Advanced Planning and Scheduling in Manufacturing

文件名称: Advanced Planning and Scheduling in Manufacturing and Supply Chains

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详细说明：This book is a guide to modern production planning methods based on new scientific achievements and various practical planning rules of thumb. Various batch computation methods are described in detail, while production planning is considered on several levels, including supply planningf or customersYuri auergauz Sophus Group Moscow Russia Additionalmaterialtothisbookcanbedownloadedfromhttp://extrasspringer.com ISBN978-3-319-27521-5 ISBN978-3-31927523-9( e Book) DOI10.10079783-319-27523-9 Library of Congress Control Number: 2016933485 C Springer International Publishing Switzerland 2012, 2016 This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, express or implied, with respect to the material contained herein or for any errors or omissions that may have been made Printed on acid-free paper This Springer imprint is published by Springer Nature The registered company is Springer International Publishing AG Switzerland copyrighted material Contents Part I Modeling 1 Reference model 1.1 Modelling of business process 1.2 Concept of Reference Model 1. 2. 1 Reference Models in Supply Chains 1. 2.2 Reference Modelling Methodology 335679 1.3 Production Description 1.3.1 Basic Types of Production 1.3.2 Production Scale and Strategy.......... 13 1. 4 Advanced planning in IT Systems 15 1. 4.1 Planning in IT Systems 1. 4.2 Popularity and Effects of Advanced Planning....... 19 1. 5 IT System Interaction Standards 21 1.6 Quality Parameters in Supply Chains.......... 24 1.6.1 Markets and Their Main properties 5 1.6.2 Quality Parameters and Different Supply Chain Levels.,,,,,,,,,,,,,,,,,,,,,,,,,,,, 26 1.6.3 Balanced Scorecard 28 1.7 Utility of Quality Parameters 31 1.7.1 Concept of Utility 31 1.7.2 Typical Utility Functions 34 1.7.3 Utility Functions in Business Process Quality Evaluations 37 References,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 42 2 Mathematical models 43 Simplest Planning Models 43 2.1.1 Classical Supply management model 43 2. 1.2 Continuous Linear Optimization model 45 2. 2 Correlations between mathematical and Reference models 52 2.2.1 Main Criteria and Constraints..,....... 52 2.2.2 Standard Classification of Planning optimization Models 53 copyrighted material Contents 2.2.3 Production Scale and Plan Hierarchy in Classification.. 55 3 Priority rules...... 58 2.3.1 Simple Rules 58 2.3.2 Some Useful Theorems 62 2.3.3 Combined Priority rules........... 62 2. 4 Production Intensity and utility of Orders 64 2.4.1 Production Intensity 65 2.4.2 Dynamic Utility Function of Orders 70 2.5 More Complex Models of Linear Optimization 74 2.5.1 Integer Linear Optimization model 74 2.5.2 Integer Linear Optimization Models with Binary Ⅴ ariables, 75 2.6 Fixed Job Sequence Models 78 2.6.1 Branch-and-Bound Method with minimum Cumulative Tardiness t 79 2.6.2 Branch-and-Bound Method with Maximum average Utility v 81 References..,,,,,,,,,,,,,,,,,,,,, 87 3 Production Bottlenecks models 89 3.1 Theory of Constraints 89 3.1.1 Fundamentals of Theory of Constraints 89 3.1.2 Bottleneck Operation Planning......... 92 3.1.3 Planning for Buffers, Ropes, and Non-bottleneck Machin 95 3.1.4 Simple Example of Theory of Constraints in appl Ication 7 3.1.5 Theory of Constraints in Process Manufacturing 98 3.1.6 Review of Toc applications 3.2 Theory of Logistic Operating Curves 10l 3.2.1 Production Logistics)Variables 101 3.2.2 Some Notions Used in Queuing Theory...... 