簡易檢索 / 詳目顯示

研究生: 陳君涵
Chen, Juin-Han
論文名稱: 訂單允諾與可承諾量之分配計劃
Order Promising with ATP Allocation Planning
指導教授: 林則孟
Lin, James T.
口試委員:
學位類別: 博士
Doctor
系所名稱: 工學院 - 工業工程與工程管理學系
Department of Industrial Engineering and Engineering Management
論文出版年: 2010
畢業學年度: 98
語文別: 英文
論文頁數: 112
中文關鍵詞: 訂單允諾可承諾量TFT-LCD產業顧客指定用料/廠區先進規劃與排程系統
外文關鍵詞: Order promising, Available-to-promise (ATP), TFT-LCD manufacturing, Customer’s preference material/plant constraint, Advanced planning and scheduling (APS)
相關次數: 點閱:2下載:0
分享至:
查詢本校圖書館目錄 查詢臺灣博碩士論文知識加值系統 勘誤回報
  • 由主生產排程(Master Production Schedule; MPS)所計算出之可承諾量(Available-to-Promise; ATP),是指尚未被用於承諾顧客訂單的存貨量以及主生產排程的計劃生產量,據以回覆顧客訂單可允諾之數量與交期。此訂單允諾機制採用先到先服務(First-Come-First-Served; FCFS)之原則,將所有訂單之重要度視為一致,且只考量成品之可承諾量,因此僅適用於存貨式生產模式(Make-to-Stock; MTS)。然而,由於目前大量客製化成為顧客訂單需求之趨勢,製造商逐漸將其生產模式轉變為接單後組裝的生產模式(Assemble-to-Order; ATO)或接單後製造的生產模式(Make-to-Order; MTO),以滿足來自客戶需求端的要求限制,例如指定產品用料供應商、指定生產廠區等限制。而且,由於大量客製化也將造成不同的產品價位與訂單契約合作關係,導致差別化與區隔化顧客需求。
    許多製造商導入先進規劃與排程系統(Advanced Planning and Scheduling; APS)來協助供應鏈環境下之生產相關規劃,其中的訂單允諾與可承諾量模組,即是在將可承諾之製造資源配置給各個需求訂單,進而回覆顧客可承諾之交期與數量。在ATO或MTO模式下,顧客必須等候產品的前置時間要比MTS模式長,不過顧客至少希望可以獲知可靠的允諾時間與數量,因此訂單允諾機制的可靠性就顯得非常重要。
    首先,因應生產模式由MTS轉變為ATO與MTO,在進行訂單允諾時必須考量來自客戶需求端的要求限制如指定產品用料供應商、指定生產廠區等限制等,本研究以TFT-LCD產業為例,探討在ATO或MTO生產模式下之訂單允諾規劃,考量接單後之物料與產能等製造資源之特性與限制如:顧客指定用料、顧客指定廠區、物料相容性等,以及訂單產品之利潤與顧客之重要程度等,利用混整數規劃模式(Mixed Integer Linear Programming; MILP),將產能與物料之生產製造資源進行最佳化之配置規劃。
    其次,為了保留物料與產能等製造資源給重要的顧客或高利潤產品,本研究提出兩階段式的訂單允諾程序。在第一階段,依據預測之各顧客對各產品需求量,將可承諾量ATP根據優先配置法則,依序配置保留給重要的顧客或高利潤產品;在第二階段,則依據實際顧客之訂單需求量,考量可承諾之製造資源、來自顧客之要求限制(如:指定用料供應商等)以及階段一的保留量限制,將可承諾之製造資源配置給各個需求訂單,進而回覆顧客可允諾之交期與數量。其中利用混合整數規劃模式,將產能與物料之生產製造資源進行最佳化之配置規劃,並以TFT-LCD產業為例,探討所提出之兩階段式的訂單允諾程序的有效性。


    Available-to-promise (ATP) calculating from master production schedule (MPS) exhibit availability of manufacturing resources that can be used to support customer order promising. This traditional order promising mechanism is adapted in MTS (make-to-stock) production model and all orders are treated the same on first-come-first-served (FCFS) policy. However, increasingly mass customization results in production model gradually transfers from MTS to ATO (assembly-to-order) or MTO (make-to-order) in order to fulfill the requests from customers such as customer’s preference materials/plants or specifications for the ordered products. Moreover, mass customization also drives the trend of customer demand to segmentation and prioritization according to differential product profit, sales growth potential, contracts or the relationships with customers.
