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1、《生產(chǎn)計(jì)劃與控制》課程教學(xué)大綱 課程編號：200262英文名：Production Planning and Control 課程類別：專業(yè)主干（雙語）前置課：運(yùn)籌學(xué)；管理學(xué) 后置課：企業(yè)資源計(jì)劃學(xué) 分：3學(xué)分 課 時(shí)：51課時(shí)選定教材：Steven Nahmial.生產(chǎn)與運(yùn)作分析（第四版）影印版.清華大學(xué)出版社,2003年08 月 課程概述： 生產(chǎn)計(jì)劃與控制是生產(chǎn)管理的主體內(nèi)容，如同計(jì)算機(jī)系統(tǒng)沒有軟件將寸步難行，企業(yè)的生產(chǎn) 系統(tǒng)離開生產(chǎn)計(jì)劃與控制，將無法正常運(yùn)行，更談不上如何有效地將生產(chǎn)要素轉(zhuǎn)變?yōu)槲镔|(zhì)或 服務(wù)產(chǎn)品，在及時(shí)滿足客戶需求的同時(shí)，獲得最大的經(jīng)濟(jì)效益。尤其是在經(jīng)濟(jì)全球化和

2、市場 需求多樣化的21世紀(jì)，隨著企業(yè)資源計(jì)劃（ERP）、精益生產(chǎn)、大規(guī)模定制、供應(yīng)鏈管理 （SCM）等與現(xiàn)代生產(chǎn)管理相關(guān)的概念的出現(xiàn)，對于生產(chǎn)計(jì)劃與控制提出了新的要求，因此生 產(chǎn)計(jì)劃與控制課程不僅要傳授經(jīng)典的生產(chǎn)計(jì)劃與控制基本原理與方法，而且要包括先進(jìn)的生 產(chǎn)計(jì)劃與控制原理與方法。本課程包括基礎(chǔ)知識模塊、經(jīng)典的生產(chǎn)計(jì)劃與控制模塊和現(xiàn)代生 產(chǎn)計(jì)劃與控制模塊三個(gè)知識模塊。其中，基礎(chǔ)知識模塊含生產(chǎn)系統(tǒng)及生產(chǎn)管理戰(zhàn)略、需求預(yù) 測、庫存管理，經(jīng)典的生產(chǎn)計(jì)劃與控制模塊含綜合生產(chǎn)計(jì)劃、主生產(chǎn)計(jì)劃、物料需求計(jì)劃、 能力需求計(jì)劃、生產(chǎn)調(diào)度、項(xiàng)目計(jì)劃與控制，現(xiàn)代生產(chǎn)計(jì)劃與控制模塊含供應(yīng)鏈管理計(jì)劃、 JIT與豐田生

3、產(chǎn)方式、生產(chǎn)計(jì)劃新進(jìn)展（包括最優(yōu)化生產(chǎn)計(jì)劃、基于TOC的生產(chǎn)計(jì)劃、高級 計(jì)劃與排程、大規(guī)模定制及其生產(chǎn)計(jì)劃）。 教學(xué)目的： 作為現(xiàn)代生產(chǎn)與運(yùn)作管理重要部分的生產(chǎn)計(jì)劃與控制，同時(shí)亦是比較盛行的企業(yè)資源規(guī)劃 （ERP）系統(tǒng)中的最核心模塊。本課程的目的是幫助學(xué)生認(rèn)識生產(chǎn)管理的概念與重要性，以 及了解生產(chǎn)管理的各項(xiàng)做法，并增進(jìn)生產(chǎn)管理的執(zhí)行或運(yùn)用的能力。通過本課程的學(xué)習(xí)，1 幫助學(xué)生認(rèn)識生產(chǎn)管理的概念與重要性，培養(yǎng)學(xué)生的生產(chǎn)計(jì)劃意識和應(yīng)用本課程所介紹的方 法編制初步的生產(chǎn)計(jì)劃，使學(xué)生通過本課程的學(xué)習(xí)后能夠解決企業(yè)存在的比較簡單的生產(chǎn)管 理問題；2能夠簡單應(yīng)用計(jì)算機(jī)軟件系統(tǒng)編制生產(chǎn)計(jì)劃，包括預(yù)測和定

