Manufacturing planning and control systems:
Saved in:
| Main Authors: | , , |
|---|---|
| Format: | Book |
| Language: | English |
| Published: |
Boston, Mass. [u.a.]
Irwin McGraw-Hill
1997
|
| Edition: | 4. ed. |
| Subjects: | |
| Online Access: | Inhaltsverzeichnis |
| Physical Description: | XXV, 836 S. graph. Darst. |
| ISBN: | 0786312092 0256138990 |
Staff View
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| 245 | 1 | 0 | |a Manufacturing planning and control systems |c Thomas E. Vollmann ; William L. Berry ; D. Clay Whybark |
| 250 | |a 4. ed. | ||
| 264 | 1 | |a Boston, Mass. [u.a.] |b Irwin McGraw-Hill |c 1997 | |
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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 3
MPC System Activities 4
The System and the Framework 4
Matching the MPC System with the
Needs of the Firm 6
An MPC Classification Schema 7
EVOLUTION OF THE MPC SYSTEM 9
The Changing Competitive World 9
Reacting to the Changes 9
CONCLUDING PRINCIPLES 10
Chapter 2 Material Requirements
Planning 13
MATERIAL REQUIREMENTS PLANNING
IN MANUFACTURING PLANNING
AND CONTROL 14
MRP and MRPII 16
RECORD PROCESSING 17
The Basic MRP Record 17
Linking the MRP Records 25
TECHNICAL ISSUES 29
Processing Frequency 29
Bucketless Systems 30
Lot Sizing 31
Safety Stock and Safety Lead Time 32
Low Level Coding 33
Pegging 33
Firm Planned Orders 34
Service Parts 34
Planning Horizon 35
Scheduled Receipts versus Planned
Order Releases 35
USING THE MRP SYSTEM 36
The MRP Planner 36
Exception Codes 38
Bottom Up Replanning 39
An MRP System Output 40
SYSTEM DYNAMICS 42
Transactions during a Period 42
Rescheduling 43
Complex Transaction Processing 44
Procedural Inadequacies 45
THE MRP DATA BASE 47
The Item Master File 47
The Subordinate Item Master File 47
The Bill of Material File 47
The Location File 48
The Calendar File 48
Open Order Files 48
Other File Linkages 48
MRP SYSTEM EXAMPLES 48
Ethan Allen Furniture Company—
A Manual Application 49
Jet Spray—An Integrated On Line
Example 49
CONCLUDING PRINCIPLES 52
Chapter 3 Just in Time 68
JIT IN MANUFACTURING PLANNING
AND CONTROL 69
Major Elements of Just in Time 70
JIT s Impact on Manufacturing
Planning and Control 71
The Hidden Factory 73
JIT Building Blocks in MPC 74
A JIT EXAMPLE 78
Leveling the Production 78
Pull System Introduction 79
Product Design 83
Process Design 85
Bill of Material Implications 87
JIT APPLICATIONS 89
Single Card Kanban 89
Toyota 91
Hewlett Packard 96
NONREPETITIVE JIT 99
A Service Enhanced View of
Manufacturing 99
Flexible Systems 100
Simplified Systems and Routine
Execution 101
JIT IN PURCHASING 102
The Basics 102
Lessons 105
JIT SOFTWARE 105
HP JIT Software 105
JIT Using MRP Software 108
MANAGERIAL IMPLICATIONS 108
Information System Implications 109
Manufacturing Planning and Control 109
Scorekeeping 110
Pros and Cons 111
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 Montell
USA, Inc. 147
Capacity Planning at Twin Disc 148
Capacity Planning at Applicon 152
CONCLUDING PRINCIPLES 153
Chapter 5 Production Activity
Control 165
A FRAMEWORK FOR PRODUCTION
ACTIVITY CONTROL 166
MPC System Linkages 167
The Linkages between MRP and
PAC 167
Just in Time Impact on PAC 168
The Company Environment 169
PRODUCTION ACTIVITY CONTROL
TECHNIQUES 169
Basic Shop Floor Control Concepts 169
Gantt Charts 172
Priority Sequencing Rules 173
Finite Loading 174
Vendor Scheduling and Follow Up 178
Lead Time Management 179
PRODUCTION ACTIVITY CONTROL
EXAMPLES 180
Critical Ratio Shop Floor Control at
Twin Disc 181
The CAPOSS System at Swissair 186
Vendor Scheduling at Steelcase 188