    Many manufacturers employ advanced planning and scheduling (APS) solutions with new planning and scheduling techniques to support supply chain planning. In which, the solution module of order promising & ATP is to match customer orders against available manufacturing resources and then to reply promised quantities and due dates. In ATO or MTO model, the manufacturing resource such as materials and capacity after order penetration point should be checked and allocated for customer orders considering customer’s preference constraints. An upstream CODP (customer order decoupling point) such as ATO or MTO involves rather long order lead-time but customers at least want to get a reliable promise that they can receive the products in the promised quantities at the promised dates. Therefore, order promising process is very important within such competitive supply chain environment to build core-competence through reliable order promises in order to retain customers and increase market share.
    First, this research proposes one order promising mechanism that applies mixed integer linear programming (MILP) model to prioritize allocating manufacturing resource for high profit products or important customers and to consider material and capacity constraints after order penetration point. Furthermore, this order promising mechanism takes thin film transistor liquid crystal display (TFT-LCD) manufacturing as illustration for these material and capacity constraints after order penetration point.
    Second, to reserve manufacturing resources for high-margin products or high-priority customers, this dissertation proposes two-phase order promising process. In phase 1, ATP are reserved (called Allocated ATP; AATP) first for the demand with higher profit or higher priority. And then in phase 2, customer orders are promised according to time-phase supply calendar of manufacturing resource and restricted by the AATP in phase 1 and requests from customers such as customer’s preference material/plant constraint. In which, mixed integer linear programming (MILP) is applied to prioritize allocating manufacturing resource for high profit products or important customers and to consider customer’s preference material/plant constraints after CODP.
    One TFT-LCD manufacturing is taken as illustration for demonstrating the validity of the proposed two-phase order promising process. The results of numerical comparison show that the proposed two-phase order promising process can assist company to reserve manufacturing resources beneficially in advance phase 1 and then to provide more reliable customer order promises in phase 2 with considering available resources and requests from customers such as customer’s preference material/plant constraint.

    ABSTRACT LIST OF FIGURES LIST OF TABLES Chapter 1. INTRODUCTION 1.1 Research Background and Motivation 1.1.1 The role of order promising 1.1.2 The influence of CODP on order promising and ATP 1.2 Purpose of Research 1.3 Research Organization 2. LITERATURE REVIEW 2.1 Order Promising Based on the ATP of Finished Goods Level 2.2 Order Promising Based on the ATP of Manufacturing Resources Levels 2.3 Order Promising by Interacting with Manufacturing Resource Planning 3. ORDER PROMISING WITH ATP ALLOCATION PLANNING 3.1 Problem Statement 3.2 ATP Allocation Planning Mechanism 3.3 ATP Allocation Planning Model 3.4 TFT-LCD Manufacturing as Illustration 3.4.1 Introduction of TFT-LCD Manufacturing 3.4.2 Numerical Examples and Result Analysis 4. TWO-PHASE ORDER PROMISING PROCESS 4.1 Problem Statement 4.2 Two-Phase Order Promising Process 4.3 Planning Models for Two-Phase Order Promising Process 4.3.1 Forecast Reservation Planning Model for Phase I 4.3.2 ATP Allocation Planning Model for Phase II 4.4 TFT-LCD Manufacturing as Numerical Illustration 4.4.1 The critical characteristics of TFT-LCD manufacturing 4.4.2 The hierarchical planning framework of TFT-LCD manufacturing 4.4.3 The two-phase order promising process in the hierarchical planning framework of TFT-LCD manufacturing 4.4.4 Numerical illustration and result analysis 4.5 Sensitivity analysis 4.5.1 Description and analysis data 4.5.2 Scenario design and results 4.5.3 Summary and managerial insights 5. CONCLUSION AND FUTURE RESEARCH 5.1 Conclusion 5.2 Future Research References

    Bagchi, U., Julien, F. M. and Magazine, M. J., Due-date assignment to multi-job customer orders. Manag. Sci., 40(10), 1994, 1389-1392.