4、單等數(shù)據(jù)輸入、建構(gòu) 產(chǎn)品的B0M等。 教學(xué)方法： 本課程課堂教學(xué)主要采用多媒體授課，并輔助以案例教學(xué)、課堂討論和軟件應(yīng)用。 各章教學(xué)要求及教學(xué)要點(diǎn)第一章生產(chǎn)系統(tǒng)和運(yùn)作策略（Production system and operation strategy） 課時(shí)分配：6課時(shí)教學(xué)要求： 通過本章的教學(xué)，使學(xué)生了解生產(chǎn)與生產(chǎn)系統(tǒng)、生產(chǎn)流程與生產(chǎn)方式、生產(chǎn)管理的研究內(nèi)容 及與生產(chǎn)管理的關(guān)系、生產(chǎn)管理的基本概念。 教學(xué)內(nèi)容： 1.1 Basic conception of Production & OperationsOrganization of production system 1

5、.2 Production system and its classificationOperations Management &Operations Strategy 1.3 The Classical View of Operations StrategyModern Operations Strategy and Competition 1.4 Matching Process and Product Life CyclesCapacity Growth Planning 思考題： 1. Compare different type of production system c

6、lassified based on customization degree, point out in which situation they can be used, illustrate theirs advantages and disadvantages, and used some practical examples to explain in details. 2. Compare the four classical view of Operation Strategy, point out theirs different management emphasis an

7、d different application enterprises, enumerate practical examples. 3. Enumerate the main strategic initiatives, use the practical enterprises to illustrate theirs characteristics, advantages and disadvantages. 4. a. What are the four phases of the manufacturing process that appear in the product-p

8、rocess matrix. b. Discuss the disadvantages of operating off the diagonal of the matrix. 5. What is the difference between the product life cycle and the process life cycle? In what way are these concepts related? 第二章 需求預(yù)測(Forecasting)課時(shí)分配：6課時(shí) 教學(xué)要求： 通過本章的教學(xué)，使學(xué)生了解預(yù)測基本概念。掌握預(yù)測的定性分析和定量分析方法，主要的 定性分析

9、方法有：一般預(yù)測方法、市場調(diào)研、小組共識、歷史類比和德爾菲法。重點(diǎn)掌握定 量預(yù)測的分析方法，主要有時(shí)間序列分析技術(shù)和因果預(yù)測，時(shí)間序列分析有簡單移動(dòng)平均法、 加權(quán)移動(dòng)平均法、時(shí)間序列分解和指數(shù)平滑法，掌握可用于時(shí)間序列分析和因果預(yù)測的線性 回歸分析方法。 教學(xué)內(nèi)容： 2.1 The Time Horizon in ForecastingCharacteristics of Forecasts 2.2 Subjective Foresting MethodsObjective Forecasting Methods 2.3 Notation Conventions and Evaluat

10、ing ForecastMethods for Forecasting Stationary Series. 2.4 Trend-Based MethodsMethods for Seasonal Series 思考題： 1. What does the term biased mean in reference to a particular forecasting technique? 2. Observed weekly sales of ball peen hammers at the town hardware store over an eight-week period

11、have been 14,9,30,22,34,12,19,23. suppose that three-week moving averages are used to forecast sales. Determine the one-step-ahead forecasts for weeks 4 through 8. Suppose that exponential smoothing is used with a smoothing constant of a=.15. Find the exponential smoothing forecasts for weeks 4 th

12、rough8.( To get the method started, use the same forecast for week 4 as you used in part(a).)Based o the MAD, which method did better? What is the exponential smoothing forecast made at the end of week 6 for the sales in week 12? 第三章 綜合生產(chǎn)計(jì)劃Aggregate Planning課時(shí)分配：6課時(shí) 教學(xué)要求： 通過本章的教學(xué)，使學(xué)生了解綜合生產(chǎn)計(jì)劃的基本概念

13、。掌握綜合生產(chǎn)計(jì)劃的直觀試算方法、 運(yùn)輸方法（圖解法）。 教學(xué)內(nèi)容： 3.1 Aggregate unit of productionCosts in Aggregate planning 3.2 A prototype problemSolution of Aggregate planning problems 思考題： Harold Grey owns a small farm in the Salinas Valley that grows apricots. The apricots are dried on the premises and sold to a number

