Mô tả:
Sustainable Manufacturing and Factory
Planning
Production Planning and Control (PPC ) I
12.04.2017
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
© IWF TU Berlin
Page 1
Table of Contents
Introduction
Production Systems
Tasks and Dilemma of PPC
Solution Approaches for PPC
Literature and References
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 2
Introduction
Flow of material and information in PPC
Purchase
Orders
Production Planning and
Control (PPC)
Customer
Orders
Production Order /
Job
Customer
Supplier
Raw Material, Semi-finished
Products, Assemblies, Components
Products
Production
System
Material Flow
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Information
Flow
Page 3
Introduction
Complex Framework for PPC
Different areas of a company with
different goals influence the PPC
purchase
Many objectives have to be
considered
assembly
controlling
PPC
human
resource
management
manufacturing
marketing
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 4
Introduction
Planning Levels for PPC – objective-related
The network can be interpreted as
Planning Levels
Network
production units linked by material and
information flows along the supply chain
A factory in the PPC case describes a
production unit with more than one
product segment and serves as a node of a
supply chain network
Factory
Departments are segments in which whole
products are typically produced ready to
ship
Departments
A system in the PPC case is understood as a
System
group of more or less automatically
interlinked cells.
Cell
Often several resources are arranged into
cells that typically perform most of the
necessary operations to finish a work piece
or an assembly including quality assurance
Workstation
Process
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
E.g. Milling
The main concern on the level above the
processes is about the single workstations
and their value adding operations including
work piece and tool handling
Source: [Wei-10], [Wie-07], [Wie-09] Page 5
Introduction
Main components of PPC
Planning
Production program planning
Which product? When? Where?
Quantity planning
How many?
Time scheduling
When? How long? During which
time? Which delivery date?
Capacity planning
Where? Which machine
tool/equipment?
Often centralized
responsibility by a
planning
department
Control
Often decentralized
responsibility by
the staff on site
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Order release
Sequence planning
Progress control
Page 6
Y-cim-model
business process chain
technical process chain
planning level
Production Program
Planning
Product Draft
Material Requirement
Planning
Work Planning
Order Release
Production Control
manufacturing level
CAD
Product Design
Capacity Requirements
Planning
Shop Floor Control
Control of NC-,CNC-, DNC-,
machines
Production Data Aquisition
Control of transportation
systems
Target-Actual Comparision
(quantities, times, costs)
CAE
CAP
CAM
Control of robots and assembly
PPC
Quality Control
CAQ
CAE
Y-cim-model
CIM
Computer integrated
manufacturing
CAE
Computer aided
engineering
CAD
Computer aided design
CAP
Computer aided
planning
CAM
Computer aided
manufacturing
Computer aided quality
CAQ
PPC
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Production planning and
control
Source: [Sch-97] Page 7
Introduction
Functions of PPC
Production planning and control determines
When to make available work orders, the required material, consumables, equipment and
manpower
How to realize the allocation of work in time to the different work groups and workplaces
How to utilize limited resources effectively
How to manage the material flow through these resources
Which product to which amount and in which period should be produced
Manpower
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Time
Material
www.hsteel.cn
Equipment
www.cnet.de
www.dmg.de
How to deal with rework and rejection of course to be avoided by all means
manpower
Page 8
Introduction
Inventory Strategies for PPC
Supplier
Customer
make-to-stock
production
assembly-toorder
make-to-order
production
customized nonrepetitive
production
Source
Manufacturing
Assembly
Deliver
Strategy
Value Creation
Customized
Storage point
Customer decoupling point
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Source: [Löd-13] Page 9
Introduction
Objectives of PPC I
Costs
Quality
make-to-order-production:
delivery time
delivery date deviation
delivery reliability
Flexibility
Production Cost &
Logistic Costs/
Flexibility
price
make-to-stock-production:
service level
Internal
External
Production Performance &
Logistic Performance
Time
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
throughput time
due date deviation
due date reliability
inventory
utilization
cost of delays
Source: [Löd-13]Page 10
Introduction
Objectives of PPC I
Costs
Quality
Time
Flexibility
Low costs
Reducing costs in supporting processes of administration
Reducing costs in the value creation process (material, staff, product,
process, equipment)
Reducing inventory in stocks and shop floor
High quality
In products, equipment, decisions and high precision in planning
Short time
Decreased processing-, throughput-, waiting-, transport-, and delivery
time in the material flow, high delivery reliability
Meet due dates
High flexibility
Resource utilization
Reacting on unforeseen events
High availability (material, machine, staff) and high service level
orientation
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 11
Table of Contents
Introduction
Production Systems
Tasks and Dilemma of PPC
Solution Approaches for PPC
Literature and References
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 12
Production Systems
Toyota Production System
Toyota Production System (1980s) - TPS
Toyota Production System
Just in time
Autonomation
Flexible production
Total quality control
Elimination of waste
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Source: [Ohn-88]
Page 13
Production Systems
Lean Production System – Ganzheitliches Produktionssystem I
Lean Production System – Ganzheitliches Produktionssystem (State of the Art)
Objectives
Improve quality
Sustained process mastery
in manufacturing
Value Creation
Processes
Principles
Methods and
Tools
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Manufacturing process including
selected process steps
Zero defects principle
Method: Statistical process
control
Tool: Quality control card
Source: [VDI-2870]
Page 14
Production Systems
Lean Production System – Ganzheitliches Produktionssystem II
Lean Production System – Ganzheitliches Produktionssystem (State of the Art)
Principles
Standardization
Zero defects principle
Flow principle
Pull principle
Continuous improvements process
Employee orientation and management by objectives
Avoidance of waste
Visual management
VDI 2870 provides a detailed overview
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Source: [VDI-2870]
Page 15
Production System
Example: Methods-Catalogue of “Siemens Production System”
Action area
Lean production &
Value stream
improvement
Reliable & Zero defect
processes
Method
Reduction of setup time
Lean manufacturing
Total productive
maintenance
Value stream analysis /
design
Poka yoke
Six sigma tools
FMEA
Action area
Method
Organization and tidiness
as discipline
5S Methodology
(sort, set in order, sweep clean,
standardize, sustain)
Proactive change
management &
communication
Lean-thinking training
Consumption driven
Production
Pull-principle
Production leveling
Systemic target
agreements
Target agreement process
Transparency
Visualization in the work
environment
Continuous
improvement of value
adding
Continuous improvement
workshop
Overall lean administration
Lean manufacturing support
FMEA: Failure Mode and Effects Analysis
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Source: siemens.com
Page 16
Example: 5S Methodology
sort
set in order
sweep clean
standardize
sustain
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 17
Production System
Example: Lean Production System – KPI Chart
OEE: Overall Equipment Effectiveness
NRFT: Not right first time
KPI: Key Performance Indicator
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Source: [VDI-2870]
Page 18
Table of Contents
Introduction
Production Systems
Tasks and Dilemma of PPC
Solution Approaches for PPC
Literature and References
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 19
Strategic Planning Level
Demand Planning
Demand
Planning
Determination
according to origin
and product level
Determination with
consideration of
stock
Primary
demand:
Dependent
demand:
Tertiary
demand:
Gross
demand:
Net
demand:
Demand of
salable products
Demand of raw
materials, parts,
components for
assembly of
primary demand
Demand of
operating supply
items
Period-oriented
primary,
dependent or
tertiary demand
Gross demand
minus available
stock
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Source: [Pfo-10]
Page 20
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