    Ball, M. O., Chen, C. Y. and Zhao, Z. Y., Material compatibility constraints for make-to-order production planning. Oper. Res. Lett., 31, 2003, 420-428.
    Ball, M.O., Chen, C.Y. and Zhao, Z.Y., Available to promise, Working Paper, Rober H Smith School of Business, University of Maryland, 2002.
    Belobaba, P. P., Airline yield management: An overview of sear inventory control. Transport. Sci., 21(3), 1987, 63-73.
    Bermudez, J., Advanced planning and scheduling: Is it as goods as it sounds? The report on supply chain management, Advanced Manufacturing Research, 1998, 1-24.
    Bertrand, J. W., Zuijderwijk, M. M. and Hegge, H. M. H., Using hierarchical pseudo bills of material for customer order acceptance and optimal material replenishment in assemble to order manufacturing of non-modular products. Int. J. Prod. Econ., 66, 2000, 171-184.
    Blackstone Jr., J. H. and Cox III, J. F., APICS Dictionary, Alexandria, VA, 12th ed., 2008.
    Chanas, S. and Kasperski, A., Minimizing maximum lateness in a single machine scheduling problem with fuzzy processing times and fuzzy due dates. Engineering Applications of Artificial Intelligence, 14, 2001, 377-386.
    Chanas, S. and Kasperski, A., On two single machine scheduling problems with fuzzy processing times and fuzzy due dates. Eur. J. Oper. Res., 147, 2003, 281-296.
    Chen, C. T. and Huang, S. F., Order-fulfillment ability analysis in the supply-chain system with fuzzy operation times. Int. J. Prod. Econ., 101, 2006, 185-193.
    Chen, C. Y., Zhao, Z. Y. and Ball, M. O., Quantity and due date quoting available to promise. Inform. Syst. Front., 3(4), 2001, 477-488.
    Chen, C. Y., Zhao, Z. Y. and Ball, M. O., A model for batch advanced available-to-promise. Prod. Oper. Manag., 11(4), 2002, 424-440.
    Chen, J. H., Lin, J. T. and Wu, Y. S., Order Promising Rolling Planning with ATP/CTP Reallocation Mechanism, Ind. Eng. & Manage. Syst., 7(1), 2008, 57-65.
    Cheng, T. C. E. and Gupa, M. C., Survey of scheduling research involving due date determination decisions. Eur. J. Oper. Res., 38, 1989, 156-166.
    Christou, I. T. and Ponis, S., A hierarchical system for effective coordination of available-to-promise logic mechanisms. Int. J. Prod. Res., 47(11), 2009, 3063-3078.
    Duenyas, I., Single facility due date setting with multiple customer classes. Manag. Sci., 41(4), 1995, 608-619.
    Fleischmann, B. and Meyr, H., Customer orientation in advanced planning systems, In: Dyckhoff, H., Lackes R., Reese, J. (Eds.), Supply Chain Management and Reverse Logistics. Springer, Berlin et al., pp. 297-321, 2003.
    Fleischmann, B., Meyr H. and Wagner, M., Advanced planning, In:Stadtler H., Kilger, C. (Eds.), Supply Chain Management and Advanced Planning Concepts, Models, Software and Case Studies, Springer, Berlin, pp. 81-106, 2005.
