面向大规模定制的重钢公司产销一体化系统研究
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摘要
随着市场竞争的加剧,用户需求的个性化日益凸现,企业尤其是中小企业要立足于市场,必须有能力及时生产出满足用户个性化需求的产品,同时有效降低成本。因此对企业组织产销过程敏捷地响应市场提出了更高的要求。
重钢公司的生产模式为小批量、多品种的生产模式,其产品上万种,大部分(65%以上)板材都属于客户化定制的产品,如何能够达到客户的要求,及时、有效地根据合同对产品生产全流程的信息进行跟踪,同时把成本降低作为一个关键的问题。
本文首先针对重钢公司的生产模式及需求,结合大规模定制的理论和相关技术,对面向大规模定制的重钢产销一体化系统进行了总体设计:确定了基于四层结构的重钢产销一体化框架,构建了重钢产销一体化集成运行流程,并对主要功能系统进行了设计。
其次,针对重钢生产过程中流程长,订单和物料实时跟踪难的问题,提出了以炉号、生产批次为依据物料跟踪模型,该模型可以区别具有相同属性的同一批物料;再根据生产号和订单号的对应关系建立了订单跟踪模型;在此基础上,对以合同为主轴的产销全流程跟踪系统进行了层次结构设计和功能结构设计。
最后,为实现炼钢环节的动态成本跟踪,采用了基于作业的动态成本方法,建立了基于作业的重钢动态成本集成管理体系。在实现物料跟踪的基础上,研究了生产数据向成本数据转化的方法,建立了基于物料跟踪的动态作业成本计算模型;在此基础上进行了动态成本系统的设计。
本文的研究结果和涉及到的技术方法在重钢公司产销一体化系统的设计和实施中得到了应用,取得了较好的应用效果;以本文研究内容作为重要组成部分的国家高技术研究发展计划(863计划)课题“冶金行业信息集成技术研究开发与应用(编号:2005BA201A88)”已顺利通过国家科技部组织的项目验收并获好评。
With the competition of market pricking up, the individuation of the users’demand is represented evidently, corporations especially the mini and middle corporations want to take a position on the market, they must have ability to manufacture the productions which can satisfy the individuation of the users’demand in time, and meanwhile, they must reduce the cost effectually. Consequently there is higher demand about corporations organize the process of produce and sale to answer market astutely.
The production mode of Chongqing Iron&Steel Corporation is small batches and many varieties. The variety of its production is counted by thousand, most of plank material (above 65%) are products which custom-built by the customers, how to obtain the demand of users and run after the information about the process of manufacturing production according to contract timely and effectual, at the same time, it will regard the reduce of the cost as the pivotal problem. In allusion to the problem above, based on the embed analytic of the integrative among produce and sale in Chongqing Iron&Steel corporation, the test researches system and the track mode of full flow information giving priority to the compact, while makes design the mode of dynamic cost of steel-making and systems analysis. The mostly research jobs as follows:
Firstly, based on the analytic of process of production and demand about Chongqing Iron&Steel corporation, it puts forward frame of produce and sale founded on four-floor structural, which conceives the integration function process of produce and sale about Chongqing Iron&Steel corporation.
Aimed at the long process of the produce and the difficult of the track about the order and material, it lodges the track mode which gist stove size and production batch, which can parts the same set materials having the same property; Secondly it sets up the track modes of orders basing the mark of production and order. Based on above, the test makes the design of hierarchy and function structure about the full flow track system of produce and sale according to the contract.
Lastly, in order to realize the dynamic cost track of the steel-making, it adopts the way of dynamic cost and puts forward the integration management system of dynamic cost about Chongqing Iron&Steel Corporation based on busywork. Based on the implement of the material track, it researches the mean which transforms the production data to cost data and lodges the costing mode of dynamic cost basing on the material track; It design the dynamic cost system based on above.
