Manufacturing planning and control systems:
Saved in:
| Main Authors: | , , |
|---|---|
| Format: | Book |
| Language: | English |
| Published: |
Homewood, Ill. u.a.
Irwin
1992
|
| Edition: | 3. ed. |
| Subjects: | |
| Online Access: | Inhaltsverzeichnis |
| Physical Description: | XX, 844 S. graph. Darst. |
| ISBN: | 025608808X 1556236085 |
Staff View
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| 100 | 1 | |a Vollmann, Thomas E. |e Verfasser |4 aut | |
| 245 | 1 | 0 | |a Manufacturing planning and control systems |c Thomas E. Vollmann ; William L. Berry ; D. Clay Whybark |
| 250 | |a 3. ed. | ||
| 264 | 1 | |a Homewood, Ill. u.a. |b Irwin |c 1992 | |
| 300 | |a XX, 844 S. |b graph. Darst. | ||
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| adam_text | Contents
CHAPTER 1 Manufacturing Planning
and Control i
THE MPC SYSTEM DEFINED 2
Typical MPC Support Tasks 2
Costs and Benefits of MPC Systems 2
AN MPC SYSTEM FRAMEWORK 4
MPC System Activities 4
The System and the Framework 4
Matching the MPC System with the
Needs of the Firm 7
An MPC Classification Schema 7
EVOLUTION OF THE MPC SYSTEM 9
The Changing Competitive World 9
Reacting to the Changes 10
CONCLUDING PRINCIPLES 11
CHAPTER 2 Material Requirements
Planning 14
MATERIAL REQUIREMENTS PLANNING
IN MANUFACTURING PLANNING
AND CONTROL 15
MRP and MRPII 17
RECORD PROCESSING 18
The Basic MRP Record 18
Linking the MRP Records 26
TECHNICAL ISSUES 30
Processing Frequency 30
Bucketless Systems 31
Lot Sizing 32
Safety Stock and Safety Lead
Time 33
Low-Level Coding 34
Pegging 34
Firm Planned Orders 35
Service Parts 35
Planning Horizon 36
Scheduled Receipts versus Planned
Order Releases 36
USING THE MRP SYSTEM 37
The MRP Planner 37
Exception Codes 39
Bottom-Up Replanning 40
An MRP System Output 41
SYSTEM DYNAMICS 43
Transactions during a Period 43
Rescheduling 44
Complex Transaction Processing 45
Procedural Inadequacies 45
THE MRP DATA BASE 48
The Item Master File 48
The Subordinate Item Master File 48
The Bill of Material File 48
The Location File 49
The Calendar File 49
Open Order Files 49
Other File Linkages 49
xiii
The Linkages between MRP and PAC 170
Just-in-Time Impact on PAC 171
The Company Environment 172
PRODUCTION ACTIVITY CONTROL
TECHNIQUES 172
Basic Shop-Floor Control Concepts 172
Gantt Charts 175
Priority Sequencing Rules 176
Finite Loading 178
Vendor Scheduling and Follow-Up 181
Lead Time Management 182
PRODUCTION ACTIVITY CONTROL
EXAMPLES 183
Critical Ratio Shop-Floor Control
at Twin Disc 184
The CAPOSS System at Swissair 189
Vendor Scheduling at Steelcase 191
PAC Procurement Practices under
World Class Manufacturing 193
THE PRODUCTION ACTIVITY CONTROL
DATA BASE 194
Data Acquisition and Feedback 196
CONCLUDING PRINCIPLES 197
CHAPTER 6 Master Production
Scheduling 209
THE MASTER PRODUCTION SCHEDULING
ACTIVITY 210
The Anticipated Build Schedule 210
Linkages to Other Company Activities 211
The Business Environment for the MPS 212
MASTER PRODUCTION SCHEDULING
TECHNIQUES 214
The Time-Phased Record 214
Rolling through Time 217
Order Promising 218
Consuming the Forecast 221
BILL OF MATERIAL STRUCTURING FOR
THE MPS 224
Key Definitions 224
The Modular Bill of Material 225
Contents xv
The Planning Bill of Material 227
THE FINAL ASSEMBLY SCHEDULE 230
