IntroductiontoRhythmFactoryPlanner（英文）.pptx

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1、Introduction to Rhythm Factory PlannerMay 17,2000AgendaWhat Is Rhythm Factory Planner(FP)Rhythm FP ArchitectureRhythm Factory Planner(FP)Planning ConceptRhythm FP featuresWhat Is Rhythm Factory Planner(FP)?What Is Rhythm Factory Planner(FP)Factory Planner uses the information from the existing trans

2、action system(ERP)to provide intelligent decision support capability in Planning and SchedulingFactory Planner provides a global integrated view PurchasingOrder EntryShippingMRPFactory PlannerFloor ControlDataDecisions&DataWhat Can Rhythm FP Do?Factory Planner provides a systematic and constraint-ba

3、sed 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 processRhythm FP ArchitectureRhythm FP ArchitectureClient-Server ArchitectureBoth server and cl

4、ient processes can run on Windows NT machinesMay run server and client on separate machinesUse existing data(from Triton and SFCS)Memory ResidentMulti-User capabilityRhythm FP Architecture(cont.)Rhythm FP ClientRhythm FP ClientRhythmFP ClientData FilesRhythm FP ServerRhythmFP ServerProduction Planne

5、rMaterialPlannerReport ReaderProduction ServerWhat-ifServerRhythm FP Framework(Input&Output)DemandProduct Structure:Part numberBOMRoutingsFactory Model:ResourcesResource CalendarMaterial Availability:Unassigned InventoryP.O./Vendor Info.WIPOther Information:Tools.Production Plan:CapacityMaterialRhyt

6、hm 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 suggestionBasic FP Data ObjectsBOM dataDemand order dataPart number dataUnassigned inventory dataSupplier part da

7、ta Resource dataRouting dataMore FP Data ObjectsWip dataOperation resource dataResource calendar dataVendor calendar dataVariable capacity bucket size dataFP Output FilesCritical delivery dataPurchase order EDC recommendationsManufacturing order dataPlanned start timesProcurement dataProcurement by

8、part dataetc.FP Data Objects RelationshipDemand Orders&Forecast OrdersBOMUnassignedinventoryRouting dataVendor Info Resource dataResource calendar dataWIP dataFinished GoodsPart NumbersMfg OrdersRhythm FP Planning ConceptFP Planning ConceptBTO(Build-to-order)engine:use Demands as the driver to creat

9、e planConsider both material and capacity constraints at the same timeConsider both Sales Orders and Forecasts as the demand input with different prioritiesStart as an Infinite Capacity Plan and progress to a Finite Capacity PlanFP Planning Concept(cont.)Materials are assigned according to the BOM e

10、xplosion from the finish good levelalso consider Time factorsRaw Materials(Procured Parts)are supplied by on-hand inventory or P.O.from vendors.Manufactured parts(finish goods and intermediate parts)are supplied by WIP or manufacturing orders(work orders).Process Flow in FPInfinite Capacity Planning

11、Finite Capacity PlanningCAO(constraint anchor optimization)Detail SchedulingIdentify Material and Capacity ProblemsFix Material ProblemsAttempt to fix Capacity ProblemsCreate detailed schedulesFP Infinite Capacity Planning(ICP)Build factory model phaseInventory Assignment phasePlanned start time pha

12、seCapacity utilization phasePresents plan through user interface(client)ICP-Build Factory ModelRead files into memory and create resident memory modelFile formats in Spec FilesDo consistency checkingICP-Inventory AssignmentExplore Bill of MaterialsDetermines BOM configuration and routing assignments

13、Creates manufacturing orders to satisfy demandsNet requirements for raw materials and sub-assemblies against on-hand inventory and WIP(Work-In-Process)Creates material requirementsICP-Inventory Assignment(cont.)Backward Schedule Definition:Latest Possible Start Time(LPST)-the latest date a manufactu

14、ring task can begin and still complete on timeLPST=Task Due Date-Task Processing timeCalculates the LPST for each manufacturing taskEach manufacturing task will have a LPSTSoft constraint:violate LPST constraint will deteriorate the order-fulfillment performanceICP-Inventory Assignment(cont.)Backwar

15、d ScheduleSubassembly 1R.W.#1R.W.#2Sub assembly 2Computer Order Due DateTask Due Date(LPST)LPSTLPSTMfg order#1Mfg order#3Mfg order#2ICP-Inventory Assignment(cont.)Inventory AssignmentPrioritize demand orders(due date,priority,quantity)Sort prioritized demand ordersSort parts from end-item to raw mat

16、erialsCalculate demandsAllocate supplies 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 manufac

17、turing taskEach manufacturing task will have an EPSTHard constraint:production cannot be started without materials availableICP-Inventory Assignment(cont.)Sub assembly 1R.W.#1R.W.#2ComputerOrder CompletionTimeMaterial AvailableTime(EPST)EPSTEPSTMfg order#1Mfg order#3Mfg order#2Forward ScheduleSub as

18、sembly 2ICP-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 through the user i

19、nterfaceICP-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 taskFP Finite Capacity PlanningIdentify the

20、 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 quicklyFP Detail SchedulingSchedule based on flexible strategy options(e.g.FIFO)Able to specify the scheduling horizonAble t

21、o generate a global optimized production scheduleGenerate the dispatch list for executionIntelligent scheduling algorithm and resultsHow to make it successfulUser-own projectTrust and CooperationWhat are our game rules?Forecast/Acceptance,S/O,P/O,etc.Thinking of future,reasonable proceduresData Clea

22、n-up Should be started from the very beginningWhere,when,who,how,etc.etc.Rhythm FP FeaturesList of Some FeaturesTransfer BatchingManufacturing Lot Sizing(CMO)Procurement Lot SizingWIP ReportingAdvanced Scheduler(AS)Due Date QuotingBatch ClientAlternatesAlternate PartsAlternate ResourcesAlternate Rou

23、tingECN EffectivityDate effectivityUse-up effectivitySequence-Dependent SetupsResource ModelingUsing Rhythm FPUsing FP-Basic UI entitiesProblem windowsReportsDemand ordersDemand order planMfg orders Mfg order planPart bufferUsing FP-Problem WindowsFP has the outstanding problem analytical capabiliti

24、esShort order problemLate order problemCapacity shortage problemMaterial shortage problemLate manufacturing parts problemUsing FP-Problem Windows(cont.)Using FP-FP reports Critical delivery reportPurchase order EDC reportProcurement reportLate material reservationsMaster scheduleResource loadUsing FP-Demand ordersUsing FP-Demand Order PlanUsing FP-Mfg OrdersUsing FP-Mfg Order PlanUsing FP-Part BufferQuestions&Answers