14、of large supermarket chains. Based on past experience and committed contracts, he estimates that sales over the next five years in thousands of packages will be as follows: Year Forecasted Demand (thousands of packages) 1 300 2 120 3 200 4 110 5 135 Assume that each worker stays on the

15、job for at least one year; and that Grey currently has three workers on the payroll. He estimates that he will have 20,000 packages on hand at the end of the current year. Assume that, on the average, each worker is paid $25,000 per year and is responsible for producing 30,000 packages. Inventory co

16、sts have been estimated to be 4 cents per package per year, and shortages are not allowed. Based on the effort of interviewing and training new workers, Farmer Grey estimates that it costs $500 for each worker hired. Severance pay amounts to $1,000 per worker. a. Assuming that shortages are not all

17、owed, determine the minimum constant workforce that he will need over the next five years. b. Evaluate the cost of the plan found in part (a). 第四章 已知需求的庫存控制Inventory Control Subject to Known Demand課時(shí)分配：6課時(shí) 教學(xué)要求： 了解庫存分析與控制基本概念:庫存的類型、持有庫存的目的、庫存系統(tǒng)的特征以及庫存系， 重點(diǎn)掌握庫存分析的模型：定量訂貨模型。 教學(xué)內(nèi)容： 4.1 Types of I

18、nventoriesMotivation for Holding Inventories 4.2 Characteristics of Inventory SystemsRelevant Costs 4.3 The EOQ ModelEOQ Model with Finite Production Rate 思考題： A specialty coffeehouse sells Colombian coffee at a fairly steady rate of 280 pounds annually. The beans are purchased from a local suppl

19、ier for $2.40 per pound. The coffeehouse estimates that it costs $45 in paperwork and labor to place an order for the coffee, and holding costs are based on a 20 percent annual interest rate. a. Determine the optimal order quantity for Colombian coffee. b. What is the time between placement of ord

20、ers? c. What is the average annual cost of holding and setup due to this item? d. If replenishment lead time is three weeks, determine the reorder level based on the on-hand inventory. 第五章 不確定需求的庫存控制 Inventory Control Subject to Uncertain Demand課時(shí)分配：6課時(shí) 教學(xué)要求： 掌握庫存ABC分析基本思想和庫存盤點(diǎn)。重點(diǎn)掌握庫存分析的模型：定量訂貨

21、模型、數(shù)量 折扣模型、定期訂貨模型、混合系統(tǒng)模型和其它訂貨模型。 教學(xué)內(nèi)容： 5.1 The nature of randomnesssOptimization Criterion 5.2 The newsboy modelLot Size-Reorder Point System. 5.3 Service levels in (Q,R) SystemsAdditional discussion of periodic-Review system 5.4 multi-product system思考題： An automotive warehouse stocks a variet

22、y of parts that are sold at neighborhood stores. One particular part, a popular brand of oil filter, is purchased by the warehouse for $1.50 each. It is estimated that the cost of order processing and receipt is $100 per order. The company uses an inventory carrying charge based on a 28 percent annu

23、al interest rate. The monthly demand for the filter follows a normal distribution with mean 280 and standard deviation 77. Order lead time is assumed to be five months. Assume that if a filter is demanded when the warehouse is out of stock, then the demand is back-ordered, and the cost assessed fo

24、r each back-ordered demand is $12.80. Determine the following quantities: a. The optimal values of the order quantity and the reorder level. b. The average annual cost of holding, setup, and stock-out associated with this item assuming that an optimal policy is used. c. Evaluate the cost of uncer

25、tainty for this process. That is, compare the average annual cost you obtained in part (b) with the average annual cost that would be incurred if the lead time demand had zero variance. 第六章 物料需求計(jì)劃 (material requirements planning) 課時(shí)分配：9課時(shí)教學(xué)要求： 通過本章的教學(xué)，使學(xué)生了解主生產(chǎn)計(jì)劃、物料需求計(jì)劃和能力計(jì)劃的基本概念。掌握掌握 主生產(chǎn)計(jì)劃的編制，熟悉主生

