Supply Chain Management and Advanced Planning (eBook)

Preface 5
Preface to the Third Edition 5
Preface to the Second Edition 7
Preface to the First Edition 8
Contents 11
Introduction 17
References 21
Basics of Supply Chain Management 22
1 Supply Chain Management – An Overview 23
1.1 Definitions 23
1.2 Building Blocks 25
1.3 Origins 38
References 47
2 Supply Chain Analysis 50
2.1 Motivation and Goals 50
2.2 Process Modelling 52
2.3 Performance Measurement 62
2.4 Inventory Analysis 69
References 75
3 Types of Supply Chains 77
3.1 Motivation and Basics 77
3.2 Functional Attributes 78
3.3 Structural Attributes 81
3.4 Example for the Consumer Goods Industry 83
3.5 Example for Computer Assembly 88
References 92
4 Advanced Planning 93
4.1 What is Planning? 93
4.2 Planning Tasks Along the Supply Chain 98
4.3 Examples of Type-Specific Planning Tasks and Planning Concepts 104
References 118
Concepts of Advanced Planning Systems 119
5 Structure of Advanced Planning Systems 120
References 126
6 Strategic Network Planning 127
6.1 Components of the Strategic Network Design Problem 131
6.2 Review of Models in the Literature 137
6.3 Modelling Strategic Supply Chain Design 138
6.4 SNP Modules in Advanced Planning Systems 143
6.5 Conclusions 144
References 146
7 Demand Planning 148
7.1 A Demand Planning Framework 148
7.2 Statistical Forecasting Techniques 152
7.3 Incorporation of Judgmental Factors 157
7.4 Additional Features 159
References 166
8 Master Planning 167
8.1 The Decision Situation 168
8.2 Model Building 174
8.3 Generating a Plan 182
References 185
9 Demand Fulfilment and ATP 186
9.1 Available-to-Promise (ATP) 187
9.2 Allocated ATP 193
9.3 Order Promising 198
References 202
10 Production Planning and Scheduling 203
10.1 Description of the Decision Situation 203
10.2 How to Proceed from a Model to a Production Schedule 204
10.3 Model Building 207
10.4 Updating Production Schedules 213
10.5 Number of Planning Levels and Limitations 215
References 219
11 Purchasing and Material Requirements Planning 221
11.1 Basics of Material Requirements Planning 221
11.2 Generation and Timing of Uncritical Orders 223
11.3 Quantity Discounts and Supplier Selection 228
References 232
12 Distribution and Transport Planning 234
12.1 Planning Situations 234
12.2 Models 240
References 248
13 Coordination and Integration 250
13.1 Coordination of APS Modules 250
13.2 Integration of APS 253
13.3 Supply Chain Event Management 261
References 262
14 Collaborative Planning 263
14.1 Introduction 264
14.2 Types of Collaborations 266
14.3 A Generic Collaboration Process 274
14.4 Software Support 280
References 282
Implementing Advanced Planning Systems 283
15 The Definition of a Supply Chain Project 284
15.1 Supply Chain Evaluation 286
15.2 Supply Chain Potential Analysis 294
15.3 Project Roadmap 300
References 303
16 The Selection Process 305
16.1 Creation of a Short List 306
16.2 APS Requirements 311
16.3 Implementation and Integration 313
16.4 Post-implementation Effort and Support Model 317
References 318
17 The Implementation Process 319
17.1 The APS Implementation Project 319
17.2 Modelling Phases of an APS-Project 334
References 339
Actual APS and Case Studies 340
18 Architecture of Selected APS 341
18.1 i2 Technologies – i2 Six.One 341
18.2 Peoplesoft – EnterpriseOneTM Supply Chain Planning 346
18.3 SAP – APO 350
References 353
19 SCM in a Pharmaceutical Company 354
19.1 Case Description 354
19.2 Objectives of Project 357
19.3 Planning Processes 360
19.4 Results and Lessons Learned 368
20 Food and Beverages 370
20.1 Case Description 370
20.2 Aim of the Project 376
20.3 Model Building in Peoplesoft Strategic Network Optimization 376
20.4 Implementing the Master Planning model 380
20.5 Results and Lessons Learned 386
References 387
21 Computer Assembly 388
21.1 Description of the Computer Assembly Case 388
21.2 Scope and Objectives 392
21.3 Planning Processes in Detail 394
21.4 Summary and Lessons Learned 404
References 405
22 Demand Planning of Styrene Plastics 406
22.1 Description of the Supply Chain 406
22.2 The Architecture of the Planning System 407
22.3 Model Building with SAP APO Demand Planning 409
22.4 The Demand Planning Process of the Styrene Plastics Division 414
22.5 Concluding Remarks 418
References 419
23 Semiconductor Manufacturing 420
23.1 Case Description 420
23.2 Objectives of Project 424
23.3 Model Building with the i2 Factory Planner 426
23.4 Lessons Learned 433
24 Scheduling of Synthetic Granulate 434
24.1 Case Description 434
24.2 Objectives 436
24.3 Modelling the Production Process in APO PP/ DS 436
24.4 Planning Process 447
24.5 Results and Lessons Learned 448
Conclusions and Outlook 451
25 Conclusions and Outlook 452
References 455
Supplement 456
26 Forecast Methods 457
26.1 Forecasting for Seasonality and Trend 457
26.2 Initialization of Trend and Seasonal Coefficients 463
References 467
27 Linear and Mixed Integer Programming 469
27.1 Linear Programming 469
27.2 Pure Integer and Mixed Integer Programming 473
27.3 Remarks and Recommendations 477
References 479
28 Genetic Algorithms 480
28.1 General Idea 480
28.2 Populations and Individuals 481
28.3 Evaluation and Selection of Individuals 483
28.4 Recombination and Mutation 485
28.5 Conclusions 486
References 487
29 Constraint Programming 488
29.1 Overview and General Idea 488
29.2 Constraint Satisfaction Problems 489
29.3 Constraint Propagation 490
29.4 Search Algorithms 492
29.5 Concluding Remarks 493
References 494
Index 495
About Contributors 503