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Table of Contents Session 1—Introduction to Supply Chain Management Introduction to Manufacturing ...................................................................................... 1-9 Role of Manufacturing................................................................................................................ 1-9 Global Citizenship ....................................................................................................................... 1-11 Manufacturing Business Model................................................................................................. 1-15 Business Environment ............................................................................................................... 1-23
Manufacturing Environment and Process Choices ...................................................... 1-27 Manufacturing Environments .................................................................................................... 1-27 Product Life Cycle and Manufacturing Environments .............................................................. 1-33 Choice of Processes and Layouts.............................................................................................. 1-35
The Manufacturing Supply Chain................................................................................... 1-45 The Supply Chain Concept ......................................................................................................... 1-45 Views of the Supply Chain.......................................................................................................... 1-47 Supply Chain Organizational Issues .......................................................................................... 1-51 Performance Measures.............................................................................................................. 1-53 Role of Materials Management ................................................................................................. 1-55
Manufacturing Planning and Control ............................................................................ 1-57 Objectives of Manufacturing. ..................................................................................................... 1-57 Priority and Capacity Planning ................................................................................................... 1-57 Manufacturing Planning and Control Hierarchy ....................................................................... 1-59
From MRP TO ERP .......................................................................................................... 1-61 From MRP to ERP ....................................................................................................................... 1-61 From MRP to MRP II ................................................................................................................... 1-61 From MRP II to ERP. ................................................................................................................... 1-63
Impact of New Systems and Philosophies .................................................................... 1-65
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aChain - APICS International Channel Partner - www.achain.com.br Programas CPIM e CSCP abertos e in company i Instructor Guide Version 4.2
Basics of Supply Chain Management
Session 2—Demand Management Demand Management Processes ................................................................................. 2-7 Marketing Management ............................................................................................................. 2-7 Customer Relationship Management ........................................................................................ 2-11 Demand Planning ....................................................................................................................... 2-11
Characteristics of Demand ............................................................................................ 2-13 Independent Versus Dependent Demand ................................................................................. 2-13 Sources of Demand .................................................................................................................... 2-13 Demand Patterns and Stability .................................................................................................. 2-15
Forecasting ..................................................................................................................... 2-19 Purposes and Uses of the Forecast ........................................................................................... 2-19 Principles of Forecasting ............................................................................................................ 2-21 Data Collection and Preparation Principles .............................................................................. 2-23
Forecasting Techniques ................................................................................................. 2-25 Qualitative Techniques ............................................................................................................... Quantitative Techniques: Extrinsic............................................................................................. Quantitative Techniques: Intrinsic ............................................................................................. Moving Average Forecast ...........................................................................................................
2-25 2-25 2-27 2-27
Exponential Smoothing............................................................................................................... 2-35 Seasonal Forecast ...................................................................................................................... 2-39
Tracking the Forecast .................................................................................................... 2-43 Bias .............................................................................................................................................. 2-43 Random Variation (Error) ............................................................................................................ 2-43 Measuring Forecast Error ........................................................................................................... 2-45
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Session 3—Master Planning Purpose and Scope of Master Planning ........................................................................
3-7
Priority Planning.......................................................................................................................... Planning Horizon and Level of Detail ........................................................................................
3-7 3-7
S&OP and Production Planning .....................................................................................
3-9
Sales and Operations Planning ................................................................................................. Production Planning ...................................................................................................................
3-9 3-11
Master Scheduling and Master Production Schedule ..................................................
3-37
Purpose ....................................................................................................................................... Objectives ................................................................................................................................... Inputs .......................................................................................................................................... Relationship to the Production Plan.......................................................................................... Developing a Master Schedule.................................................................................................. Projected Available Balance ...................................................................................................... Preliminary MPS ......................................................................................................................... Planning Horizon ........................................................................................................................ Time Fences and Zones ............................................................................................................. Aggregating the Master Schedules ........................................................................................... Rough-Cut Capacity Planning .................................................................................................... Resolving Differences and Publishing the MPS .......................................................................
3-37 3-37 3-39 3-39 3-41 3-41 3-43 3-47 3-49 3-49 3-51 3-51
Master Scheduling and Sales ........................................................................................
3-53
MPS and Delivery Promises .......................................................................................................
3-53
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aChain - APICS International Channel Partner - www.achain.com.br Programas CPIM e CSCP abertos e in company iii Instructor Guide Version 4.2
Basics of Supply Chain Management
Session 4—Material Requirements Planning (MRP) Material Requirements Planning Environment ............................................................
4-7
Nature of Demand ......................................................................................................................
4-7
Linkages with Other Manufacturing Planning and Control Functions .....................................
4-7
Objectives of MRP .......................................................................................................................
4-9
MRP Process Inputs and Outputs ..............................................................................................