Relation to the MPS 230
The Hill-Rom FAS 231
THE MASTER PRODUCTION SCHEDULER 235
The MPS as a Set of Firm Planned
Orders 235
The Job 236
EXAMPLES 238
The Ethan Allen Master Production
Schedule 239
Master Production Scheduling at
Jet Spray 241
MASTER PROOUCTION SCHEDULE
STABILITY 243
Firm Planned Order Treatment at
Black Decker 245
Ethan Allen Stability 248
Freezing and Time Fencing 248
MANAGING THE MPS 250
The Overstated MPS 251
MPS Measures 251
Monitoring the MPS at Ethan Allen 252
CONCLUDING PRINCIPLES 255
CHAPTER 7 Production Planning 275
PRODUCTION PLANNING IN THE FIRM 276
Production Planning and Management 276
Production Planning and MPC Systems 278
Payoffs 280
THE PRODUCTION PLANNING PROCESS 281
Routinizing Production and Game
Planning 281
The Basic Trade-Offs 284
Evaluating Alternatives 288
THE NEW MANAGEMENT OBLIGATIONS 292
Top-Management Role 292
Functional Roles 293
Integrating Strategie Planning 294
Controlling the Production Plan 295
Waste or Slack Reduction 410
Job Design 411
THE IMPLEMENTATION PROJECT TEAM 412
Project Team Structure 412
The Primary Project Team 413
Team Building 414
EDUCATION 417
Education Levels and Requirements 417
An Education Program 419
Problem Solving 420
Coping with Change 421
PROJECT MANAGEMENT 423
Defining the Scope 423
Where to Start 423
Project Planning 424
Project Control 424
When to Quit 426
AUDITING 427
Cross-Checking the Data Base 428
Reconciling Data Base Errors 428
The Justin-Time Approach to Data
Accuracy 429
A Detailed Checklist for the
MRP-Based System 431
The Audit Process 432
Continual Improvement 433
CONCLUDING PRINCIPLES 434
CHARTER 11 Advanced Concepts in
Material Requirements
Planning 443
DETERMINING MANUFACTURING ORDER
QUANTITIES 444
Economic Order Quantities (EOQ) 445
Periodic Order Quantities (POQ) 447
Part Period Balancing (PPB) 447
McLarens Order Moment (MOM) 449
Wagner-Whitin Algorithm 451
Simulation Experiments 452
Contents xvii
DETERMINING PURCHASE ORDER
QUANTITIES 453
The Purchasing Discount Problem 453
Look-Ahead Feature 457
Performance Comparisons 458
BUFFERING CONCEPTS 460
Categories of Uncertainty 460
Safety Stock and Safety Lead Time 461
Safety Stock and Safety Lead Time
Performance Comparisons 463
Other Buffering Mechanisms 465
NERVOUSNESS 466
Sources of MRP System
Nervousness 466
Reducing MRP System Nervousness 466
OTHER ADVANCED MRP CONCEPTS 468
Timing Conventions 469
Bucketless Systems 469
Phantom Assemblies 470
Scrap Allowances 471
Automatic Updating 471
CONCLUDING PRINCIPLES 472
CHARTER 12 Advanced Concepts in
Just-in-Time 485
A JIT RESEARCH FRAMEWORK 486
SCHEDULING 486
Scheduling Mixed Model Assembly
Lines under JIT 489
Schedule Stability in Implementing JIT 493
SUPPLIER MANAGEMENT 494
PRODUCTION FLOOR MANAGEMENT 502
Setup Time Reduction 503
Determining the Optimal Number of
Kanbans 507
JIT PERFORMANCE AND OPERATING
CONDITIONS 512
Variability in Operating Conditions 512
Lot Size 514
APPLICATIONS POTENTIAL 642
Application of Modeling Techniques 643
Data Issues 643
The Future 644
CONCLUDING PRINCIPLES 645
CHAPTER 16 Short-Term Forecasting
Systems 657
THE FORECASTING PROBLEM 658
Forecasting Perspectives 658
Forecast Evaluation 659
BASIC FORECASTING TECHNIQUES 662
Example Forecasting Situation 662
Moving Averages 665