105 3.2.3 Plotting Logistic Operating Curves 107 3.2.4 Main Properties of Logistic Curves 110 3.3 Application of Logistic Operating Curves .110 3.3.1 logistic Positioning..... 110 3.3.2 Bottleneck Analysis and Improvements............ 111 3.3.3 Evaluation of Overall Production performance,,,,, 112 3.4 Optimal Lot Sizing for Production Bottlenecks....... 116 3.4.1 Lot Sizing Heuristic 116 3.4.2 Analysis of Heuristic Solutions 119 3.5 Hierarchical Approach to Machinery Load Management... 122 3.5.1 Principles of Workload Control Concept 123 3.5.2 Example of Application of Controlled Load Approach.. 124 R eferences 126 copyrighted material Contents 4 Multi-criteria Models and Decision-Making .127 4.1 Basic Concepts in Multi-criteria Optimization Theory 127 4. 1.1 Definition of Multi-criteria Optimization problems 127 4.1.2 Pareto Optimality 130 4.1.3 Main Methods of Solving Multi-criteria Planning Problems 132 4.1.4 Analytical Method of Constructing a Trade-Off Curve.. 136 4.2 Optimized Multi-criteria Lot Sizing 138 4.2.1 Lot Sizing Based on Costs and Equipment 138 4.2.2 Analytical Lot Sizing with Two Criteria: Setup Time and Cost 140 4.3 Example of Multi-scheduling Problem.......... 143 4.3.1 Special e-Neighbourhood of Efficiency Points.... 144 4.3.2 Solving Algorithm 145 4.4 Methods of Decision-Making Theory in Planning Problems... 150 4.4.1 Some Information from the Decision Making Theory.. 150 4.4.2 Example of the Planning Problem Requiring Decision Makin g 153 4.4.3 Decision-Making based on the guaranteed result Principle...........,.....................156 4.4.4 Optimistic Decision-Making 157 4.5 Applications of Complex Decision-Making Methods .158 4.5.1 Hurwitz Principle 158 4.5.2 Savage Principle ..159 4.5.3 Shifted ideal method..,,,,,,,,,,,,,,,,,,,,,.160 References 162 5 Data for Planning 163 5.1.1 Archives of Design-Engineering Documentation anld . 163 5.1 Composition of the Data Used for Planning Orders .,,,,163 5.1.2 Reference Data and Standards 167 5.1.3 Databases of Transactional IT Systems 169 5.1.4 Decision Support Databases.......... 170 5.1.5 Knowledge bases .,171 5.2 Data Storage and management .174 5.2.1 Relational Databases ,,,,,,,,174 5.2.2 Concept of Object-Oriented Databases 176 5.2.3 Database management systems 177 5.2.4 Tiered Data Storage 178 5.2.5 Distributed databases.,,,,,,,,,,,,,,,.,,,,,,.179 5.2.6 Service Oriented Architecture of IT Systems l81 5.2.7 On-Line Analytical Processing.......... 183 5.3 Information Exchange 186 Contents 5.3.1 Internal Data Communication 186 5.3.2 Data Transfer Between Enterprises........ 187 5.3.3 Information Exchange in Different Types of Cooperation..... 189 5.3.4 Information Exchange Automation........ 191 5.3.5 USe of Cloud Environment 194 References..,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,,,,,.196 Demand Forecasting....,,,,,,,,,,,…,.,,,…,.199 6. 1 Demand Modelling Based on Time Series Analysis...... 199 6.2 Main Methods of Forecasting............. 201 6.2.1 Moving average method,.,......... 201 6.2.2 Exponentially Smoothing Forecasting 203 6.2.3 Trend Adjusted Exponential smoothing......... 204 6.2.4 Trend and Seasonality Adjusted Exponential Smoothing 206 6.3 Demand aggregation 208 6.4 Aggregated Demand Forecasting............ 210 References 214 7 Examples of Advanced Planning Models........... 