PAC Procurement Practices under
World Class Manufacturing 188
THE PRODUCTION ACTIVITY CONTROL
DATA BASE 191
Data Acquisition and Feedback 192
CONCLUDING PRINCIPLES 194
Chapter 6 Master Production
Scheduling 205
THE MASTER PRODUCTION
SCHEDULING ACTIVITY 206
The Anticipated Build Schedule 206
Linkages to Other Company Activities 207
The Business Environment for the
MPS 208
MASTER PRODUCTION SCHEDULING
TECHNIQUES 210
The Time Phased Record 210
Rolling through Time 213
Order Promising 214
Consuming the Forecast 217
Mitel Corporation: Order Promising
with ATP 220
BILL OF MATERIAL STRUCTURING FOR
THE MPS 222
Key Definitions 224
The Modular Bill of Material 225
The Planning Bill of Material 227
THE FINAL ASSEMBLY SCHEDULE 229
Relation to the MPS 230
The Hill Rom FAS 231
THE MASTER PRODUCTION
SCHEDULER 233
The MPS as a Set of Firm Planned
Orders 234
The Job 235
EXAMPLES 238
The Ethan Allen Master Production
Schedule 238
Master Production Scheduling at
Jet Spray 242
MASTER PRODUCTION SCHEDULE
STABILITY 244
Ethan Allen Stability 244
Freezing and Time Fencing 246
MANAGING THE MPS 247
The Overstated MPS 247
MPS Measures 248
Monitoring the MPS at Ethan Allen 248
CONCLUDING PRINCIPLES 251
Chapter 7 Production Planning 269
PRODUCTION PLANNING IN THE FIRM 270
Sales and Operations Planning 270
Production Planning and
Management 270
Production Planning and MPC
Systems 272
Payoffs 274
THE PRODUCTION PLANNING
PROCESS 275
Routinizing Production and Game
Planning 276
The Basic Trade Offs 278
Evaluating Alternatives 282
THE NEW MANAGEMENT
OBLIGATIONS 286
Top Management Role 286
Functional Roles 287
Integrating Strategic Planning 288
Controlling the Production Plan 289
OPERATING PRODUCTION PLANNING
SYSTEMS 290
Production Planning at
Compugraphic 290
Mohawk s Integrated Planning
Process 293
Hill Rom s Use of Planning Bills of
Material 300
CONCLUDING PRINCIPLES 302
Chapter 8 Demand Management 312
DEMAND MANAGEMENT IN
MANUFACTURING PLANNING AND
CONTROL SYSTEMS 313
Demand Management and
Production Planning 314
Demand Management and Master
Production Scheduling 314
Make to Demand 316
Outbound Product Flow 318
Data Capture 318
Dealing with Day to Day Customer
Orders 319
DEMAND MANAGEMENT TECHNIQUES 319
Aggregating and Disaggregating
Forecasts 320
Make to Stock Demand Management 325
Assemble to Order Demand
Management 327
Make to Order Demand Management 330
MANAGING DEMAND 331
Organizing for Demand Management 332
Managing Service Levels 333
Using the System 335
COMPANY EXAMPLES 336
Forecasting at Ross Laboratories 336
Customer Order Promising at Kirk
Motors, Ltd. 340
Make to Order Products at Elliott
Company, Division of Carrier
Corporation 342
CONCLUDING PRINCIPLES 342
Chapter 9 Integrated MPC
Systems 354
MPC DESIGN OPTIONS 354
Master Production Scheduling
Options 355
Detailed Material Planning Options 357
Shop Floor System Options 358
CHOOSING THE OPTIONS 361
Market Requirements 361
The Manufacturing Task 362
Manufacturing Process Design 363
MPC System Design 364
THE CHOICES IN PRACTICE 369
Moog, Inc., Space Products Division 369
Kawasaki, U.S.A. 372
Applicon 374
The Driver Is the Marketplace 377
INTEGRATING MRP AND JIT 377
The Need to Integrate 377
Timing Conventions 464
Bucketless Systems 465
Phantom Assemblies 465
Scrap Allowances 466
Automatic Updating 467
CONCLUDING PRINCIPLES 467
Chapter 12 Advanced Concepts in
Just in Time 480
A JIT RESEARCH FRAMEWORK 481
SCHEDULING 481
Scheduling Mixed Model Assembly
Lines under JIT 484
Schedule Stability in Implementing
JIT 488
SUPPLIER MANAGEMENT 489
PRODUCTION FLOOR MANAGEMENT 497
Setup Time Reduction 498