4-11
Planning Software .......................................................................................................................
4-13
Bill of Material ................................................................................................................
4-15
Introduction .................................................................................................................................
4-15
Summarized Bill of Material and the Indented Bill ...................................................................
4-15
Single-Level Bill of Material ........................................................................................................
4-17
Multilevel Bill of Material ............................................................................................................
4-17
Parent-Component Relationship ................................................................................................
4-17
Bill of Material: Summary ...........................................................................................................
4-19
Planning Bill.................................................................................................................................
4-23
Where-Used and Pegging Data ..................................................................................................
4-25
Uses of the Bill of Material .........................................................................................................
4-27
Material Requirements Planning Logic..............................................................
4-29
Approach to this Section ............................................................................................................
4-29
MRP Logic Overview....................................................................................................................
4-29
Lead-Time Offsetting and Exploding ..........................................................................................
4-31
Gross and Net Requirements .....................................................................................................
4-37
Basic MRP Record ......................................................................................................................
4-41
Capacity Requirements Planning ...............................................................................................
4-47
Using and Managing the Priority Plan...........................................................................
4-49
Role of MRP Software .................................................................................................................
4-49
Order Control ...............................................................................................................................
4-51
Releasing Planned Orders ..........................................................................................................
4-53
Maintaining Priorities and Replanning ......................................................................................
4-55
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Session 5—Capacity Management and Production Activity Control Introduction ..................................................................................................................... 5-7 Manufacturing Planning and Control Hierarchy. ...................................................................... 5-7 Transition from MRP to CRP and PAC ....................................................................................... 5-7
Capacity Management ................................................................................................... 5-9 Phases of Capacity Management.............................................................................................. Definition of Capacity ................................................................................................................. Capacity Planning Process ......................................................................................................... Determining Capacity Available ................................................................................................ Rated Capacity............................................................................................................................ Demonstrated Capacity .............................................................................................................
5-9 5-11 5-11 5-13 5-21 5-25
Capacity Requirements Planning .................................................................................. 5-27 Introduction................................................................................................................................ 5-27 Key Inputs ................................................................................................................................... 5-27 CRP Process................................................................................................................................ 5-33
Production Activity Control ............................................................................................ 5-41 Objectives ................................................................................................................................... Functions .................................................................................................................................... Information Requirements ......................................................................................................... Data Requirements ....................................................................................................................
5-41 5-43 5-45 5-47
Scheduling. ...................................................................................................................... 5-49 Introduction................................................................................................................................ 5-49 Scheduling and Loading Techniques ........................................................................................ 5-49 Bottleneck Scheduling ............................................................................................................... 5-53
Implementation ............................................................................................................... 5-55 Shop Order Packet ..................................................................................................................... 5-55 Order Release Process ............................................................................................................... 5-55
Control ............................................................................................................................. 5-57 Goals, Objectives, and Control Levers ...................................................................................... Priority Control ............................................................................................................................ Input/Output Control .................................................................................................................. Flow Control ................................................................................................................................
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Basics of Supply Chain Management
Session 6—Aggregate Inventory Management Introduction to Inventory ................................................................................................ 6-7 What is Inventory? ...................................................................................................................... 6-7 Aggregate and Item Inventory Management. ............................................................................ 6-9
Aggregate Inventory Management ................................................................................ 6-11 Inventory and the Flow of Materials .......................................................................................... 6-11 Reasons for Carrying Inventory .................................................................................................. 6-13 Functions of Inventory ................................................................................................................ 6-15 Inventory Objectives.................................................................................................................... 6-17
Inventory Costs ............................................................................................................... 6-21 Item Costs.................................................................................................................................... 6-21 Carrying Costs ............................................................................................................................. 6-23 Ordering Costs............................................................................................................................. 6-25 Stockout Costs ............................................................................................................................ 6-29 Capacity-Related Costs ............................................................................................................... 6-29
Financial Statements and Inventory ............................................................................. 6-33 Balance Sheet and Income Statement Accounts ..................................................................... 6-33 Balance Sheet ............................................................................................................................. 6-35 Income Statement ...................................................................................................................... 6-37 Aggregate Inventory Management and Financial Statements ................................................. 6-39 Cash Flow Analysis ...................................................................................................................... 6-43 Inventory Valuation ..................................................................................................................... 6-45 Financial Inventory Performance Measures ............................................................................. 6-47
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Session 7—Item Inventory Management Order Quantities .............................................................................................................. 7-7 How Much to Order..................................................................................................................... 7-7 Lot-Size Decision Rules .............................................................................................................. 7-9 Economic Order Quantity (EOQ)................................................................................................ 7-13 Economic Order Quantity Formula ............................................................................................ 7-21 Validity of EOQ Assumptions..................................................................................................