The Basic Exponential Smoothing
Model 666
ENHANCING THE BASIC EXPONENTIAL
SMOOTHING MODEL 669
Trend Enhancement 669
Seasonal Enhancement 671
Trend and Seasonal Enhancement 674
Other Enhancements 675
FOCUS FORECASTING 675
COMPARISONS OF METHODS 676
The Forecasting Competition 676
The Focus Forecasting Comparison 677
USING THE FORECASTING SYSTEM 679
Incorporating External Information 679
Getting Started 680
Demand Filter Monitoring 681
Tracking Signal Monitoring 682
Strategie Issues 683
FORECASTING IN INDUSTRY 685
CONCLUDING PRINCIPLES 686
CHAPTER 17 Independent Demand
Inventory Management 697
BASIC CONCEPTS 698
Independent versus Dependent
Demand Items 698
Contents xix
Functions of Inventory 700
MANAGEMENT ISSUES 701
Routine Inventory Decisions 701
Determining Inventory System
Performance 702
Timing the Implementation 702
INVENTORY RELATED COSTS 703
Order Preparation Costs 703
Inventory Carrying Costs 703
Shortage and Customer Service Costs 704
Incremental Inventory Costs 705
Example Cost Trade-Offs 705
ECONOMIC ORDER QUANTITY MODEL 707
Solving the EOQ Model 708
QUANTITY DISCOUNT MODEL 710
ORDER TIMING DECISIONS 711
Sources of Demand and Supply
Uncertainty 712
The Introduction of Safety Stock 713
Continuous Distributions 716
Probability of Stocking-Out Criterion 717
Customer Service Criterion 719
Time Period Correction Factor 719
Forecast Error Distribution 721
ORDER QUANTITY AND REORDER POINT
INTERACTIONS 722
Service Levels and Order Quantities 723
Total Cost Criterion 726
Grid Search Procedure 727
The Iterative (Q, R) Procedure 728
MULTI-ITEM MANAGEMENT 729
Single-Criterion ABC Analysis 729
Multiple-Criteria ABC Analysis 731
MULTIPLE ITEMS FROM A SINGLE
SOURCE 734
Methods Based on Individual Item
Reorder Points 736
Methods Based on Group Reorder
Points 739
A Group Service Level Method 740
CtHtlcnts
Simulation Experiments 741
CONCLUDING PRINCIPLES 742
CHAPTER 18 Distribution
Requirements Planning 752
ORP IN MANUFACTURING PLANNING
AND CONTROL SYSTEMS 753
DRP and the Marketplace 754
DRP and Demand Management 755
DRP and Master Production Scheduling 756
DRP TECHNIQUES 757
The Basic DRP Record 757
Time-Phased Order Point (TPOP) 759
Linking Several Warehouse Records 761
Managing Day-to-Day Variations
from Plan 763
Safety Stock in DRP 767
MANAGEMENT ISSUES WITH DRP 770
Data Integrity and Completeness 770
Organizational Support 771
Problem Solving 773
COMPANY EXAMPLE 777
CONCLUDING PRINCIPLES 782
CHAPTER 19 MPC Frontiers 798
THE MPC SYSTEM SCHEMATIC 799
The Standard for MPC Systems 800
Beyond the Schematic 800
OPTIMIZED PRODUCTION
TECHNOLOGY (OPT) 801
Basic Concepts of OPT 801
OPT and the MPC Framework 806
Philosophical Underpinnings 808
Theory of Constraints 809
Implementation Issues 810
The Repetitive Lot Concept 811
THE PERIODIC CONTROL SYSTEM AT
KUMERA OY 813
The System 814
Using the System 818
Payoffs 819
MPC FOR THE PROCESS
INDUSTRIES (PRISM) 820
Production Resources 821
Production Models 822
Transaction Processing 823
Performance Measurement 824
Implications for MPC Practice 825
OBSERVATIONS ON MPC EVOLUTION 826
CONCLUDING PRINCIPLES 827
Index 837
xiv Contents
MRP SYSTEM EXAMPLES 50
Ethan Allen Furniture Company—
A Manual Application 50
Jet Spray—An Integrated On-Line
Example 50
CONCLUDING PRINCIPLES 53
CHAPTER 3 Just-in-Time 67
