產能管理 (Capacity Management)

1. 產能管理(Capacity Management)

2. Outline • 生產環境演變與相關管理工具之關係 • 製造環境分類 • 製造規劃及控制系統架構 • 產能管理相關概念 • 粗估產能規劃(RCCP) • 產能需求規劃(CRP) • 投入/產出規劃及控制(I/O Planning & Control) • 作業排程(Operation Sequencing) • 結論

3. Competitive Priority • 1950~1960 • Cost  • 1970~1980 • Quality  • 1990~2000 • Delivery、Flexibility、Service  • Global-wise

4. Competitive Priority 服務、創新、全球化 交期 彈性 品質 世界級製造 零庫存生產系統 成本 及時生產系統 豐田生產系統 大量生產 手工藝時代 1920 1950 1960 1970 1980 1990 2000

5. Planning Evolution MRP MRP II ERP APS 1970 1980 1990 2000

6. MRP-1960’s and 70’s • Material Requirements Planning • Master Production Scheduling • Unconstrained Demand Supply

7. MRP II-1980’s • Unconstrained • Manufacturing Planning and Control, with manual processes to “close the loop” • Capacity Management • Financial Integration

8. 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]

9. The vision of ERP is Evolving to include the Extended Enterprise The Vision The Delivery MRP MRP Reduced inventory through “infinite” manufacturing planning MRP II MRP II Reduced inventory, fewer stock-outs and accurate financial records through “infinite” manufacturing planning and periodic transaction processing. MRP II (plus) ERP Customer focused, dynamically balanced enterprise through asset optimization and real-time transaction processing. Supply Chain Extended ERP Customer focused, dynamically balanced value network through asset optimization and real-time transaction processing. Source Gartner Group

10. 資訊系統之演進 • MRP I -- 1960~1980 • 生產者導向大量生產 • 產品以價格及功能取勝生產成本降低 • 整合：MPS及BOM • MRP II -- 1980~1990 • 消費者導向少樣多量生產 • 產品以多樣化及高品質取勝生產彈性及消除浪廢 • 整合：製造、行銷、財務、人事、專案 • ERP/SCM--1990~ • 消費者導向大量客製化 • 快速反應市場需求 • 跨地區、跨幣別的即時、整合資訊

11. 資訊系統 資料來源: 資策會MIC IT IS計畫

12. 企業應用軟體演變趨勢 EDI (電子資訊交換) E-Commerce (電子商務) E-Business (電子企業環境) ESCM (延伸型供應鏈管理) EERP (延伸型企業資源規畫) SFA (銷售自動化) CRM (客戶關係管理) Planning (計劃) SCM (供應鏈管理) Scheduling (排程) Distribution(配銷) ERP (企業資源規畫) MRP (物料需求規劃) MRP II (製造需求規劃) HR (人力資源) Payroll (薪資系統) FMIS (財務系統) GL (總帳會計) AP (應收帳款系統) AR (應付帳款系統) 1970 1980 1990 2000 資料來源：HP簡報

13. Employee E-business =e-commerce +ERP +SCM +MES/MCS +KM +CRM E-Business Application Architecture Supplier Customer E-Procurement Knowledge Management Customer Relationship Management Supply Chain Management Enterprise Resource Planning Selling Chain Management Manufacturing Execution Manufacturing Control Enterprise Applications Integration

14. 製造環境分類 • 以製造策略分類 • Job Shop (零工型) • Repetitive (重複型) • Batch (批量型) • Flow Shop (流線型) • 以產品定位策略分類 • Engineering-to-order • Make-to-order • Assemble-to-order • Make-to-stock

15. 製造環境 Product Low volume differentiated High volume differentiated Custom Commodity PERT/CPM One-of-a-kind Aerospace Industrial machinery Job shop MRP; CRP Machine tools Specialty chemicalsand drugs MRP; Line Balancing JIT Electrical and electronics Repetitive production AutomobileTire and rubberSteel products Process Major chemicals and drugs Paper Containers Brewers Flowshop OilSteelForest products Source: Taylor et al., hy the Process Industries Are Different,?Production and Inventory Management Journal, 1981.