7-25
Independent Demand Ordering Systems ....................................................................... 7-27 Order Point System..................................................................................................................... 7-29 Safety Stock. ............................................................................................................................... 7-35 Determining When the Order Point is Reached........................................................................ 7-43 Periodic Review System ............................................................................................................. 7-47
ABC Inventory Control .................................................................................................... 7-55 ABC Principles............................................................................................................................. 7-55 ABC Classification....................................................................................................................... 7-57 ABC Process ................................................................................................................................ 7-57 Sample Calculation .................................................................................................................... 7-59 Control Based on ABC Classification ......................................................................................... 7-63
Auditing Inventory Records ............................................................................................ 7-65 Periodic Inventory Audit ............................................................................................................. 7-65 Cycle Counting ............................................................................................................................ 7-67
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Session 8—Purchasing and Physical Distribution Purchasing ...................................................................................................................... 8-7 Types of Purchased Items .......................................................................................................... 8-7 Purchasing Objectives ................................................................................................................ 8-9
Purchasing Activities and Participants ......................................................................... 8-11 Purchasing Activities ................................................................................................................... 8-11
Physical Distribution....................................................................................................... 8-29 Scope and Value ......................................................................................................................... Global Distribution ...................................................................................................................... Influence of Marketing................................................................................................................ Interface with Production and Finance...................................................................................... Other Factors: Distribution Channels .. ...................................................................................... Scope of Physical Distribution Factors ......................................................................................
8-29 8-29 8-31 8-33 8-37 8-37
Distribution Inventory ..................................................................................................... 8-39 Purpose of Distribution Inventory .............................................................................................. Objectives .................................................................................................................................... Distribution Inventory Planning Systems ................................................................................... Push System................................................................................................................................ Distribution Requirements Planning (DRP) ...............................................................................
8-39 8-41 8-43 8-45 8-45
Transportation................................................................................................................. 8-49 Introduction ................................................................................................................................ Reverse Logistics ........................................................................................................................ Basic Transportation Modes ...................................................................................................... Costs of Moving Goods ...............................................................................................................
8-49 8-55 8-55 8-65
Warehousing ................................................................................................................... 8-71 Purpose of Warehousing ............................................................................................................ Warehousing Process and Activities .......................................................................................... Stock Location Systems ............................................................................................................. Public Versus Private Warehousing ...........................................................................................
8-71 8-71 8-73 8-75
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Session 9—Lean and Quality Systems Product and Quality Systems ......................................................................................... 9-7 Product and Quality Cycle .......................................................................................................... 9-7 Objectives.................................................................................................................................... 9-7 Systems and Methodologies...................................................................................................... 9-9 Principles, Practices, and Tools ................................................................................................ 9-11
Focus on the Customer ................................................................................................... 9-13 Value of a Product to the Customer .......................................................................................... 9-15 Quality Functional Deployment .................................................................................................. 9-15
Lean.................................................................................................................................. 9-17 House of Toyota .......................................................................................................................... 9-17 Why Implement Lean?................................................................................................................ 9-17 Waste .......................................................................................................................................... 9-19 Continuous Flow Production ...................................................................................................... 9-21 Pull Systems................................................................................................................................ 9-21 Work Layouts .............................................................................................................................. 9-23 Process Flexibility ....................................................................................................................... 9-25 Total Productive Maintenance ................................................................................................... 9-27 Process and Continuous Improvement ..................................................................................... 9-29 Employee Involvement and Empowerment .............................................................................. 9-31 Lean Tools and Techniques ....................................................................................................... 9-33 Supplier Partnerships. ................................................................................................................ 9-35
Total Quality Management ............................................................................................. 9-37 Product Quality ........................................................................................................................... 9-37 Quality-Related Costs ................................................................................................................. 9-41 Quality Control Tools................................................................................................................... 9-43 Six Sigma..................................................................................................................................... 9-57 Summary ..................................................................................................................................... 9-63
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Session 10—Theory of Constraints Introduction to Theory of Constraints............................................................................ 10-7 Philosophy and Basic Principles ................................................................................................ 10-7 Types of Constraints ................................................................................................................... 10-9 Problem-Solving Tools ................................................................................................................ 10-9
General Applications ...................................................................................................... 10-11 VATI Analysis................................................................................................................................ 10-11 Drum-Buffer-Rope Planning and Scheduling ............................................................................ 10-13 Simplified Drum-Buffer-Rope (S-DBR) ....................................................................................... 10-27 Throughput Accounting............................................................................................................... 10-29 Critical-Chain Method ................................................................................................................. 10-31 Distribution .................................................................................................................................. 10-33
Appendix Progress Check Answer Sheet. ...................................................................................... A-1 Bibliography .................................................................................................................... A-2
Index Index ................................................................................................................................ Index 1
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