Determining the Optimal Number of
Kanbans 502
JIT PERFORMANCE AND OPERATING
CONDITIONS 507
Variability in Operating Conditions 507
Lot Size 509
Comparing MPC System Approaches 511
INCLUDING PRINCIPLES 515
hapter 13 Advanced Concepts in
Scheduling 524
SCHEDULING FRAMEWORK 525
Performance Criteria 525
Shop Structure 526
Product Structure 527
Work Center Capacities 528 ,
! SIC SCHEDULING RESEARCH 528
Static Scheduling Approaches 529
Dynamic Scheduling Approaches 529
The One Machine Case 530
The Two Machine Case 531
Queuing Model Approaches 533
Sequencing Rules 533
Sequencing Research Results 535
ADVANCED RESEARCH FINDINGS 537
Due Date Setting Procedures 537
Dynamic Due Dates 540
Labor Limited Systems 544
Lessons for Practice 546
EMERGING ISSUES IN SCHEDULING 548
Scheduling Cellular Manufacturing
Systems 548
Scheduling Manned Cellular
Manufacturing Systems 549
Scheduling FMS Systems 553
CONCLUDING PRINCIPLES 560
Chapter 14 Advanced Concepts in
Master Production
Scheduling 574
TWO LEVEL MASTER PRODUCTION
SCHEDULING 575
Two Level MPS Example 575
Booking Customer Orders 577
Managing with a Two Level MPS 578
TWO LEVEL MPS AT MITEL
CORPORATION 579
MPS Planning 579
MPS Detail 581
ADDITIONAL TECHNIQUES 582
Alternative ATP Explosion
Conventions 582
Consumption by Actual Orders 584
Capacity Planning 586
METHODS FOR CONSTRUCTING
PLANNING BILLS OF MATERIAL 587
The Matrix Bill of Material Approach 588
Commonality and Bill of Material
Depth 588
Component Commonality Analysis
System 591
Material Handling Equipment
Manufacturer Example 591
CONCLUDING PRINCIPLES 595
Chapter 15 Advanced Concepts in
Production Planning 612
MATHEMATICAL PROGRAMMING
APPROACHES 613
Linear Programming 613
Mixed Integer Programming 615
OTHER APPROACHES 617
The Linear Decision Rule 617
The Management Coefficients Model 619
Search Decision Rules 620
DISAGGREGATION 620
The Disaggregation Problem 620
Hierarchical Production Planning 621
Disaggregation through Mathematical
Programming 623
COMPANY EXAMPLE 627
Owens Corning Fiberglas: Anderson,
South Carolina, Plant 627
Aggregate Production Planning 628
Disaggregating the Production Plan 631
APPLICATIONS POTENTIAL 633
Application of Modeling Techniques 634
Data Issues 634
The Future 635
CONCLUDING PRINCIPLES 636
Chapter 16 Short Term
Forecasting Systems 648
THE FORECASTING PROBLEM 649
Forecasting Perspectives 649
Forecast Evaluation 650
BASIC FORECASTING TECHNIQUES 653
Example Forecasting Situation 653
Moving Averages 656
The Basic Exponential Smoothing
Model 657
ENHANCING THE BASIC EXPONENTIAL
SMOOTHING MODEL 660
Trend Enhancement 660
Seasonal Enhancement 662
Trend and Seasonal Enhancement 665
Other Enhancements 666
FOCUS FORECASTING 666
COMPARISONS OF METHODS 667
The Forecasting Competition 667
The Focus Forecasting Comparison 668
USING THE FORECASTING SYSTEM 670
Incorporating External Information 670
Getting Started 671
Demand Filter Monitoring 672
Tracking Signal Monitoring 673
Strategic Issues 674
FORECASTING IN INDUSTRY 676
CONCLUDING PRINCIPLES 677
Chapter 17 Independent Demand
Inventory
Management 688
BASIC CONCEPTS 689
Independent versus Dependent
Demand Items 689
Functions of Inventory 691
MANAGEMENT ISSUES 692
Routine Inventory Decisions 692
Determining Inventory System
Performance 693
Timing the Implementation 693
INVENTORY RELATED COSTS 694
Order Preparation Costs 694
Inventory Carrying Costs 694
Shortage and Customer Service
Costs 695
Physical Changes That Support
Integration 378
Some Techniques for Integrating
MRP and JIT 378
Strategy for Combining MRP and JIT 379
CONCLUDING PRINCIPLES 380