    Garcia-Diaz, A. and Kuyumcu, A., A cutting-plane procedure for maximizing revenues in yield management. Comput. Ind. Eng., 33(1-2), 1997, 51-54.
    Guerrero, H. H., Demand management strategies for assemble-to-order production environments. Int. J. Prod. Res., 29(1), 1991, 39-51.
    Gunther, H. O., Supply chain management and advanced planning systems: A tutorial, in Proceedings of the 33rd International Conference on Computers and Industrial Engineering, Jeju, Korea, 2004, March 25-27.
    Harris, F. H. deB. and Pinder, J. P., A revenue management approach to demand management and order booking in assemble-to-order manufacturing. J. Oper. Manag., 13, 1995, 299-309.
    Hegedus, M. G. and Hopp, W. J., Due date setting with supply constraints in systems using MRP. Comput. Ind. Eng., 39, 2001, 293-305.
    Hendry, L. C. and Kingsman, B. G., Production planning systems and their applicability to make-to-order companies. Eur. J. Oper. Res., 40, 1989, 1-15.
    Hiller, F. S. and Lieberman, G. J., Introduction to Operations Research, (8th ed.), McGraw-Hill, New York, 2005.
    Hoekstra, S. and Romme, J. (Eds.), Integral Logistic Structures: Developing Customer-oriented Goods Flow, Industrial Press Inc., New York, 1991.
    Hopp, W. J. and Roof Sturgis, M. L., Quoting manufacturing due dates subject to a service level constraint. IIE T., 32, 2000, 771-784.
    Jeong, B., Sim, S. B., Jeong, H. S. and Kim, S. W., An available-to-promise system for TFT LCD manufacturing in supply chain. Comput. Industrial Eng., 43, 2002, 191-212.
    Jung, H., Song, I., Jeong, B. and Yoo, W., An optimized ATP (Available-to-promise) system for make-to-order company in supply chain environment. Int. J. Industr. Eng., 10(4), 2003, 367-374.
    Kern, G. M. and Guerrero, H. H., A conceptual model for demand management in the assemble-to-order environment. J. Oper. Manag., 9(1), 1990, 65-84.
    Kilger, C. and Schneeweiss, L., Demand fulfillment and ATP, In:Stadtler H., Kilger, C. (Eds.), Supply Chain Management and Advanced Planning Concepts, Models, Software and Case Studies, Springer, Berlin, pp. 179-195, 2005.
    Kimes, S. E., Yield management: A tool for capacity-constrained service firms. J. Oper. Manag., 8(4), 1989, 348-363.
    King, B. E. and Benton, W. C., Master production scheduling, customer service and manufacturing flexibility in an assemble-to-order environment. Int. J. Prod. Res., 26(6), 1988, 1015-1036.
    Kuroda, M. and Wang, Z., Fuzzy job shop scheduling. Int. J. Prod. Econ., 44, 1996, 45-51.
    Lam, S. S. and Cai, X., Single machine scheduling with nonlinear lateness cost functions and fuzzy due dates. Nonlinear Analysis: Real Word Applications, 3, 2002, 307-316.
    Lin, J. T., Chang, P., Chen, J. H. and Xin, W. X., KPI With Data Flow Analysis for CPFR: A CMC Case Study. Int. J. Electron. Bus. Manuf., 1(3), 2003, 110-119.
    Lin, J. T. and Chen, J. H., Enhance order promising with ATP allocation planning considering material and capacity constraints. J. Chinese Inst. Industr. Eng., 22(4), 2005, 282-292.
    Lu, C. Y., ATP-based demand fulfillment process, Department of Industrial Engineering and Engineering Management, National Tsing Hua University, Hsinchu, Taiwan, 2003.
    McClelland, M. K., Order promising and master production schedule. Decis. Sci., 19(4), 1988, 858-879.