215 7.1 Joint Operation Model of APs System and erP System from sap r乃3.....,,,,,,,,.......,,....215 7. 1.1 Main Business process attributes in various Industries,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 216 7. 1.2 Software Modules for Planning solutions.......... 218 7. 1.3 Planning modules interaction 219 7.2 Reference Model of Production Planning for Instrument Engineering plant....,.. 221 7.2.1 Initial Planning Status Analysis......... 221 7. 2.2 Decision Support Database....... 223 7.3 Mathematical Model in Chemical Industry 226 7.3.1 Analytical Structure of Model.......... 226 7.3.2 Objective Function and Constraints 229 7.3.3 Some Results of Modelling........... 233 7.4 Rapid Supply Chain Reference Model in Clothing Industry.. 234 7.5 Schedule Model for a Machine Shop 237 7. 5. 1 Schedule model with Specified Processing stages... 238 7.5.2 Optimality Criteria and Constraints 239 7.6 Multi-stage Logistics Chain Model .,,241 7.6.1 Some Notions in Logistics Chain Modelling 241 7.6.2 Dynamic Logistics Chain Optimization Model in Multi-stage Production ...241 References 24 Contents Part II Planning Processes 8 Single-Echelon Inventory Planning......... 247 8.1 Inventory Types and Parameters............ 247 8.2 Inventory Management Models....... 248 8.2.1 Model with Fixed Quantity of Order 249 8.2.2 Model with Fixed Reorder Cycle 250 8.2.3 Two-Tier Inventory Management Model ...251 8.2. 4 Benchmarking of Inventory management Models.... 253 8.2.5 Kanban Inventory Management Model 254 8.3 Inventory Management Model Under Uncertainty.......... 256 8.3.1 Customer service level 256 8.3.2 Shortages Permitted Inventory Management Model.. 257 8.3.3 Demand Distribution Functions.,,.,..,..,. 258 8.3. 4 Newsvendor Problem .260 8.4 Inventory Management Using Logistic Operating Curves 262 8.4.1 Storage Curves and Their Applications............ 262 8.4.2 Finished Product Inventory Sizing to Optimize the Overall Production Performance,,.,........ 264 8.5 Safety Stock Sizing 265 8.5.1 Calculation of Safety Stock with Random demand 266 8.5.2 Sizing of Safety Stock with Two Random Variables... 267 8.5.3 Sizing of Safety Stock with Three random variables.. 269 References 270 9 Supply Chain Inventory Dynamics 273 9.1 Stock distribution planning in the chain 273 9.1.1 DRP Technique 273 9.1.2 Regular Maintenance of DRP Tables 276 9.1.3 Parallel Multi-product Planning......... 278 9. 1. 4 Inventory dynamics at Long Lead cycles 279 9.2 Supply Chain Fluctuations 281 9.2.1 Bullwhip effect............... 281 9.2.2 Bullwhip Effect Factors 284 9.2.3 Methods of Reducing Supply Chain Fluctuations... 286 9.3 Application of Logistics Operating Curves in Supply Chains.. 289 9.4 Inventory Echelon Accounting 292 9.4.1 Inventory Echeloning............. 292 9.4.2 Sequential Supply Chain 293 9.4.3 Supply Chain with Distribution 297 9.4.4 Dependency between Echelon Stock and Number of Links of One Level in the Supply Chain .299 9.5 Inventory Planning in Spare Parts Supply Chains...... 300 9.5.1 METRIC Method in Spare Parts Supplies 301 Contents 9.5.2 Inventory Planning for Central Spare Parts Storage Usin (R, Q)Model 96 Coordinated Planning Between Two Supply cnat∴· 305 Members 308 References 311 10 Planning of Supplies to Consumers............. 313 10.1 Sales and Operation Planning 313 10.1.1 Interrelation Between Various planning directions with Sales and Operations Plan... .313 10.1.2 Sales and Operation planning methods 315 10.2 Sales and Operation Plan Optimization Using Linear Programming 318 10.2.1 Single Aggregated Product Group Optimization.... 