Chapter 10 Implementation of
MPC Systems 389
INITIATING THE PROJECT 390
The Yardstick of Performance 390
The Company Environment 393
Justification 394
An Evolutionary Point of View 399
ESSENTIAL PREREQUISITES 400
Matching the Manufacturing Task to
System Design 401
MPC Data Base Integrity 402
Discipline to Use the Formal System 405
ORGANIZATIONAL ISSUES 405
Top Management Commitment 406
Waste or Slack Reduction 406
Job Design 407
THE IMPLEMENTATION PROJECT
TEAM 408
Project Team Structure 408
The Primary Project Team 409
Team Building 410
EDUCATION 412
Education Levels and Requirements 413
An Education Program 415
Problem Solving 416
Coping with Change 418
PROJECT MANAGEMENT 419
Defining the Scope 419
Where to Start 420
Project Planning 420
Project Control 421
When to Quit 423
AUDITING 424
Cross Checking the Data Base 424
Reconciling Data Base Errors 425
The Just in Time Approach to Data
Accuracy 425
A Detailed Checklist for the
MRP Based System 427
The Audit Process 428
Continual Improvement 430
CONCLUDING PRINCIPLES 430
Chapter 11 Advanced Concepts
in Material
Requirements
Planning 439
DETERMINING MANUFACTURING
ORDER QUANTITIES 440
Economic Order Quantities (EOQ) 441
Periodic Order Quantities (POQ) 442
Part Period Balancing (PPB) 443
McLaren s Order Moment (MOM) 445
Wagner Whitin Algorithm 447
Simulation Experiments 447
DETERMINING PURCHASE ORDER
QUANTITIES 449
The Purchasing Discount Problem 449
Look Ahead Feature 453
Performance Comparisons 453
BUFFERING CONCEPTS 455
Categories of Uncertainty 456
Safety Stock and Safety Lead Time 457
Safety Stock and Safety Lead Time
Performance Comparisons 459
Other Buffering Mechanisms 461
NERVOUSNESS 461
Sources of MRP System
Nervousness 462
Reducing MRP System Nervousness 462
OTHER ADVANCED MRP CONCEPTS 464
Incremental Inventory Costs 696
Example Cost Trade Offs 696
ECONOMIC ORDER QUANTITY MODEL 698
Solving the EOQ Model 699
QUANTITY DISCOUNT MODEL 701
ORDER TIMING DECISIONS 702
Sources of Demand and Supply
Uncertainty 702
The Introduction of Safety Stock 704
Continuous Distributions 707
Probability of Stocking Out Criterion 708
Customer Service Criterion 710
Time Period Correction Factor 710
Forecast Error Distribution 712
ORDER QUANTITY AND REORDER
POINT INTERACTIONS 713
Service Levels and Order Quantities 714
Total Cost Criterion 717
Grid Search Procedure 718
The Iterative (Q, R) Procedure 719
MULTI ITEM MANAGEMENT 720
Single Criterion ABC Analysis 720
Multiple Criterion ABC Analysis 722
MULTIPLE ITEMS FROM A SINGLE
SOURCE 725
Methods Based on Individual Item
Reorder Points 727
Methods Based on Group Reorder
Points 730
A Group Service Level Method 731
Simulation Experiments 732
CONCLUDING PRINCIPLES 733
Chapter 18 Distribution
Requirements
Planning 743
DRP IN MANUFACTURING PLANNING
AND CONTROL SYSTEMS 744
f)RP anri thfi Markptnlarp 74R
Best Practices 808
Implications for MPC Systems 810
CONCLUDING PRINCIPLES 812
Index 823
DRP and Demand Management 746
DRP and Master Production
Scheduling 747
DRP TECHNIQUES 748
The Basic DRP Record 748
Time Phased Order Point (TPOP) 750
Linking Several Warehouse Records 751
Managing Day to Day Variations
from Plan 754
Safety Stock in DRP 758
MANAGEMENT ISSUES WITH DRP 761
Data Integrity and Completeness 761
Organizational Support 762
Problem Solving 765
COMPANY EXAMPLE 768
CONCLUDING PRINCIPLES 773
Chapter 19 MPC Frontiers 787
THE MPC SYSTEM SCHEMATIC 788
The Standard for MPC Systems 788
Beyond the Schematic 789
OPTIMIZED PRODUCTION
TECHNOLOGY (OPT) 789
Basic Concepts of OPT 790
OPT and the MPC Framework 795
Philosophical Underpinnings 796