JIT IN MANUFACTURING PLANNING
AND CONTROL 68
Major Elements of Just-in-Time 69
JIT s Impact on Manufacturing
Planning and Control 70
The Hidden Factory 72
JIT Building Blocks in MPC 73
A JIT EXAMPLE 77
Leveling the Production 77
Pull System Introduction 78
Product Design 82
Process Design 84
BIM of Material Implications 84
JIT APPLICATIONS 88
Single-Card Kanban 88
Toyota 90
Hewlett-Packard 95
NONREPETITIVE JIT 98
A Service-Enhanced View of
Manufacturing 98
Flexible Systems 99
Simplified Systems and Routine
Execution 100
JIT IN PURCHASING 101
The Basics 101
Lessons 104
JIT SOFTWARE 104
HP JIT Software 104
JIT Using MRP Software 107
MANAGERIAL IMPLICATIONS 107
Information System Implications 108
Manufacturing Planning and Control 108
Scorekeeping 10g
Pros and Cons 110
CONCLUDING PRINCIPLES 111
CHAPTER 4 Capacity Planning 120
CAPACITY PLANNING S ROLE IN MPC
SYSTEMS 121
Hierarchy of Capacity Planning
Decisions 121
Links to Other MPC System Modules 122
CAPACITY PLANNING AND CONTROL
TECHNIQUES 124
Capacity Planning Using Overall
Factors (CPOF) 124
Capacity Bills 126
Resource Profiles 128
Capacity Requirements Planning (CRP) 135
Input/Output Control 137
The Capacity Bath Tub 140
MANAGEMENT AND CAPACITY
PLANNING 141
Capacity Planning in the MPC System 141
Choosing the Measure of Capacity 142
Choice of a Specific Technique 144
Using the Capacity Plan 145
DATA BASE REQUIREMENTS 146
Data Base Design Considerations 146
EXAMPLES OF APPLICATIONS 147
Capacity Planning at Black Decker 148
Capacity Planning at Twin Disc 151
Capacity Planning at Applicon 151
CONCLUDING PRINCIPLES 154
CHAPTER 5 Production Activity
Control 168
A FRAMEWORK FOR PRODUCTION
ACTIVITY CONTROL 169
MPC System Linkages 170
xvi Contents
OPERATING PRODUCTION-PLANNING
SYSTEMS 296
Production Planning at Compugraphic 296
Mohawk s Integrated Planning
Process 299
Hill-Rom s Use of Planning Bills of
Material 306
CONCLUDING PRINCIPLES 308
CHAPTER 8 Demand Management 317
DEMAND MANAGEMENT IN
MANUFACTURING PLANNING
AND CONTROL SYSTEMS 318
Demand Management and Production
Planning 319
Demand Management and Master
Production Scheduling 319
Outbound Product Flow 321
Data Capture 322
Dealing with Day-to-Day Customer
Orders 323
DEMAND MANAGEMENT TECHNIQUES 323
Aggregating and Disaggregating
Forecasts 324
Make-to-Stock Demand Management 329
Assemble-to-Order Demand
Management 331
Make-to-Order Demand Management 334
MANAGING DEMAND 336
Organizing for Demand Management 336
Managing Service Levels 337
Using the System 339
COMPANY EXAMPLES 340
Abbott Laboratories, Inc.: Forecasting 340
Tennant Company: Order Promising
and Flexibility Management 342
Make-to-Order Products at Elliott
Company, Division of Carrier
Corporation 346
CONCLUDING PRINCIPLES 347
CHAPTER 9 Integrated MPC Systems 358
MPC DESIGN OPTIONS 358
Master Production Scheduling Options 359
Detailed Material Planning Options 361
Shop-Floor System Options 363
CHOOSING THE OPTIONS 365
Market Requirements 365
The Manufacturing Task 367
Manufacturing Process Design 367
MPC System Design 368
THE CHOICES IN PRACTICE 373
Moog, Inc., Space Products Division 374
Kawasaki, U.S.A. 376
Applicon 378
The Driver Is the Marketplace 380
INTEGRATING MRP AND JIT 380
The Need to Integrate 380
Physical Changes That Support
