The Planning And Control Method And Its Application Of General And Standard Parts In The MTO Environment

As China becomes a world factory, the small and medium enterprises (SMEs) can receive numerous customer orders from many countries. Such customer orders are characterized as a stringent but short delivery time, a large number of product variants, small production batches, etc. As a result, the production management in these SMEs is under a great pressure to offer the diverse products on time. In the MTO environment, As a result of intense customization, the production schedule of the finished products are often made by considering a loss of quality according to the requirement of orders, which is quite different from the traditional MRP. However, the method is not fit for general and standard parts of these customized products. In these products, the basic characteristics of general and standard parts are similar to each other besides few process customization. Therefore it is not appropriate to use the traditional MRP to make production schedule and control. It is worth studying how to make production schedule and control of the general and standard parts.This paper combines the production requirements in tool manufacuring enterprises, making research of several key techniques including the MPS of general and standard parts, MRP method of general and standard parts, A finite capacitated real-time planned order release(FCRTPOR) scheme, a real-time feed back and control technology, etc. On this basis, a production management information system of general and standard parts in the MTO environment is developed. The main reaserch work is as followed.1) It researches the MPS of general and standard parts. According to the independence and integrity of structure of general and standard parts, it researches the structure separation method of general and standard parts. It gives a safe stock setting scheme. On the basis of GBOMP, a requirements combination scheme of main general and standard parts in several orders is developed. The calculation formulas of several key concepts in the MPS are developed, including gross requirements, scheduled receipts, projected available balance, net requirement, etc. Besides, it researches the MPS of low value parts according to their characteristics.2) It researches a MRP method of general and standard parts, including MRP of high value parts (common parts for short) and low value parts. On the basis of GBOMP, an arithmetic flow of low level code is developed. It deduces several key concepts of MRP, including gross requirements, scheduled receipts, projected available balance, net requirement, etc. On this basis, the MRP of common parts is made. The feeding plan of low value parts is made according to its MPS. A concept named corresponding stock is put forward.3) A finite capacitated real-time planned order release(FCRTPOR) scheme is developed. On the basis of the feasibility of capability, several rules of planned order release are given according to the production characteristics of common parts. A example is given to introduce how to use rules of FCRTPOR to release orders.4) It put forward a real-time feed back and control technology of common parts. It researches the throughputs allocation, including turnover quantity allocation and statistic quantity allocation of material. On this basis, the implementation procedure of real-time feed back control technology is given. Compared to the function of the closed loop MRP, it reveals that the real-time control technology discussed above is much more superior than the closed loop MRP in the shop floor control and feed-back for the adjustment of plan.5) A production management information system of general and standard parts in the MTO environment is developed. On the basis of the language of ASP.NET and in the development environment of Visual Studio 2005 and SQL Server 2005, an information system is developed including modules such as basic datamanagment, schedule management of general and standrad parts, planned order release, shop floor management, etc.On the basis of the research of planning and control method discussed above, a production management information system of general and standard parts in the MTO environment is developed. Based on Maxpower Group Ltd., Wendeng, Shandong, the system was implemented which achieved the anticipated results.