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Production - distribution planning in supply chain

Production - distribution planning in supply chain. 서울대학교 산업공학과 제조 통합 자동화 연구실 2002/08/16. 발표자 : 정 성 원. Contents. Main Topic Production-distribution planning in supply chain Sub Topic Extended model for a hybrid production planning approach Bokang Kim, Sooyoung Kim

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Production - distribution planning in supply chain

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  1. Production - distribution planning in supply chain 서울대학교 산업공학과 제조 통합 자동화 연구실 2002/08/16 발표자 : 정 성 원

  2. Contents • Main Topic • Production-distribution planning in supply chain • Sub Topic • Extended model for a hybrid production planning approach Bokang Kim, Sooyoung Kim • Production-distribution planning in supply chain considering capacity constraints Young Hae Lee*, Sook Han Kim, computers & industrial engineering • Discussion

  3. Extended model for a hybrid production planning approach Bokang Kim, Sooypung Kim Department of Industrial Engineering POSTECH International journal of production economics 73 (2001)

  4. Machine2 Machine1 Machine3 Introduction • Production Planning • Classical LP Model(Byrne and Bakir. IJPE 1999) Factory Product • 기간별 제품에 대한 수요는 주어짐 • 각 기계들은 용량 제약 조건을 가짐 (Capacity Constraint) (Inventory Balance Equation) 이월 주문량 LP에 의해 나온 생산 계획을 실제 적용 시 문제점이 발생 !! 생산량 재고량 4/25

  5. Two unrealistic parts in constraint(1/2) • Two unrealistic parts in the classical capacity constraint • The whole working hours of the machines can not be utilized • The workload of the production quantity at a machine as calculated above constraint seldom occurs (Capacity Constraint) aik Product 1 : 19 Product 2 : 19 Product 3 : 23 MC 1 PT(1)=5 PT(2)=7 PT(3)=7 MC 2 PT(2)=7 PT(3)=6 MC 3 PT(1)=4 PT(2)=5 PT(3)=10 1 2 3 Machine Break, Buffer Limits MC 4 PT(1)=10 Machine Capacity : 100 5/25

  6. Two unrealistic parts in constraint(2/2) • Two unrealistic parts in the classical capacity constraint • The workload of the production quantity at a machine as calculated above constraint seldom occurs (Capacity Constraint) 150 100 Planning period1 period2 period3 100 50 60 40 Simulation period1 period2 period3 6/25

  7. Proposed approach(1/3) • Using simulation model to assess • How much workload is occurred for each machine in every period by the current production mix and volume • How much of the full capacity is actually consumed by the current plan for each machine in each period • Notation 150 Planning 100 • the proportion of the start quantity released in a period p (p,t ) that contributes to the workload of product i at process j at machine k in period t period1 period2 period3 Simulation 100 50 60 40 period1 period2 period3 Item 1, Process 3, Machine2 7/25

  8. Proposed approach(2/3) • Expanded LP Formulation • The proportion of the total capacity of the machine available to process the start quantities during the period (Byrne and Bakir. IJPE 1999) 8/25

  9. Proposed approach(3/3) • Procedure Initial simulation run Solve LP model and Generate the production plan Run simulation model based Upon the plan No Capacity Feasible? Workload and capacity adjustment In LP Model Yes Optimal production plan found (Byrne and Bakir. IJPE 1999) 9/25

  10. Conclusion • Experiment Model • Result MC 1 PT(1)=5 PT(2)=7 PT(3)=7 MC 2 PT(2)=7 PT(3)=6 MC 3 PT(1)=4 PT(2)=5 PT(3)=10 1 2 3 MC 4 PT(1)=10 Proposed Model Byrne and Bakir Model 6 2 Iteration 196214 198913 Total cost 10/25

  11. Production-distribution planning in supply chain considering capacity constraints Young Hae Lee, Sool Han Kim Department of Industrial Engineering, Hanyang University Computers & industrial engineering 43 (2002)

  12. Problem Statement • Production planning & Distribution planning Shop과 Warehouse에는 각각 용량 제약 조건 존재 Question? 12/25

  13. Proposed approach Solve analytic model and Generate production distribution plans Run simulation model based upon the current production distribution plan Initial production Distribution plan? Obtain current simulation Runtime(CRT) PRT = previous CRT Input IRT as Capacity Input CRT as Capacity Run simulation model Based on the initial Production-distribution plan |PRT-CRT| <0.05 CRT Obtain initial simulation Runtime(IRT) Stop 13/25