The result of the research and way of technique the test involved were applied well during the design and implement of Chongqing Iron&Steel produce and sale’system, and received preferable applied effect; The national high tech research and develop plan(863plan) task“the R&D and application about information integration technology of the metallurgy industry (number:2005BA201A88)”which regarded the study content of the test as an important part has passed the item check and accept by national science and technology organized and obtained well repute。
重钢公司的生产模式为小批量、多品种的生产模式,其产品上万种,大部分(65%以上)板材都属于客户化定制的产品,如何能够达到客户的要求,及时、有效地根据合同对产品生产全流程的信息进行跟踪,同时把成本降低作为一个关键的问题。
本文首先针对重钢公司的生产模式及需求,结合大规模定制的理论和相关技术,对面向大规模定制的重钢产销一体化系统进行了总体设计:确定了基于四层结构的重钢产销一体化框架,构建了重钢产销一体化集成运行流程,并对主要功能系统进行了设计。
其次,针对重钢生产过程中流程长,订单和物料实时跟踪难的问题,提出了以炉号、生产批次为依据物料跟踪模型,该模型可以区别具有相同属性的同一批物料;再根据生产号和订单号的对应关系建立了订单跟踪模型;在此基础上,对以合同为主轴的产销全流程跟踪系统进行了层次结构设计和功能结构设计。
最后,为实现炼钢环节的动态成本跟踪,采用了基于作业的动态成本方法,建立了基于作业的重钢动态成本集成管理体系。在实现物料跟踪的基础上,研究了生产数据向成本数据转化的方法,建立了基于物料跟踪的动态作业成本计算模型;在此基础上进行了动态成本系统的设计。
本文的研究结果和涉及到的技术方法在重钢公司产销一体化系统的设计和实施中得到了应用,取得了较好的应用效果;以本文研究内容作为重要组成部分的国家高技术研究发展计划(863计划)课题“冶金行业信息集成技术研究开发与应用(编号:2005BA201A88)”已顺利通过国家科技部组织的项目验收并获好评。
With the competition of market pricking up, the individuation of the users’demand is represented evidently, corporations especially the mini and middle corporations want to take a position on the market, they must have ability to manufacture the productions which can satisfy the individuation of the users’demand in time, and meanwhile, they must reduce the cost effectually. Consequently there is higher demand about corporations organize the process of produce and sale to answer market astutely.
The production mode of Chongqing Iron&Steel Corporation is small batches and many varieties. The variety of its production is counted by thousand, most of plank material (above 65%) are products which custom-built by the customers, how to obtain the demand of users and run after the information about the process of manufacturing production according to contract timely and effectual, at the same time, it will regard the reduce of the cost as the pivotal problem. In allusion to the problem above, based on the embed analytic of the integrative among produce and sale in Chongqing Iron&Steel corporation, the test researches system and the track mode of full flow information giving priority to the compact, while makes design the mode of dynamic cost of steel-making and systems analysis. The mostly research jobs as follows:
Firstly, based on the analytic of process of production and demand about Chongqing Iron&Steel corporation, it puts forward frame of produce and sale founded on four-floor structural, which conceives the integration function process of produce and sale about Chongqing Iron&Steel corporation.
Aimed at the long process of the produce and the difficult of the track about the order and material, it lodges the track mode which gist stove size and production batch, which can parts the same set materials having the same property; Secondly it sets up the track modes of orders basing the mark of production and order. Based on above, the test makes the design of hierarchy and function structure about the full flow track system of produce and sale according to the contract.
Lastly, in order to realize the dynamic cost track of the steel-making, it adopts the way of dynamic cost and puts forward the integration management system of dynamic cost about Chongqing Iron&Steel Corporation based on busywork. Based on the implement of the material track, it researches the mean which transforms the production data to cost data and lodges the costing mode of dynamic cost basing on the material track; It design the dynamic cost system based on above.
The result of the research and way of technique the test involved were applied well during the design and implement of Chongqing Iron&Steel produce and sale’system, and received preferable applied effect; The national high tech research and develop plan(863plan) task“the R&D and application about information integration technology of the metallurgy industry (number:2005BA201A88)”which regarded the study content of the test as an important part has passed the item check and accept by national science and technology organized and obtained well repute。
引文
[1]卡瓦纳·L钢铁工业技术开发指南.韩静涛,王福明主译,北京:科学出版社,2000
[2]何麟生,杨章远,许志宏.应用信息技术加速我国钢铁工业现代化.钢铁,1996,31(4):81~83
[3]胡仁安.钢铁工业自动化的新技术(下).冶金自动化,2001,(2):8~9
[4]王纪韶,谢学钧.钢铁企业计算机管控一体化系统的设计与实践.自动化博览, 2001,28(3): 44~45
[5] Wu Yanrui.The Chinese steel industry:recent developments and prospects,Resources Policy, 2000,26(3):172~174
[6] Raymond McLeod,Jr.George Schell.Management Information System.2002
[7]漆永新.钢铁企业信息化成功之道.冶金管理,2003,(2):15~18
[8]欧文沛."上证50"联合调研--武钢股份调研报告.上海证券报,2004,8
[9]证券时报,http://media.stock.163.com,2005年3月14日
[10]郝颜辉,郝永敬等.MRPII与JIT的比较与集成.工业工程,2000,(3):21-24
[11]李昕.ERP在首钢东华机械厂的应用.辽宁工学院学报,2002,12(22):24-26
[12]干解民,王国栋,刘相华.现代企业信息化管理平台的构筑---宝钢整体产销管理系统的开发.东北大学学报(社会科学版),2000,7(2):33-35
[13]漆永新.钢铁企业信息化建设“十五”回顾.中国钢铁业.2006,(6):19-22
[14] Shari Lawrence Pfleeger.Software Engineering Theory and Practice.Higher Education Press Pearson Education.2001-8
[15] Wallace,T.F.“MRPII&JIT Work Together in Plan and Practice.”Automation. March 1990.pp.40-42
[16]王强,史贤荣,瞿晓川.ERP系统在钢铁行业的开发方式比较及趋势应对.中国制造业信息化,2005,34(10):72-74
[17]陈佳.我国制造业ERP应用分析与研究.中国制造业信息化.2003,32(1):75-78
[18]李桂陵,李云陵.网络经济时代提高企业竞争力的三大法宝—SCM,ERP,CRM[J].商业研究.2002,(4):35-37
[19] David J.Collis,Cynthia A.Montgomery.创建公司优势.Harvard Business Review May-June 1999,国外社会科学文摘,2000,(9)
[20]马广华.湘钢ERP的实施.中国计算机报.2003,(10):13-14
[21] Cooper R, Kaplan R S. Measure costs right: Make the right decisions [J]. Management Accounting, 1988.