319 10.2.2 More Complex Case of Optimization of Sales and Operations plan.......................322 10.3 Customized Reservation of Products 326 10.3. 1 Business Process of Response to New Orders...... 326 10.3.2 Arrangement of Orders 327 10.3.3 Running atP Process 329 10.4 Agreement of Order Specifications with Customers......... 331 10.4.1 Problem Criteria and Their evaluation 331 10.4.2 Selection of Ordered Product Analogues 332 References 338 11 Lot sizing 339 11.1 Classification of Lot-Sizing Problems 339 I1. 1. 1 Lot Properties and main problems.......... 339 11.1.2 Lot-Sizing Problems with No Capacity Limits.... 341 11.1.3 Lot-Sizing Problems with Limited Capacities and Large Planning periods 342 11.1.4 Lot-Sizing Problems with Limited Capacities and Small Planning Periods..,....,.,...,,,,....343 1.2 Constant Demand Lot-Sizing Problems 344 11. 2.1 Models with Gradual Inventory Replenishment.... 345 11.2.2 Model Applicable to the Machinery Industry If No Cost Information Is available ,,347 1 1.2.3 Three-Parameter Models for Machinery Industry 349 11.2. 4 Lot Sizing at Discounted Prices 351 11.3 Lot Sizing at Variable Demand and Limited Planning Horizon 352 11.3.1 Exact Solution 353 11.3.2 Heuristic Silver-Meal algorithm 356 11.3.3 Part Period Balancing 359 11. 3. 4 Groffs heuristic Rule 360 copyrighted material Contents XIX 11.3.5 Period Order Quantity 362 11.4 Lot Sizing with Constraints ,.363 5 Multi-product Deliveries and Orders 366 11. 5.1 Optimal Multi-product Lot Sizing 366 11.5.2 Multi-product Deliveries over Multiple Periods 368 11.5.3 Power-of-Two Policies for Multi-product Deliveries 370 References 371 12 Production planning 373 12.1 Master Production Planning 373 12. 1. 1 Master Planning as Product tables 374 12.1.2 Group Master Planning 379 12.1.3 Master Production Plan Optimization........ 381 12.2 Material Requirement Planning 383 12.2.1 Production Lot duration 384 12.2.2 Optimal Production Lot Sizing 386 12.2.3 Analysis of the Material Requirement plan .390 12.3 Project- Based planning......…..…..4……....391 12.3.1 Critical Path Method .391 12.3.2 Cost Optimization at Various Project Stages.... 394 12.4 Stability of Planning..... 398 12.4.1 Quantitative Evaluation of Planning Stability go 12.4.2 Methods of Planning Stability Improvement..... 401 References 404 13 Shop Floor Scheduling: Single-Stage Problems 405 13.1 Single-Machine Scheduling with Minimized Overdue Penalties 405 13. 1. 1 Schedule with the Minimum of Delayed Jobs 406 13.1.2 Scheduling with minimum Weighted Tardiness per Each Job... ..406 13.1.3 Schedule Optimization with Earliness/Tardiness.....409 13.2 Common Shipment Date Scheduling 410 13.2.1 Fixed Date Schedule Optimization............ 410 13. 2.2 More Complex Cases of Scheduling with Fixed Date.. 412 13.2.3 Selection of Optimal Midpoint Date for Shipping 413 13.3 Some Other Scheduling Problems for Jobs with Fixed Processing Ti Ime 415 13.3.1 Schedules for the Case of several Jobs the part of which has the Preset Sequence ,.415 13.3.2 Scheduling of Jobs with Different Arrival Time...... 417 13.3.3 Scheduling of Jobs with Different Arrival Time and Different Shipment Time 418 13.3.4 Job Sequence-Based Setup Time scheduling...... 419 copyrighted material

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