V公司基于同步供货条件下的库存优化设计
摘要
V公司是一家外商独资企业在广州的分公司,也是专为为广州东风日产提供汽车零部件的供应商之一,该公司在2005年建厂时决策采用同步供货的供货方式准时将客户东风日产所需要的零部件配送到指定的总装线边滑道。为了顺利实现这种小批量多品种多频次的供货方式,V公司根据同步供货要求建立了以看板为基础的JIT拉动式生产模式:利用在成品库存的取货看板来拉动生产补货,利用零部件的取货看板来拉动原材料的订购,并以客户的需求预测及生产与运输的提前期,严格按照MRP的方法设定成品与原材料的库存数量和订货批量。在工厂实际运营中,这种库存控制策略只强调了不能缺货,并没有考虑在库存与运输成本的整体优化下的经济生产批量应该是多少,所以,在这种情况下,V公司工厂的物流运作现状就是库存水平居高不下,导致大量的资金积压在仓库原材料、半成品、包材上。所以,我们通过对V公司成品和原材料的库存水平与库存成本进行优化,在保证同步供货的前提下,设定合理的成品与原材料的经济生产批量,这将有利于减少V公司的库存资金,在保证平衡生产和满足客户的需求前提条件下增加现金流。
文章主要选用精益生产中价值流图的方法分析V公司为客户东风日产同步供货的生产与供应流程,分析了在满足同步供货条件下同步供货供应商的生产、库存和运输过程,主要的研究重点在于对成品和原材料库存联合优化进行了详细研究,建立了集成化的库存模型,完成了V公司在准时制生产模式下的库存优化方案。
F company is a tie1 supplier of DFL. As DFL’s request, F company implement synchronized supply system to provide components to assembly line of DFL JUST-IN-TIME. In order to achieve this kind of supply method of small lots and high frequency, F company setups a JIT pull production system based on KANBAN. Component production KANBAN of finished goods supermarket is used to start production. And material withdraw KANBAN is used to trigger replenishment of raw material. And MRP also is used for master production plan and raw material purchase. But this kind of inventory control policy only focuses on no shortage; never consider the cost and efficiency of inventory system. So, it causes high inventory level and hold lots of money in store. Optimal on inventory level and cost, will be helpful to reduce the operation cost, increase cash flow, and positive to economic crisis.
This paper uses the value stream analysis tool of lean manufacturing, to analysis the synchronized supply system between F Company and DFL, to analysis the process of material flow. And focus on optimal of integrated inventory, make a model for integrated inventory, and raise some ideas for this JIT system.
文章主要选用精益生产中价值流图的方法分析V公司为客户东风日产同步供货的生产与供应流程,分析了在满足同步供货条件下同步供货供应商的生产、库存和运输过程,主要的研究重点在于对成品和原材料库存联合优化进行了详细研究,建立了集成化的库存模型,完成了V公司在准时制生产模式下的库存优化方案。
F company is a tie1 supplier of DFL. As DFL’s request, F company implement synchronized supply system to provide components to assembly line of DFL JUST-IN-TIME. In order to achieve this kind of supply method of small lots and high frequency, F company setups a JIT pull production system based on KANBAN. Component production KANBAN of finished goods supermarket is used to start production. And material withdraw KANBAN is used to trigger replenishment of raw material. And MRP also is used for master production plan and raw material purchase. But this kind of inventory control policy only focuses on no shortage; never consider the cost and efficiency of inventory system. So, it causes high inventory level and hold lots of money in store. Optimal on inventory level and cost, will be helpful to reduce the operation cost, increase cash flow, and positive to economic crisis.
This paper uses the value stream analysis tool of lean manufacturing, to analysis the synchronized supply system between F Company and DFL, to analysis the process of material flow. And focus on optimal of integrated inventory, make a model for integrated inventory, and raise some ideas for this JIT system.
引文
[1]杨帅.几类库存控制模型及其应用[D].重庆大学, 2005:9-23
[2] Clark, A.J., Scarf,H..Optimal policies for a multi-echelon inventory problem[J]. Management Science, 1960(6):475-490
[3] Banerjee, A.. A joint economic lot size model for purchaser and vendor. Decision Science, 1986(17):291-311
[4] Goyal,S.K..A joint economic lot size model for purchaser and vendor: A comment. Decision Science, 1988(19):236-241
[5] Banerjee A.,Kim S.L. An integrated JIT inventory model[J]. International Journal of Operation & Production Management, 1995, 15(9):237-244
[6]Bhaba R.Sarker,Gyana R.Parija.Optimal batch size and raw material ordering policy for aproduction system with a fixed-interval,lumpy demand delivery system[J].European Journalof Operational Research,1996(89):593-608.