[22] Cooper R, Kaplan R S. Activity-based Systems: Measuring the Cost of Resource Usage [J].Accounting Horizons, 1992:1-12.
[23] Ben-Arieh David, Qian Li. Activity-based cost management for design and development stage [J]. International Journal of Production Economics,2003,83 (2):169-183.
[24] Kaplan RS, Cooper R. Cost &Effect Using Integrated Cost Systems to Drive Profitability and Performance [J]. Harvard Business School Press,1997:40.
[25]李从东,齐二石,刘子先等.基于过程和成本动因理论的成本控制问题研究.系统工程理论与实践,1999,3(3):88-93.
[26]邓华,杜晶.基于企业资源计划的资源分类型作业成本管理模型.计算机集成制造系统-CIMS,2005,11(8):1069-1072.
[27]张人千,魏法杰.作业成本法的实用化模型探讨.工业工程,2001,4(6):2-3.
[28]刘晓敏,邓为民,刘其智.作业成本管理中的差异分析.管理评论,2003,17(2):27-31.
[29]丁立言,张铎.物流基础.第7版.北京:清华大学出版社,2000:55.
[30]汪方军.制造企业集成成本管理模式及应用研究:(博士学位论文)[D].西安:西安交通大学,2003.
[31]柴天佑,金以慧,任德祥等.基于三层结构的流程工业现代集成制造系统[J].控制工程,2002,9(3):1-6.
[32]王平心.作业成本计算理论与应用研究[M].大连:东北财经大学出版社,2001.
[33] J.B Sidney. Software for Activity-based management. Journal of Cost Management, 1999, 2(4):38-40.
[34] Liu Xiaobing, Meng Qiunan, Ma Yue. The Design and Implementation of the Special Steel Corporation-oriented Manufacturing Execution System. The Third International Conference on Electronic Commerce Engineering, Hangzhou, 2003.
[35]潘双夏,姜少飞,冯培恩,赵亮.产品生命周期的成本决策支持系统框架研究.计算机集成制造系统-CIMS,2002,8(11):881-886.
[36]张继焦.优化业务流程与组织,提升企业综合竞争力[M].北京:中国物价出版社,2001.
[37] PineⅡB. J. Victor, B., & Boynton, A. C. New competitive strategies: challenges to organization and information technology [J]. IBM Systems Journal.1993. 32(1),40-64.
[38]阴向阳,童秉,李和良等.大批量定制综述[EB/OL].http://www. cmd.cims.edu.cn/zpjs/ mc/papers, 2001-03-21.
[39]林勇,马士华.供应链管理(SCM)与信息技术(IT)[EB/OL]. http://www.mrp.com.cn/ SCM/ scm_it_ 0823.html,2001-03-21.