Theory of Constraints 798
Implementation Issues 798
The Repetitive Lot Concept 799
MPC FOR THE PROCESS INDUSTRIES
(PRISM) 802
Production Resources 803
Production Models 804
Transaction Processing 804
Performance Measurement 805
Implications for MPC Practice 807
INTEGRATED SUPPLY CHAIN
MANAGEMENT: THE NEXT FRONTIER 807
Supply Chain Complexity 808
|
| 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 |
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| author_sort | Vollmann, Thomas E. |
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| callnumber-first | T - Technology |
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| callnumber-subject | TS - Manufactures |
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| dewey-full | 658.5 |
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| dewey-ones | 658 - General management |
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| dewey-search | 658.5 |
| dewey-sort | 3658.5 |
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| discipline | Werkstoffwissenschaften / Fertigungstechnik Wirtschaftswissenschaften |
| edition | 4. ed. |
| format | Book |
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| id | DE-604.BV012291163 |
| illustrated | Illustrated |
| indexdate | 2025-02-20T06:43:48Z |
| institution | BVB |
| isbn | 0786312092 0256138990 |
| language | English |
| oai_aleph_id | oai:aleph.bib-bvb.de:BVB01-008333996 |
| oclc_num | 36066120 |
| open_access_boolean | |
| owner | DE-355 DE-BY-UBR DE-862 DE-BY-FWS DE-703 DE-83 DE-384 |
| owner_facet | DE-355 DE-BY-UBR DE-862 DE-BY-FWS DE-703 DE-83 DE-384 |
| physical | XXV, 836 S. graph. Darst. |
| publishDate | 1997 |
| publishDateSearch | 1997 |
| publishDateSort | 1997 |
| publisher | Irwin McGraw-Hill |
| record_format | marc |
| spellingShingle | Vollmann, Thomas E. Berry, William L. Whybark, D. Clay Manufacturing planning and control systems Controle da producao (administracao) larpcal Planejamento da producao (administracao) larpcal Productiecontrole gtt Productieplanning gtt Production - Contrôle Production - Planification Production control Production planning Fertigungskontrolle (DE-588)4016901-7 gnd Produktionsplanung (DE-588)4047360-0 gnd Fertigungsplanung (DE-588)4113545-3 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)4016901-7 (DE-588)4047360-0 (DE-588)4113545-3 (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 | Controle da producao (administracao) larpcal Planejamento da producao (administracao) larpcal Productiecontrole gtt Productieplanning gtt Production - Contrôle Production - Planification Production control Production planning Fertigungskontrolle (DE-588)4016901-7 gnd Produktionsplanung (DE-588)4047360-0 gnd Fertigungsplanung (DE-588)4113545-3 gnd Supply Chain Management (DE-588)4684051-5 gnd PPS (DE-588)4115606-7 gnd Produktionskontrolle (DE-588)4175800-6 gnd |
| topic_facet | Controle da producao (administracao) Planejamento da producao (administracao) Productiecontrole Productieplanning Production - Contrôle Production - Planification Production control Production planning Fertigungskontrolle Produktionsplanung Fertigungsplanung Supply Chain Management PPS Produktionskontrolle |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=008333996&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
THWS Schweinfurt Teilbibliothek Logistik
| Call Number: |
2350 ZM 9200 V924(4) |
|---|---|
| Copy 1 | nicht ausleihbar Available Place a Hold |
THWS Schweinfurt Zentralbibliothek Lesesaal
| Call Number: |
2000 ZM 9200 V924(4) |
|---|---|
| Copy 1 | ausleihbar Available Place a Hold |