[7] Ha,D.,Kim,S.L..Implementation of JIT purchasing: an integrated approach. Production Planning Control,1997[8]152-157
[8] Wee,H.M., Jong,J.F. . An integrated multi-lot-size production inventory model for deteriorating items. Management System, 1998(5):97-114
[9]R.Sarker, X. Yao. Simulated Annealing and Joint Manufacturing Batch-Sizing. Yugoslav Journal of Operations Research, 2003(13):245-259
[10]王圣东,周永务.基于原材料订购及预防性维修中断的EPQ模型[J].系统工程学报,2005,20(4):381-386,418.
[11]York Y.Woo,Shu-Lu Hsu,Soushan Wu.An integrated inventory model for a single vendorand multiple buyer with ordering cost reduction[J].Production Econmics,2001,73:203-215.
[12]余玉刚,梁樑,王晨,王志强.一种考虑最终产品变质的供应商管理库存集成模型[J].中国管理科学,2004,12(2):32-37.
[13]罗兵,杨帅,卢娜.部分短缺量拖后且考虑费用时值的VMI模型[J].控制与决策,2005,20(9):1061-1064.
[14]罗兵,卢娜,杨帅.耐烦期有限的供应商管理库存模型[J].重庆大学学报(自然科学版),2005,28(5):143-147.
[15]卢娜,罗兵,廖冰,杨帅.部分短缺量拖后且考虑最终产品变质的VMI模型[J].工业工程与管理,2005,10(6):23-27,32.
[16]Frank Y.CHEN,TONG WANG, TOMMY Z.XU. Integrated Inventory Replenishment and Temporal Shipment Consoldiation: A Comparison of Quantity-Based and Time-Based Models. Annals of Operations Research, 2005(135);197-210。
[17]陈晖.几类库存控制模型研究[D].重庆大学,2007
[18]余玉刚,梁樑,徐克安,王志强.考虑产品定价、生产能力和原料采购的VMI系统集成[J].中国科学技术大学学报,2006,36(7):781-787.
[19]方叶祥,陆敬筠,张元超.准时制下非核心企业最佳生产数学模型研究[J].数学的实践与认识, 2006, 36(6):16-22
[20]P.C.Yang,H.M.Wee,H.J.Yang.Global optimal policy for vendor-buyer integrated inventory system within just in time environment. Globe Optimal, 2007(37):505-511
[21]任芳.汽车工厂混流装配线物料供应策略研究[D],吉林大学, 2008
[22]杜鹏,王炬香,丁宝录. JIT环境下考虑运输成本的一种供需综合物料采购模型[J].科学技术与工程, 2008,8(5):1247-1251
[23]杜鹏,王炬香,丁宝录. JIT环境下供需采购模型的研究[J].运筹与管理, 2008, 17(2):93-97
[24]马宇波,徐克林.基于价值流图的L企业供应链分析[J].物流科技,2008,10:130-132
[25]杰弗瑞.莱克,戴维.梅尔.丰田汽车精益模式的实践[M].中国财政经济出版社, 2006,6:33-35
[26]何浩宇.同步供货制下的生产与物流控制[D].华中科技大学,2005
[27]李斌云.浅谈准时生产方式实施的若干问题[J].山西机械, 2003,6(2):6-7
[28]魏芬发.江淮汽车线束厂原材料库能制策略研究[D].合肥工业大学,2008:11-12
[29]黄晓裕.MRP II与JIT集成的生产库存管理研究[D].上海海事大学,2005:5-13
[30]赵禹骅,周小庄.JIT供应实现的必要条件-园区采购.科技管理研究,2006(4):220-221
[31]徐莉.关于经济订购量模型中有关成本的正确定界与计算[J].武汉水利电力大学学报,1999,32(4):96-98
[32]方四平.EOQ模型的敏感性分析.北京工业职业技术学院学报.2003,2(3):74-77
[33]森尼尔_乔普瑞,彼得_梅因德尔.供应链管理-战略、规划与运营[M].社会科学文献出版社,2003:194-205
[34]陈荣秋,马士华.生产运作管理[M].机械工业出版社,2006:214-215
[35]王平该.面向供应链的汽车制造业准时采购方式研究[D].华中科技大学,2005
[36]王廷丽.EOQ与零库存.社科纵横.2004,19(6):45-69
[2] Clark, A.J., Scarf,H..Optimal policies for a multi-echelon inventory problem[J]. Management Science, 1960(6):475-490
[3] Banerjee, A.. A joint economic lot size model for purchaser and vendor. Decision Science, 1986(17):291-311
[4] Goyal,S.K..A joint economic lot size model for purchaser and vendor: A comment. Decision Science, 1988(19):236-241
[5] Banerjee A.,Kim S.L. An integrated JIT inventory model[J]. International Journal of Operation & Production Management, 1995, 15(9):237-244
[6]Bhaba R.Sarker,Gyana R.Parija.Optimal batch size and raw material ordering policy for aproduction system with a fixed-interval,lumpy demand delivery system[J].European Journalof Operational Research,1996(89):593-608.