Integration 382
Some Techniques for Integrating MRP
and JIT 383
Strategy for Combining MRP and JIT 383
CONCLUDING PRINCIPLES 384
CHAPTER 10 Implementation of MPC
Systems 393
INITIATING THE PROJECT 394
The Yardstick of Performance 394
The Company Environment 397
Justification 398
An Evolutionary Point of View 403
ESSENTIAL PREREQUISITES 404
Matching the Manufacturing Task to
System Design 405
MPC Data Base Integrity 406
Discipline to Use the Formal System 409
ORGANIZATIONAL ISSUES 409
Top-Management Commitment 409
xviii Contents
Comparing MPC System Approaches 516
CONCLUDING PRINCIPLES 520
CHAPTER 13 Advanced Concepts in
Scheduling 529
A SCHEDULING FRAMEWORK 530
Performance Criteria 530
Shop Structure 531
Product Structure 532
Work Center Capacities 533
BASIC SCHEDULING RESEARCH 533
Static Scheduling Approaches 534
Dynamic Scheduling Approaches 534
The One-Machine Case 535
The Two-Machine Case 536
Queuing Model Approaches 538
Sequencing Rules 538
Sequencing Research Results 540
ADVANCED RESEARCH FINDINGS 542
Due Date Setting Procedures 543
Dynamic Due Dates 545
Labor-Limited Systems 550
Lessons for Practice 551
EMERGING ISSUES IN SCHEDULING 553
Scheduling Cellular Manufacturing
Systems 553
Scheduling Manned Cellular
Manufacturing Systems 554
Scheduling FMS Systems 558
CONCLUDING PRINCIPLES 565
CHAPTER 14 Advanced Concepts in
Master Production
Scheduling 579
TWO-LEVEL MASTER PRODUCTION
SCHEDULING 580
Two-Level MPS Example 580
Booking Customer Orders 582
Managing with a Two-Level MPS 583
THE HYSTER LIFT TRUCK EXAMPLE 584
The Portland Plant 584
The Two-Level MPS 586
Buffering 589
The MPS Records 590
ADDITIONAL TECHNIQUES 592
Alternative ATP Explosion Conventions 592
Consumption by Actual Orders 593
Capacity Planning 596
METHODS FOR CONSTRUCTING
PLANNING BILLS OF MATERIAL 597
The Matrix Bill of Material Approach 597
Commonality and Bill of Material
Depth 599
Component Commonality Analysis
System 600
Material Handling Equipment
Manufacturer Example 601
CONCLUDING PRINCIPLES 605
CHAPTER 15 Advanced Concepts in
Production Planning 621
MATHEMATICAL PROGRAMMING
APPROACHES 622
Linear Programming 622
Mixed Integer Programming 624
OTHER APPROACHES 626
The Linear Decision Rule 626
The Management Coefficients Model 628
Search Decision Rules 629
DISAGGREGATION 629
The Disaggregation Problem 629
Hierarchical Production Planning 630
Disaggregation through Mathematical
Programming 632
COMPANY EXAMPLE 636
Owens-Corning Fiberglas: Anderson,
South Carolina, Plant 636
Aggregate Production Planning 637
Disaggregating the Production Plan 640
|
| any_adam_object | 1 |
| author | Vollmann, Thomas E. Berry, William L. Whybark, D. Clay |
| author_facet | Vollmann, Thomas E. Berry, William L. Whybark, D. Clay |
| author_role | aut aut aut |
| author_sort | Vollmann, Thomas E. |
| author_variant | t e v te tev w l b wl wlb d c w dc dcw |
| building | Verbundindex |
| bvnumber | BV008272276 |
| callnumber-first | T - Technology |
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| callnumber-sort | TS 3176 |
| callnumber-subject | TS - Manufactures |
| classification_rvk | QP 542 |
| classification_tum | FER 040f FER 050f |
| ctrlnum | (OCoLC)24174844 (DE-599)BVBBV008272276 |
| dewey-full | 658.5 |
| dewey-hundreds | 600 - Technology (Applied sciences) |
