《制程规划的意义》PPT课件.ppt
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1、製程規劃的意義製程規劃的意義l l指企業在其有限的內部資源及外在因素等指企業在其有限的內部資源及外在因素等限制條件限制條件下,從事下,從事生產過程的規劃生產過程的規劃,規劃,規劃出適合自己公司的出適合自己公司的製程技術及製程系統製程技術及製程系統,俾達到以最低的俾達到以最低的成本成本及最有及最有效率效率的方法的方法/技技術來生產出令術來生產出令顧客滿意顧客滿意的產品的產品/服務之品質。服務之品質。1 1製程規劃製程規劃製程選擇與系統設計製程選擇與系統設計 預測預測產品與產品與服務設計服務設計產能規劃產能規劃設施與設備設施與設備佈置佈置工作設計工作設計 製程製程 選擇選擇技術變動技術變動2 2製
2、程規劃製程規劃主要的製程決策主要的製程決策l l製程選擇製程選擇(process choice)l l垂直整合垂直整合(vertical integration)l l由廠商自己的生產系統或服務設備,操縱處理由廠商自己的生產系統或服務設備,操縱處理由廠商自己的生產系統或服務設備,操縱處理由廠商自己的生產系統或服務設備,操縱處理整個供應鏈的程度。整個供應鏈的程度。整個供應鏈的程度。整個供應鏈的程度。l l資源彈性資源彈性(resource flexibility)l l指員工和設備在處理多樣化產品、產出水準、指員工和設備在處理多樣化產品、產出水準、指員工和設備在處理多樣化產品、產出水準、指員工和
3、設備在處理多樣化產品、產出水準、職責和功能的能力。職責和功能的能力。職責和功能的能力。職責和功能的能力。l l顧客參與顧客參與(customer involvement)l l資本密集程度資本密集程度(capital intensity)3 3製程規劃製程規劃Processes at manufacturing organizationsHighLowVolumeCustomizationHighLowProject processSelecting location for new plant in EuropeInstalling ERP for a manufacturing firms
4、 business processesJob processMachining precision metal tubesInternal consulting team at manufacturing firmBatch processForging process to make fittings for pressure vessels accessProducing a batch of textbooks at R.R.Donnelleys plantLine processAuto assemblyKing Soopers bread lineContinuous process
5、Oil refining processBordens pasta making process4 4製程規劃製程規劃Processes at service providersHighLowVolumeCustomizationHighLowProject processReal estate process for leasing and constructing facilities for large insurance companyStudent teams field projectJob processCustomer service process at financial
6、services firmGeneral medical practiceBatch processOrder fulfillment process of importer/distributorPlacing purchase orders at public relations agencyLine processCafeteria lineTeller line at bankContinuous processPower generation plantProviding telephone line access5 5製程規劃製程規劃PROJECT PROJECT BATCHBAT
7、CHMASS MASS CONTINUOUSCONTINUOUSProductProduct UniqueUniqueMade to order Made to order Made to stock Made to stock CommodityCommodityCustomerCustomerOne-at-a-timeOne-at-a-timeFew individualsFew individualsMass marketMass marketMass marketMass marketDemandDemandInfrequentInfrequentFluctuatesFluctuate
8、sStableStableVery stableVery stableVolumeVolumeVery lowVery lowLow to medLow to medHighHighVery highVery highNo.of differentNo.of differentInfiniteInfiniteMany,variedMany,variedFewFewVery lowVery low products productsProductionProductionLong-termLong-termDiscrete,jobDiscrete,jobRepetitive,Repetitive
9、,Process industryProcess industry System System Project Projectassembly linesassembly linesEquipmentEquipmentVariedVariedGeneral-purposeGeneral-purposeSpecial-purposeSpecial-purposeHighly automatedHighly automatedType of workType of workContractsContractsFabricationFabricationAssemblyAssemblyMix,tre
10、at,refineMix,treat,refineSkillsSkillsExperts,Experts,Wide rangeWide rangeLimited rangeLimited rangeEquipmentEquipmentcraftspeoplecraftspeopleof skillsof skillsof skillsof skillsmonitorsmonitorsAdvantagesAdvantagesCustom work,Custom work,Flexibility,Flexibility,Efficiency,Efficiency,Highly efficientH
11、ighly efficienttechnologytechnologyqualityqualityspeed,low costspeed,low costlarge capacitylarge capacityDis-Dis-Nonrepetitive,Nonrepetitive,Costly,slow,Costly,slow,Capital investment,Capital investment,Difficult toDifficult to advantagesadvantagessmall customersmall customerdifficult todifficult to
12、lack of lack of changechangebase,expensivebase,expensivemanagemanageresponsivenessresponsivenessExampleExampleConstruction,Construction,Machine shops,Machine shops,Autos,TVs,Autos,TVs,Paint,chemicals,Paint,chemicals,shipbuildingshipbuildingprinting,bakeryprinting,bakeryfast foodfast foodfoodfoodType