    Meyr, H., Customer segmentation, allocation planning and order promising in make-to-stock production. OR Spectrum, 31, 2009, 229-256.
    Ozdamar, L. and Yazgac, T., Capacity driven due date settings in make-to-order production systems. Int. J. Prod. Econ., 49, 1997, 29-44.
    Pibernik, R., Advanced available-to-promise: classification, selected methods and requirements for operations and inventory management. Int. J. Prod. Econ., 93-94, 2005, 1015-1036.
    Pibernik, R. and Yadav, P., Inventory reservation and real-time order promising in a make-to-stock system. OR Spectrum, 31, 2009, 281-307.
    Rudberg, M. and Wikner, J., Mass customization in terms of the customer order decoupling point. Prod. Plan. Control, 15(4), 2004, 445-458.
    Sauer, J., Suelmann, G. and Appelrath, H. J., Multi-site scheduling with fuzzy concepts. International Journal of Approximate Reasoning, 19, 1998, 145-160.
    Sheikh, K., Manufacturing resource planning (MRP II) with introduction to ERP, SCM, and CRM, McGraw-Hill, Inc, New York, 2002.
    Tajima, A. and Misono, S., Using a set packing formulation to solve airline seat allocation/reallocation problems. J. Oper. Manag., 42(1), 1999, 32-44.
    Tamura, T. and Fujita, S., Designing customer oriented production planning system (COPPS). Int. J. Prod. Econ., 41, 1995, 377-385.
    Taylor, S. G. and Plenert, G. J., Finite capacity promising. Prod. Invent. Manage. J., 40(3), 1999, 50-56.
    Vollmann, T. E., Berry, W. L. and Whybark, D. C., Manufacturing Planning and Control Systems, (4th ed.), McGraw-Hill, New York, 1997.
    Wang, C., Wang, D., Ip, W. H. and Yuen, D. W., The single machine ready time scheduling problem with fuzzy processing times. Fuzzy Sets and Systems, 127, 2002, 117-129.
    Wang, W., Wang, D. and Ip, W. H., JIT production planning approach with fuzzy due date for OKP manufacturing systems. Int. J. Prod. Econ., 58, 1999, 209-215.
    Wang, Y., Folchi, J., Blanco, T. S. and Lath, S., Exploting airline reservation technologies to improve Navy training management. Int. T. Oper. Res., 4(3), 1997,185-197.
    Ware, N. and Fogarty, D. W., Master schedule / master production schedule: the same or different? Prod. Invent. Manage. J., 31(1), 1990, 34-38.
    Weatherford, L. R. and Bodily, S. E., A taxonomy and research overview of perishable-asset revenue management: Yield management, overbooking, and pricing. Oper. Res., 40(5), 1992, 831-844.
    Weeda, P. J., A stochastic model for forecast consumption in master scheduling. Int. J. Prod. Econ., 35, 1994, 401-404.
    Wortmann, J. C., Muntslag D. R. and Timmermans P. J. M., Customer-driven manufacturing, Chapman & Hall, London, pp. 59-73, 1997.
    Xiong, M. H., Tor, S. B., Khoo, L. P. and Chen, C. H., A web-enhanced dynamic BOM-based available-to-promise system. Int. J. Prod. Econ., 84, 2003a, 133-147.
    Xiong, M. H., Tor, S. B. and Khoo, L. P. WebATP: a Web-based flexible available-to-promise computation system. Prod. Plan. Control, 14(7), 2003b, 662-672.
    Yeh, C. H., A customer-focused planning approach to make-to-order production. Industr. Manage. Data Syst., 100(4), 2000, 180-187.

    無法下載圖示 全文公開日期 本全文未授權公開 (校內網路)
    全文公開日期 本全文未授權公開 (校外網路)
    全文公開日期 本全文未授權公開 (國家圖書館:臺灣博碩士論文系統)
    QR CODE