6Sigma管理法在MPS流程达到OperationalE

上海交通大学硕士学位论文6-Sigma管理法在MPS流程达到OperationalExcellenceClassA过程中的运用姓名：邓建华申请学位级别：硕士专业：工业工程指导教师：仰书纲;冯海涛200511016-SigmaMPSOperationalExcellenceClassAMPS()ERPMPSOperationalExcellenceClassA6-Sigma(DMAIC)MPSOperationalClassAMPS6-SigmaDMAICMPSMPSClassAC&EMatrixMPSSPCClassA6-SigmaMPSMPS1.23.4,3.4,95%~105%MPSOperationalExcellenceClassAClassAMPS10000006-sigmaProvenPathOperationalExcellenceClassA,,IUSING6-SIGMAMETHODOLOGYIMPROVESMPSWORKINGPROCESSPERFORMANCETOACHIEVEOPERATIONALEXCELLENCECLASSAABSTRACTMPS(MasterProductionScheduling)isoneofthekeyprocessesinthewholeSupplyChainmanagement.Itbalancesthedemandandsupply.Whetheritiswelloperatedisthekeytothebusinesssuccess.OperationalExcellenceClassAprovidesasuperblyefficientapproachtobenchmarkingacompany’soperationperformanceandcapabilitiesagainsttheverybest.Inthearticle6-SigmamethodologywassuccessfullyusedasaprojectimprovementtooltoimproveaMNCplant’sMPSprocessperformance.WithOperationalExcellenceClassAchecklistinplace,DMAICmethodandsome6-SigmatoolssuchasC&EMartix,SPCwereadoptedtodramaticallyimproveandstabilizeMPSworkingprocess.AsaresultsMPSprocesseswerereengineeredtomeetClassArequirement,itsweeklyperformancewasimproveddramaticallyfrom1.2toabove3.4,weeklyMPSstabilitymetricswerecontinuouslygreaterthan3.4andmonthlyperformanceswerelimitedwithintherange95%~105%.ThewholeMPSprocesssuccessfullyachievedOperationalExcellenceClassAandkeepsrunningontheClassAlevel.BywayofMPSprocessachievingClassA,FinishedGoods,rawmaterialssafetystockandend-of-seasonstockwereremarkablyreduced,andmorethanonemillionRMBwassaved.Italsoimprovedproductivity,customersatisfaction,cashflowandinternalcommunication,etc.ItsharesabrandnewwaytoimplementOperationalExcellenceClassAinacompanythatusing6-Sigmaroadmapmakeseachkeyprocesssuccessfulinabusiness.KEYWORDS6-sigma,OperationalExcellence,MPSERPIIOperationalExcellenceClassA1A1.1//20044://1-1:2004.4.25A798MTB70MTC50MTD33MTA,CD120CD(1-2)OperationalExcellenceClassA2,1-220041~4A()56.0122370380()3168276264-()255494116B()2030140280()2058120349-()0-2820-69C()30.070140650()25160379810-()5-90-239-160D()168.0200200300()185180320350-()-17.020.0-120.0-50.0A300400ISO9000ISO9000ISO9000ISO9000OperationalExcellenceISO9000OperationalExcellenceClassAOperationalExcellenceClassA3OperationalExcellenceClassAOperationalExcellenceClassA1.2MRPII/ERPOperationalExcellenceClassAMRPMaterialReqirementPlanABCDMRPII/ERPMRPIIManufacturingResourcePlanning60mrpmaterialrequirementplanmrp80mrpmrpMRPIIMRPIIManufacturingResourcePlanningWhatifMRP1ERPEnterpriseResourcePlanning90ITCRMCUSTOMERRELATIONSHIPOperationalExcellenceClassA4MANAGEMENTTQMEDIElectronicDataExchange2MRPMRPIIERPMRPMRPII,MRPII/ERPMRPII1-1MRPIIBusinessPlan/S&OPMPSMRPII/ERPMRPII1-1MPS,mrpOperationalExcellenceClassA51-1MRPIIFig1-1MRPIIPlanningandControlProcess1.3MRPII/ERP(S&OP)(DM)(RCCP)(MPS)(BP)??(Routes)(MRP&CRP)??BillsofMaterial(BOM)(IRA)OperationalExcellenceClassA6ERP10%~20%ERPERPERPllllERPERPERPERPERPERPERP(GIGO)OperationExcellenceClassAHighDataIntegrity)ERP/OperationalExcellenceClassA7ERP/ERP2OneSetofNumber)ERP,ERPOperationalExcellenceClassA83FormalWorkingProcess)ERPERPSAPERPERPERPERPERP4RealisticPlan)5(ClearResponsibilityandAccountability)OperationalExcellenceClassA9(Responsible)(Accountable),(Consult)(Informed)6(SilenceisApproval)7(MetricswithRootCauseCorrectionAction)SPCOperationExcellenceClassAOnTimeDeliveryinFull95%InventoryRecordAccuracy95%BOMERPmrpmaterialrequirementplan),98%(SupplierOnTimeDelivery)(ConsensusandTeamwork)OperationalExcellenceClassA10ERPERPERPERP1.4OperationalExcellenceClassAERPERPERPERPSAPERPSAPShutupandPay,ShutupandPrey,ShutAllProductionERPERP10%~20%ERPERPERPERPERPERPMRPII/ERP,ClassAChecklist,OperationalExcellenceClassA11,ClassAERPMRPII/ERPERP1.5lassAOperationalExcellenceOliverWight“ABCDChecklist”ABCDADUPONTCoCo-Cola3M(RohmandHaas)OliverWight“ABCDChecklist25ABCMRPII/ERPABCDTheOliverWightABCDChecklistforOperationalExcellenceChecklist1-3MRPABCDMRPIIOliverWight19761982MRPMRPIIOliverWightABCDChecklist199242000TheOliverWightABCDChecklistforOperationalExcellenceOperationalExcellenceOperationalExcellenceClassA12OliverWightClassAOliverWightClassAChecklistforBusinessExcellence,SixthEditionOliverWightchecklistOliverWightClassA1-3OperationalExcellenceA3.5llClassAllB2.53.49llClassAlC1.52.49llClassA,lD1.5l,llDlOperationalExcellenceABCDChecklist3ll/OperationalExcellenceClassA13lllClassABCD3ClassAClassBClassCClassD/ClassABCD3CLASSACLASSBCLASSCCLASSDClassABCD3CLASSACLASSBClassC/ClassDOperationalExcellenceClassA14ClassABCDClassABCD3ClassAClassBClassCClassD1.6OperationalExcellenceClassAOperationalExcellenceClassAA.OperationalExcellenceClassABCDEFA.B.C.D.E./BOM98-100%,F.OperationalExcellenceClassA15G.H.I.A.50%Coco-Cola50%~70%B.10%C.10%D.E.10%F.95%CocoColaOperationalExcellenceClassA50%~75%MPSClassA16MPSClassA2.1MPS(MasterProductionScheduling)MRPII/S&OPS&OPMPS2-1•••DRP•••••••••MPSFig2-1MPSBlancesDemandandSupplyMPSDRPDistributionReplenishmentPlanMPSClassA17IntercompanyorderMPSFrozenPeriod,Slushperiod,FluidPeriodMPS22MPSOpera