| dewey-ones | 658 - General management |
| dewey-raw | 658.5 |
| dewey-search | 658.5 |
| dewey-sort | 3658.5 |
| dewey-tens | 650 - Management and auxiliary services |
| discipline | Fertigungstechnik Wirtschaftswissenschaften |
| edition | 3. ed. |
| format | Book |
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| id | DE-604.BV008272276 |
| illustrated | Illustrated |
| indexdate | 2025-02-20T06:36:54Z |
| institution | BVB |
| isbn | 025608808X 1556236085 |
| language | English |
| oai_aleph_id | oai:aleph.bib-bvb.de:BVB01-005464669 |
| oclc_num | 24174844 |
| open_access_boolean | |
| owner | DE-703 DE-859 DE-739 DE-91G DE-BY-TUM DE-945 DE-19 DE-BY-UBM DE-83 DE-188 DE-862 DE-BY-FWS |
| owner_facet | DE-703 DE-859 DE-739 DE-91G DE-BY-TUM DE-945 DE-19 DE-BY-UBM DE-83 DE-188 DE-862 DE-BY-FWS |
| physical | XX, 844 S. graph. Darst. |
| publishDate | 1992 |
| publishDateSearch | 1992 |
| publishDateSort | 1992 |
| publisher | Irwin |
| record_format | marc |
| spellingShingle | Vollmann, Thomas E. Berry, William L. Whybark, D. Clay Manufacturing planning and control systems Production - Contrôle Production - Planification Production control Production planning Produktionsplanung (DE-588)4047360-0 gnd Fertigungsplanung (DE-588)4113545-3 gnd Fertigungskontrolle (DE-588)4016901-7 gnd Supply Chain Management (DE-588)4684051-5 gnd PPS (DE-588)4115606-7 gnd Produktionskontrolle (DE-588)4175800-6 gnd |
| subject_GND | (DE-588)4047360-0 (DE-588)4113545-3 (DE-588)4016901-7 (DE-588)4684051-5 (DE-588)4115606-7 (DE-588)4175800-6 |
| title | Manufacturing planning and control systems |
| title_auth | Manufacturing planning and control systems |
| title_exact_search | Manufacturing planning and control systems |
| title_full | Manufacturing planning and control systems Thomas E. Vollmann ; William L. Berry ; D. Clay Whybark |
| title_fullStr | Manufacturing planning and control systems Thomas E. Vollmann ; William L. Berry ; D. Clay Whybark |
| title_full_unstemmed | Manufacturing planning and control systems Thomas E. Vollmann ; William L. Berry ; D. Clay Whybark |
| title_short | Manufacturing planning and control systems |
| title_sort | manufacturing planning and control systems |
| topic | Production - Contrôle Production - Planification Production control Production planning Produktionsplanung (DE-588)4047360-0 gnd Fertigungsplanung (DE-588)4113545-3 gnd Fertigungskontrolle (DE-588)4016901-7 gnd Supply Chain Management (DE-588)4684051-5 gnd PPS (DE-588)4115606-7 gnd Produktionskontrolle (DE-588)4175800-6 gnd |
| topic_facet | Production - Contrôle Production - Planification Production control Production planning Produktionsplanung Fertigungsplanung Fertigungskontrolle Supply Chain Management PPS Produktionskontrolle |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=005464669&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
| work_keys_str_mv | AT vollmannthomase manufacturingplanningandcontrolsystems AT berrywilliaml manufacturingplanningandcontrolsystems AT whybarkdclay manufacturingplanningandcontrolsystems |
Indexes
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| Call Number: |
2350 ZM 9200 V924(3) |
|---|---|
| Copy 1 | nicht ausleihbar Available Place a Hold |