13、s of Processes6 6製程規劃製程規劃垂直整合的優點垂直整合的優點l l規模經濟規模經濟l l品質較能掌控品質較能掌控l l有效利用人力資源設備和空間有效利用人力資源設備和空間l l提高生產效率提高生產效率l l適合市場需求量大之公司適合市場需求量大之公司7 7製程規劃製程規劃資源彈性資源彈性l l彈性勞動力彈性勞動力(flexible work force)l l能兼具原本及不同工作崗位之工作量和能力之能兼具原本及不同工作崗位之工作量和能力之能兼具原本及不同工作崗位之工作量和能力之能兼具原本及不同工作崗位之工作量和能力之員工。員工。員工。員工。l l專用設備專用設備 vs.泛用設
14、備泛用設備8 8製程規劃製程規劃顧客參與顧客參與l l自助式服務自助式服務(self-service)l l產品選擇產品選擇(買房子買房子)l l客製化程度客製化程度客製化程度客製化程度l l時間和地點時間和地點l l由顧客決定服務的時間和地點由顧客決定服務的時間和地點由顧客決定服務的時間和地點由顧客決定服務的時間和地點9 9製程規劃製程規劃資本密集程度資本密集程度l l自動化自動化 vs.人工作業人工作業l l自動化的優點自動化的優點l l提高生產力提高生產力提高生產力提高生產力l l改良品質改良品質改良品質改良品質l l缺點缺點l l不適合低產出量之作業,其所需投資成本非常不適合低產出量之
15、作業,其所需投資成本非常不適合低產出量之作業,其所需投資成本非常不適合低產出量之作業,其所需投資成本非常龐大。龐大。龐大。龐大。1010製程規劃製程規劃產出量與製程產出量與製程決策之關聯性決策之關聯性製造業製造業HighLowVolumeLess vertical integrationMore resource flexibilityMore customer involvementLess capital intensity/automationMore vertical integrationLess resource flexibilityLess customer involveme
16、ntMore capital intensity/automationLow volume,make-to-order processHigh volume,make-to-stock processProject processSelecting location for new plant in EuropeInstalling ERP for a manufacturing firms business processesJob processMachining precision metal tubesInternal consulting team at manufacturing
17、firmBatch processForging process to make fittings for pressure vessels accessProducing a batch of textbooks at R.R.Donnelleys plantLine processAuto assemblyKing Soopers bread lineContinuous processOil refining processBordens pasta making processProcess design choices1111製程規劃製程規劃Process design choice
18、sLess vertical integrationMore resource flexibilityMore customer involvementLess capital intensity/automationMore vertical integrationLess resource flexibilityLess customer involvementMore capital intensity/automationLow volume,customized-service processHigh volume,standardized-service processHighLo
19、wVolumeProject processReal estate process for leasing and constructing facilities for large insurance companyStudent teams field projectJob processCustomer service process at financial services firmGeneral medical practiceBatch processOrder fulfillment process of importer/distributorPlacing purchase
20、 orders at public relations agencyLine processCafeteria lineTeller line at bankContinuous processPower generation plantProviding telephone line access產出量與製程產出量與製程決策之關聯性決策之關聯性服務業服務業1212製程規劃製程規劃案例l lMaxwell vs.Coffee shop1313製程規劃製程規劃Process Selection with Break-Even Analysisc cf f=fixed cost=fixed cos
21、tv v=volume(i.e.,number of units produced and sold)=volume(i.e.,number of units produced and sold)c cv v=variable cost per unit=variable cost per unitp p=price per unit=price per unitTotal costTotal cost=fixed cost+total variable cost=fixed cost+total variable costTCTC=c cf f+vcvcv vTotal revenueTot
22、al revenue=volume x pricevolume x priceTRTR=vpvpProfitProfit=total revenue-total cost=total revenue-total costZ Z=TR-TCTR-TC=vpvp-(-(c cf f+vcvcv v)1414製程規劃製程規劃Solving for Break-Even VolumeTRTR=TC=TCvpvp=c cf f+vcvcv vvpvp-vcvcv v=c cf fv v(p-cp-cv v)=c cf fv v=c cf fp p-c cv v1515製程規劃製程規劃Break-Even
23、 AnalysisTotal cost lineTotal revenue lineBreak-even pointUnits$3,000$2,000$1,000 1616製程規劃製程規劃製程設計之考慮問題l l木製椅 vs.台灣涼椅 vs.藤椅l l年需求120 vs.年需求12000l l汽車製造廠是否需自製輪胎、座椅、燈具?l l點焊採用機械臂或半自動化?1717製程規劃製程規劃製程設計應考慮之因素製程設計應考慮之因素l l物料規格分析物料規格分析l l產品分析產品分析l l自製或外購分析自製或外購分析 l l製程技術的選擇製程技術的選擇l l設備選擇設備選擇l l製程規劃與分析製程規劃
24、與分析l l設備佈置規劃設備佈置規劃l l成本因素分析成本因素分析1818製程規劃製程規劃物料規格分析物料規格分析l l物料之類別物料之類別物料之類別物料之類別(type)type)l l物料之型式物料之型式物料之型式物料之型式(form)form)l l尺寸尺寸尺寸尺寸、形狀、形狀、形狀、形狀l l物料之物理物料之物理物料之物理物料之物理/化學特性化學特性化學特性化學特性l l所產所產所產所產生生生生的廢料及下腳料的廢料及下腳料的廢料及下腳料的廢料及下腳料(可利用度可利用度可利用度可利用度)l l物料成本物料成本物料成本物料成本l l物料來源物料來源物料來源物料來源l l搬運之難易程度搬運之
25、難易程度搬運之難易程度搬運之難易程度l l存貨之預估存貨之預估存貨之預估存貨之預估l l收料方式收料方式收料方式收料方式1919製程規劃製程規劃產品分析產品分析l l總產銷量總產銷量總產銷量總產銷量l l 生產率生產率生產率生產率l l投入生產所需時間投入生產所需時間投入生產所需時間投入生產所需時間l l生產方法生產方法生產方法生產方法l l連續連續連續連續l l間斷間斷間斷間斷l l批次批次批次批次l l壽命期望值壽命期望值壽命期望值壽命期望值l l改變之可能性改變之可能性改變之可能性改變之可能性l l使用機能使用機能使用機能使用機能l l消費者需求分析消費者需求分析消費者需求分析消費者需求
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