[2]何麟生,杨章远,许志宏.应用信息技术加速我国钢铁工业现代化.钢铁,1996,31(4):81~83
[3]胡仁安.钢铁工业自动化的新技术(下).冶金自动化,2001,(2):8~9
[4]王纪韶,谢学钧.钢铁企业计算机管控一体化系统的设计与实践.自动化博览, 2001,28(3): 44~45
[5] Wu Yanrui.The Chinese steel industry:recent developments and prospects,Resources Policy, 2000,26(3):172~174
[6] Raymond McLeod,Jr.George Schell.Management Information System.2002
[7]漆永新.钢铁企业信息化成功之道.冶金管理,2003,(2):15~18
[8]欧文沛."上证50"联合调研--武钢股份调研报告.上海证券报,2004,8
[9]证券时报,http://media.stock.163.com,2005年3月14日
[10]郝颜辉,郝永敬等.MRPII与JIT的比较与集成.工业工程,2000,(3):21-24
[11]李昕.ERP在首钢东华机械厂的应用.辽宁工学院学报,2002,12(22):24-26
[12]干解民,王国栋,刘相华.现代企业信息化管理平台的构筑---宝钢整体产销管理系统的开发.东北大学学报(社会科学版),2000,7(2):33-35
[13]漆永新.钢铁企业信息化建设“十五”回顾.中国钢铁业.2006,(6):19-22
[14] Shari Lawrence Pfleeger.Software Engineering Theory and Practice.Higher Education Press Pearson Education.2001-8
[15] Wallace,T.F.“MRPII&JIT Work Together in Plan and Practice.”Automation. March 1990.pp.40-42
[16]王强,史贤荣,瞿晓川.ERP系统在钢铁行业的开发方式比较及趋势应对.中国制造业信息化,2005,34(10):72-74
[17]陈佳.我国制造业ERP应用分析与研究.中国制造业信息化.2003,32(1):75-78
[18]李桂陵,李云陵.网络经济时代提高企业竞争力的三大法宝—SCM,ERP,CRM[J].商业研究.2002,(4):35-37
[19] David J.Collis,Cynthia A.Montgomery.创建公司优势.Harvard Business Review May-June 1999,国外社会科学文摘,2000,(9)
[20]马广华.湘钢ERP的实施.中国计算机报.2003,(10):13-14
[21] Cooper R, Kaplan R S. Measure costs right: Make the right decisions [J]. Management Accounting, 1988.
[22] Cooper R, Kaplan R S. Activity-based Systems: Measuring the Cost of Resource Usage [J].Accounting Horizons, 1992:1-12.
[23] Ben-Arieh David, Qian Li. Activity-based cost management for design and development stage [J]. International Journal of Production Economics,2003,83 (2):169-183.
[24] Kaplan RS, Cooper R. Cost &Effect Using Integrated Cost Systems to Drive Profitability and Performance [J]. Harvard Business School Press,1997:40.
[25]李从东,齐二石,刘子先等.基于过程和成本动因理论的成本控制问题研究.系统工程理论与实践,1999,3(3):88-93.
[26]邓华,杜晶.基于企业资源计划的资源分类型作业成本管理模型.计算机集成制造系统-CIMS,2005,11(8):1069-1072.
[27]张人千,魏法杰.作业成本法的实用化模型探讨.工业工程,2001,4(6):2-3.
[28]刘晓敏,邓为民,刘其智.作业成本管理中的差异分析.管理评论,2003,17(2):27-31.
[29]丁立言,张铎.物流基础.第7版.北京:清华大学出版社,2000:55.
[30]汪方军.制造企业集成成本管理模式及应用研究:(博士学位论文)[D].西安:西安交通大学,2003.
[31]柴天佑,金以慧,任德祥等.基于三层结构的流程工业现代集成制造系统[J].控制工程,2002,9(3):1-6.
[32]王平心.作业成本计算理论与应用研究[M].大连:东北财经大学出版社,2001.
[33] J.B Sidney. Software for Activity-based management. Journal of Cost Management, 1999, 2(4):38-40.
[34] Liu Xiaobing, Meng Qiunan, Ma Yue. The Design and Implementation of the Special Steel Corporation-oriented Manufacturing Execution System. The Third International Conference on Electronic Commerce Engineering, Hangzhou, 2003.
[35]潘双夏,姜少飞,冯培恩,赵亮.产品生命周期的成本决策支持系统框架研究.计算机集成制造系统-CIMS,2002,8(11):881-886.
[36]张继焦.优化业务流程与组织,提升企业综合竞争力[M].北京:中国物价出版社,2001.
[37] PineⅡB. J. Victor, B., & Boynton, A. C. New competitive strategies: challenges to organization and information technology [J]. IBM Systems Journal.1993. 32(1),40-64.
[38]阴向阳,童秉,李和良等.大批量定制综述[EB/OL].http://www. cmd.cims.edu.cn/zpjs/ mc/papers, 2001-03-21.
[39]林勇,马士华.供应链管理(SCM)与信息技术(IT)[EB/OL]. http://www.mrp.com.cn/ SCM/ scm_it_ 0823.html,2001-03-21.