16. Manufacturing System Model Long-Term Business Planning Demand Management Sales Planning Finance Planning Production Planning Resource Requirements Planning Mid Term MPS Rough-Cut Capacity Planning Inventory Management MRP Capacity Requirements Planning Short-Term Purchasing Production Activity Control Input/Output Control

17. Capacity Management in MPS System Resourcerequirements planning Production planning Rough-cutcapacity planning Masterproductionscheduling Materialrequirementsplanning Capacityrequirements planning Message toBUY or MAKE Input/Output analysis Production activity control Purchasing Operation Sequencing

18. Capacity Planning and Control Planning Control PP MPS MRP Operation Sequencing Priority RRP RCCP CRP Input/Output Control Capacity

19. 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]

20. 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

21. 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]

22. Wight’s Funnel LOAD CAPACITY OUTPUT

23. 工程研發工單 PM 重工工單 計劃工單 已發放工單 Capacity and Load [APICS] Capacity Load 加班及外包 減項 Breaks, Downtime, Rework Absenteeism, Daily, Maintenance, Other (每一作業之Setup 及 run times) 考慮人員, 設施,之 available hours 及 Time Efficiency Rate

24. Capacity Planning Terms Load Hours per resource Available Week

25. Capacity Utilization Scenarios Load Available Available Load Load Available Balanced Underloaded Overloaded

26. 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

27. Breaks 6% 13% R. Maintenance 6% 13% Run Time Un-utilized but 62% scheduled time Setup Time Utilization Actual time used (run and setup) Scheduled time intended for production Utilization = A measure of how intensively a resource is being used….

28. Utilization Example: Breaks: 20 minutes per shift Routine maintenance: 10 minutes per shift Run time charged: 6 hours Setup time: 0.5 hour Utilization =

29. Efficiency • A measure of how closely predetermined standards are achieved. Actual output (standard hours earned) Standard output expected (scheduled) efficiency =

30. Efficiency Example: Work center: 3 machines, two 8-hrs shifts, five days a week Breakdown: 12 hrs per week Utilization = records indicate that the work center produced an average of 250.8 sta. Hours of output. Efficiency = Capacity =

31. Capacity Determination Shift per Day  Machines or Work Stations  Hours per Shift  Days per Week  Utilization  Efficiency = Standard Hours per Week Ex: Shifts = 3 Shift Length = 8 hrs 5 Days per Week Number of Machines = 6 Machine Utilization = .8 Efficiency = .9

32. 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

33. Bill of Resource (Bill of Labor) • 資源清單(BOR; BOL)乃針對製造料件或零件群時，所需之主要關鍵資源的產能需求條列。 • 不是為了作為途程(Routing)用途。 • 只是一種估計特定料項所需產能的方法。

34. 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

35. Routing for Product X PERIODS Product X 1 2 3 4 5 6 7 • 8 Planned Order Released 100 50 80 100 40 60 90 Product X SEQWork CenterUsage OP 1 1 0.1 hrs/pc OP 2 2 0.5 hrs/pc

36. PERIODS Assy-01 1 2 3 4 5 6 7 • 8 Planned Order Released Routing for Assy-01 100 50 80 200 180 40 60 90 Assy-01 SEQWork CenterUsage OP 1 2 0.2 hrs/pc OP 2 3 0.8 hrs/pc

37. Resource Load Profile Work Center 2 250 200 Capacity Others 150 Load Assy-01 100 Pro X 50 0 1 2 3 4 5 6 7 8 Period

38. BOM for FG

39. Item Master Files for FG

40. Routing Files for FG

41. Work Center Master Files

42. MPS for Part 100

43. RCCP-Process Time Computation

44. RCCP-BOR Computation

45. Rough Cut Capacity Requirements

46. RCCP

47. M1 M1 P1 M2 M2 P2 A12 C12 B12 WC1 P1 WC1 B11 A11 C11 WC2 WC2 P2 B21 A21 C21 A22 C22 B22 RCCP BOR MPS RCCP

48. Backward and Forward Scheduling Forward scheduling Order Start Date OP 1 OP N-1 OP N-1 OP N ……… Order Due Date Backward scheduling

49. Infinite and Finite Loading Infinite Capacity Finite Capacity

50. 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]