  14. Production-distribution planning in supply chain using genetic algorithm

  15. Introduction • What is Production & Distribution Planning ? 1차 납품업체 a 고객 공장a 물류창고 a 고객 1차 납품업체 b 물류창고 b 공장b 고객 고객 1차 납품업체 c 목적 공급사슬 상에서의 MPS 수준의 제품에 대한 생산 및 분배계획 수립 15/25

  16. Some problems in supply chain (1/2) • 채찍 효과 (Bullwhip Effect) • 수요에 대한 분산이 상위단계로 갈수로 커지는 현상 Main factors of bullwhip effect • Errors in demand forecasting • Batch ordering • Price fluctuation • Inflated orders Batch ordering을 하지 않으면?  LFL? 16/25

  17. Some problems in supply chain (2/2) • 생산 용량을 고려하지 않은 분배 계획 비용 관점에서만 국부적으로 분배계획을 수립하면? 17/25

  18. Production Planning • Purpose of Production Planning in supply chain • LFL Production • 잦은 생산 준비 비용 발생(19) • 생산 용량 조건 위반 • Production Planning • 재고 보유를 통한 생산 횟수 감소(9) • 생산 용량 조건 고려 18/25

  19. Distribution Planning • Purpose of Distribution Planning in supply chain DC A DC A Factory A Factory B Factory A Factory B 요구되는 상위 사이트의 수요를 관련된 하위 사이트들에 적절하게 분배한다. 19/25

  20. Production Planning & Distribution Planning (PPDP) Planning in SCM System (SAP APO) Planning in ERP System (SAP R/3) DP SOP Rough Cut Plan/ Infinite Scheduling SNP(PPDP) MPS PP/DS MRP/CRP PPDP는 기존의 ERP시스템에서 MPS 계획을 대신하는 것으로 DP의 정보를 바탕으로 공급 사슬 내의 전체 업체들의 MPS를 생산 용량을 고려하여 계획하는 것이다. 20/25

  21. SNP Module in SAP AOP • SNP Strategies Heuristic CTM Optimizer PPDP 21/25

  22. Product (MPS Level) • 생산 분배 계획에서 고려하는 제품 • 공급 사슬 상에서의 MPS 수준의 제품 (주요 외주 부품, 최종 제품) • 장점 : 최적화 관점에서의 생산계획을 수립하는데 필요한 각종 비용 요소를 구하기 쉽다. • 기존의 BOM을 MPS 수준의 BOM을 변경하고 제품 당 생산에 소요되는 시간을 구해야 한다. 주요 외주 제품 최종 제품 a A Resource3 b B Resource3 c C 22/25

  23. Input Parameter (1/2) • Site • DC • Fixed Cost(입고준비비용) • Inventory Holding Cost(재고유지비용) • Capacity (면적) • Factory/Supplier • Fixed Cost(생산준비비용) • Inventory Holding Cost(재고유지비용) • Production Cost(생산비용) • Capacity (시간) • Network • Fixed Cost(운반준비비용) • Variable Cost(운반비용) S1 S --Resource-- RN : 2 R1 (48000) R2 (48000) --Handling Item-- ITEM002 Capa : 7 FC : 38000 VC : 2200 IC : 60 Resource : R1 ITEM003 Capa : 10 FC : 42000 VC : 2200 IC : 60 Resource : R1 ITEM004 Capa : 6 FC : 30000 VC : 1000 IC : 70 Resource : R2 ITEM005 Capa : 8 FC : 34000 VC : 1000 IC : 80 Resource : R1 Network 3 From : D2 To : C2 ItemNum : (2) --Handling Item-- ITEM1 Transporter : Train Fixed Cost : 4000 Var Cost : 166 Lead Time : 0 Capacity : 1000 ITEM4 Transporter : Plane Fixed Cost : 80000 Var Cost : 3000 Lead Time : 0 Capacity : 300 Transporter : Ship Fixed Cost : 50000 Var Cost : 10 Lead Time : 0 Capacity : 25000 복수의 운송 수단 존재 23/25

  24. Factory A Supplier2 C B Supplier1 BOM for PPDP Input Parameter (2/2) • BOM for PPDP A1 A3 A2 A5 C1 A4 C3 A6 C2 B1 B3 B2 Global BOM in supply chain 24/25

  25. Discussion • Research Topic Set up master data and Supply chain model Demand Plan Method Demand Plan PPDP Algorithm (GA, Lagrangean relaxation) Perform PPDP (MPS) Integration with Simulation Approach Check plan/ Solve problems CTP DPP (MRP + Capacity) (Detail Production Planning) 25/25

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