26、產(chǎn)計(jì)劃的評價(jià)和維護(hù)；掌握開環(huán)物料需求計(jì)劃、閉環(huán)物料需求 計(jì)劃和制造資源計(jì)劃(MRPII)的體系圖，掌握物料需求計(jì)劃的數(shù)據(jù)處理和計(jì)算處理邏輯； 掌握粗能力計(jì)劃(RCCP)和細(xì)能力計(jì)劃(CRP)的區(qū)別及編制技術(shù)。 教學(xué)內(nèi)容： 6.1 Master Production Schedule (MSP)Capacity Planning (CP) 6.2 The Explosion CalculusAlternative lot-sizing Schemes 6.3 Incorporating lot-sizing Algorithms into the Explosion CalculusLo

27、t sizing with capacity Constraints 思考題： 1. The Noname Computer Company builds a computer designated model ICU2. It imports the motherboard of the computer from Taiwan, but the company inserts the sockets for the chips and boards in its plant in Lubbock, Texas. Each computer requires a total of 90

28、64K DRAM (dynamic random access memory) chips. Noname sells the computers with three add-in boards and two disk drives. The company purchases both the DRAM chips and the disk drives from an outside supplier. The product structure diagram for the ICU2 computer is given in Figure 4-1. Suppose that the

29、 forecasted demands for the computer for weeks 6 to 11 are 220, 165, 180, 120, 75, and 300. The starting inventory of assembled computers in week 6 will be 75, and the production manager anticipates returns of 30 in week 8 and 10 in week 10. a. Determine the MPS for the computers. b. Determine the

30、 planned order release for the motherboards assuming a lot-for-lot scheduling rule. c. Determine the schedule of outside orders for the disk drives. FIGURE 4-1 Product structure diagram for ICU2 computer (for Problem 4-12)For the previous problem, suppose that Noname has 23,000 DRAM chips in inven

31、tory. It anticipates receiving a lot of 3,000 chips in week 3 from another firm that has gone out of business. At the current time, Noname purchases the chips from two vendors, A and B. A sells the chips for less, but will not fill an order exceeding 10,000 chips per week. a. If Noname has establis

32、hed a policy of inventorying as few chips as possible, what order should it be placing with vendors A and B over the next six weeks? b. Noname has found that not all the DRAM chips purchased function properly. From past experience it estimates an 8 percent failure rate for the chips purchased from

33、vendor A and a 4 percent failure rate for the chips purchased from vendor B. What modification in the order schedule would you recommend to compensate for this problem? 第七章 車間作業(yè)計(jì)劃 (Operation scheduling)課時(shí)分配：6課時(shí) 教學(xué)要求： 通過本章的教學(xué)，使學(xué)生了解車間作業(yè)計(jì)劃的基本概念。掌握車間作業(yè)的排序問題、作業(yè)調(diào) 度的方法和車間作業(yè)控制基本技術(shù)。 教學(xué)內(nèi)容： 6.1 Introducti

34、onJob Shop Scheduling Terminology 6.2 Sequencing RulesSequencing Theory for a Single Machine 6.3 Sequencing Theory for Multiple MachinesAssembly Line Balancing 6.4 Advanced Topics for Operations scheduling思考題： 1. Discuss each of the objectives listed below and the relationship each has with job

35、shop performance. a. Reduce WIP inventory. b. Provide a high level of customer service. c. Reduce worker idle time. d. Improve factory efficiency. 2. Define the following terms: a. Flow shop. b. Job shop. c. Sequential versus parallel processing. d. Make Span. e. Tardiness. 第八章 生產(chǎn)計(jì)劃新進(jìn)展(Ne

36、w Advancement in Production Planning & Control )課時(shí)分配：6課時(shí) 教學(xué)要求： 通過本章的教學(xué)，使學(xué)生了解生產(chǎn)計(jì)劃領(lǐng)域最新的發(fā)展技術(shù)，包括TOC、LP、MC等。 教學(xué)內(nèi)容： (1) Optimized Production PlanningTheory of Constraint Based Production Planning & Scheduling (2) Advanced Planning and SchedulingMass Customization and its Production Planning. 附錄：參考書目1、 陳榮秋，馬士華.《生產(chǎn)與運(yùn)作管理》.高等教育出版社.2001年8月； 2、 王麗亞等編著.《生產(chǎn)計(jì)劃與控制》?清華大學(xué)出版社,2007年8月；3、 潘爾順.《生產(chǎn)計(jì)劃與控制》?上海交通大學(xué)出版社,2003年08月. 4、 蔣貴善等編，《生產(chǎn)與運(yùn)作管理》，大連理工大學(xué)出版社，2004年