產計劃與排程Rhythm FP ArchitectureClient-Ser

4、ver ArchitectureBoth server and client processes can run on Windows NT machinesMay run server and client on separate machinesUse existing data (from Triton and SFCS)Memory ResidentMulti-User capabilityi2生產計劃與排程Rhythm FP Architecture (cont.)Rhythm FP ClientRhythm FP ClientRhythmFP ClientData FilesRhy

5、thm FP ServerRhythmFP ServerProduction PlannerMaterialPlannerReport ReaderProduction ServerWhat-ifServeri2生產計劃與排程Rhythm FP Framework (Input & Output)RhythmFP ServerDemandProduct Structure:Part numberBOMRoutingsFactory Model:ResourcesResource CalendarMaterial Availability:Unassigned InventoryP.O./ Ve

6、ndor Info.WIPOther Information:Tools.Production Plan:CapacityMateriali2生產計劃與排程Rhythm FP Framework (cont.)FP requires ACCURATE and SUFFICIENT data input (garbage in & garbage out)Open loop planning process in the first phasePlanners execute the production plan based on FPs suggestioni2生產計劃與排程Basic FP

7、 Data ObjectsBOM dataDemand order dataPart number dataUnassigned inventory dataSupplier part data Resource dataRouting datai2生產計劃與排程More FP Data ObjectsWip dataOperation resource dataResource calendar dataVendor calendar dataVariable capacity bucket size datai2生產計劃與排程FP Output FilesCritical delivery

8、 dataPurchase order EDC recommendationsManufacturing order dataPlanned start timesProcurement dataProcurement by part dataetc.i2生產計劃與排程FP Data Objects RelationshipDemand Orders & Forecast OrdersBOMUnassignedinventoryRouting dataVendor Info Resource dataResource calendar dataWIP dataFinished GoodsPar

9、t NumbersMfg Ordersi2生產計劃與排程Rhythm FP Planning Concepti2生產計劃與排程FP Planning ConceptBTO (Build-to-order) engine: use Demands as the driver to create planConsider both material and capacity constraints at the same timeConsider both Sales Orders and Forecasts as the demand input with different prioritie

10、sStart as an Infinite Capacity Plan and progress to a Finite Capacity Plani2生產計劃與排程FP Planning Concept (cont.)Materials are assigned according to the BOM explosion from the finish good levelalso consider Time factorsRaw Materials (Procured Parts) are supplied by on-hand inventory or P.O. from vendor

11、s.Manufactured parts (finish goods and intermediate parts) are supplied by WIP or manufacturing orders (work orders).i2生產計劃與排程Process Flow in FPInfinite Capacity PlanningFinite Capacity PlanningCAO (constraint anchor optimization)Detail SchedulingIdentify Material and Capacity ProblemsFix Material P

12、roblemsAttempt to fix Capacity ProblemsCreate detailed schedulesi2生產計劃與排程FP Infinite Capacity Planning (ICP)Build factory model phaseInventory Assignment phasePlanned start time phaseCapacity utilization phasePresents plan through user interface (client)i2生產計劃與排程ICP - Build Factory ModelRead files i

13、nto memory and create resident memory modelFile formats in Spec FilesDo consistency checkingi2生產計劃與排程ICP - Inventory AssignmentExplore Bill of MaterialsDetermines BOM configuration and routing assignmentsCreates manufacturing orders to satisfy demandsNet requirements for raw materials and sub-assemb

14、lies against on-hand inventory and WIP (Work-In-Process)Creates material requirementsi2生產計劃與排程ICP - Inventory Assignment (cont.)Backward Schedule Definition: Latest Possible Start Time (LPST) - the latest date a manufacturing task can begin and still complete on timeLPST = Task Due Date - Task Proce

15、ssing timeCalculates the LPST for each manufacturing taskEach manufacturing task will have a LPSTSoft constraint: violate LPST constraint will deteriorate the order-fulfillment performancei2生產計劃與排程ICP - Inventory Assignment (cont.)Backward ScheduleSubassembly 1R.W. #1R.W. #2Sub assembly 2Computer Or

16、der Due DateTask Due Date (LPST)LPSTLPSTMfg order #1Mfg order #3Mfg order #2i2生產計劃與排程ICP - Inventory Assignment (cont.)Inventory AssignmentPrioritize demand orders (due date, priority, quantity)Sort prioritized demand ordersSort parts from end-item to raw materialsCalculate demandsAllocate supplies

17、i2生產計劃與排程ICP - Inventory Assignment (cont.)Forward 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 Time)Calculates the EPST for each manufacturing taskEach manu

18、facturing task will have an EPSTHard constraint: production cannot be started without materials availablei2生產計劃與排程ICP - Inventory Assignment (cont.)Sub assembly 1R.W. #1R.W. #2ComputerOrder CompletionTimeMaterial AvailableTime (EPST)EPSTEPSTMfg order #1Mfg order #3Mfg order #2Forward ScheduleSub ass

19、embly 2i2生產計劃與排程ICP - Planned Start TimeAssign PST for each taskDefinition: Planned Start Time (PST) is the expected start date that a task will begin taking material availability into considerationCalculation: PST= max (EPST, LPST)Each manufacturing task will have a PSTPST values may be overriden t

20、hrough the user interfacei2生產計劃與排程ICP - Capacity UtilizationDetermine bucket (operation time interval) configuration - from variable capacity bucket size dataCalculate capacity for each bucket - from resource calendar dataCalculate work load in each bucket based on PST and run time of each taski2生產計

21、劃與排程FP Finite Capacity PlanningIdentify the constrained resourcesBalance and offload loads for constrained resources in a GLOBAL view (Global optimization)Plan based on flexible strategy options (e.g. Minimize WIP)Respond quicklyi2生產計劃與排程FP Detail SchedulingSchedule based on flexible strategy option

22、s (e.g. FIFO) Able to specify the scheduling horizonAble to generate a global optimized production scheduleGenerate the dispatch list for executionIntelligent scheduling algorithm and resultsi2生產計劃與排程How to make it successfulUser-own projectTrust and CooperationWhat are our game rules?Forecast/Accep

23、tance, S/O, P/O, etc.Thinking of future, reasonable proceduresData Clean-up Should be started from the very beginningWhere, when, who, how, etc.etc.i2生產計劃與排程Rhythm FP Featuresi2生產計劃與排程List of Some FeaturesTransfer BatchingManufacturing Lot Sizing (CMO)Procurement Lot SizingWIP ReportingAdvanced Scheduler (AS)Due Date QuotingBatch ClientAlternatesAlternate PartsAlternate ResourcesAlternate RoutingECN EffectivityDate effectivityUse-up effectivitySequence-Dependent SetupsR