[7] Ha,D.,Kim,S.L..Implementation of JIT purchasing: an integrated approach. Production Planning Control,1997[8]152-157
[8] Wee,H.M., Jong,J.F. . An integrated multi-lot-size production inventory model for deteriorating items. Management System, 1998(5):97-114
[9]R.Sarker, X. Yao. Simulated Annealing and Joint Manufacturing Batch-Sizing. Yugoslav Journal of Operations Research, 2003(13):245-259
[10]王圣东,周永务.基于原材料订购及预防性维修中断的EPQ模型[J].系统工程学报,2005,20(4):381-386,418.
[11]York Y.Woo,Shu-Lu Hsu,Soushan Wu.An integrated inventory model for a single vendorand multiple buyer with ordering cost reduction[J].Production Econmics,2001,73:203-215.
[12]余玉刚,梁樑,王晨,王志强.一种考虑最终产品变质的供应商管理库存集成模型[J].中国管理科学,2004,12(2):32-37.
[13]罗兵,杨帅,卢娜.部分短缺量拖后且考虑费用时值的VMI模型[J].控制与决策,2005,20(9):1061-1064.
[14]罗兵,卢娜,杨帅.耐烦期有限的供应商管理库存模型[J].重庆大学学报(自然科学版),2005,28(5):143-147.
[15]卢娜,罗兵,廖冰,杨帅.部分短缺量拖后且考虑最终产品变质的VMI模型[J].工业工程与管理,2005,10(6):23-27,32.
[16]Frank Y.CHEN,TONG WANG, TOMMY Z.XU. Integrated Inventory Replenishment and Temporal Shipment Consoldiation: A Comparison of Quantity-Based and Time-Based Models. Annals of Operations Research, 2005(135);197-210。
[17]陈晖.几类库存控制模型研究[D].重庆大学,2007
[18]余玉刚,梁樑,徐克安,王志强.考虑产品定价、生产能力和原料采购的VMI系统集成[J].中国科学技术大学学报,2006,36(7):781-787.
[19]方叶祥,陆敬筠,张元超.准时制下非核心企业最佳生产数学模型研究[J].数学的实践与认识, 2006, 36(6):16-22
[20]P.C.Yang,H.M.Wee,H.J.Yang.Global optimal policy for vendor-buyer integrated inventory system within just in time environment. Globe Optimal, 2007(37):505-511
[21]任芳.汽车工厂混流装配线物料供应策略研究[D],吉林大学, 2008
[22]杜鹏,王炬香,丁宝录. JIT环境下考虑运输成本的一种供需综合物料采购模型[J].科学技术与工程, 2008,8(5):1247-1251
[23]杜鹏,王炬香,丁宝录. JIT环境下供需采购模型的研究[J].运筹与管理, 2008, 17(2):93-97
[24]马宇波,徐克林.基于价值流图的L企业供应链分析[J].物流科技,2008,10:130-132
[25]杰弗瑞.莱克,戴维.梅尔.丰田汽车精益模式的实践[M].中国财政经济出版社, 2006,6:33-35
[26]何浩宇.同步供货制下的生产与物流控制[D].华中科技大学,2005
[27]李斌云.浅谈准时生产方式实施的若干问题[J].山西机械, 2003,6(2):6-7
[28]魏芬发.江淮汽车线束厂原材料库能制策略研究[D].合肥工业大学,2008:11-12
[29]黄晓裕.MRP II与JIT集成的生产库存管理研究[D].上海海事大学,2005:5-13
[30]赵禹骅,周小庄.JIT供应实现的必要条件-园区采购.科技管理研究,2006(4):220-221
[31]徐莉.关于经济订购量模型中有关成本的正确定界与计算[J].武汉水利电力大学学报,1999,32(4):96-98
[32]方四平.EOQ模型的敏感性分析.北京工业职业技术学院学报.2003,2(3):74-77
[33]森尼尔_乔普瑞,彼得_梅因德尔.供应链管理-战略、规划与运营[M].社会科学文献出版社,2003:194-205
[34]陈荣秋,马士华.生产运作管理[M].机械工业出版社,2006:214-215
[35]王平该.面向供应链的汽车制造业准时采购方式研究[D].华中科技大学,2005
[36]王廷丽.EOQ与零库存.社科纵横.2004,19(6):45-69