CPIM 용어정리

BSCM 350 제
Purest Form : Flow Manufacturing (inflexible flow line)

Floating Location System = Random-location Storage

<> Fixed Location System = SKU is assigned a permanent location

Cube Utilization : Utilization of Storage (in Transportation, Warehouse) (balance : Accessibility)

Planning Bills (BOM) : Artificial grouping of components for planning purpose, 계획목적으로 아이템 그룹에서의 평균량
계산한 BOM

Committed : 사용될 예정인, 할당된

Shop Packet : A Package of Documents used to plan and control the shop floor movement of an order (Manufacturing order,
operations sheets, engineering blueprints, picking lists, move tickets, inspection tickets, and time tickets)
= BOM, Route Sheets, Engineering drawings

Physical Distribution System : to Customer / Supply : to Manufacturer

Inventory Turn Ratio = Cost of Goods Sold / Avg Inventory

언제 어떻게 쓰였는지 확인하는 보고서

Where-Used Report : All parents where a component is used (useful for making mass component changes (자재 단위)
- 해당 부품이 쓰인 모든 부모 제품들
Pegging report : parents in existing demand used(Trace the origin of demand for a component) (수요, 오더 단위)
- 들어온 주문 중에서 해당 부품이 쓰인 부모 제품들

System Nervousness : (Nervousness) minor changes in higher-level cause significant timing or quantity changes in lower
level schedules and orders (잦은 소규모의 Requirements change 에 따라 발생)
- 메시지 Filter 활용, use firm order 사용(replanning 최소화하는)

Exception message : notices planner needs to attention

Line Haul Cost : 컨테이너로의 운반 비용

Flow Manufacturing : routings are fixed, workstation 별 처리시간 비슷하다

Intermittent Manufacturing : MTO

Time fence : policy or guideline (resist change)

Planning Time Fence (Liquid zone) : PP 안에서 MPS 의 변경은 가능. 하지만, 세부계획에 좋지 않게 작용할 수 있음
Demand Time Fence (Freeze Zone) : Forecast 계산에 포함 x, 변경 x, PAI(예상가용재고)에 Forecast 계산 x (Senior 검토)

Periodic Review System :

The periodic review system is useful in all cases where there are small issues from inventory, transactions are expensive,
ordering costs are small, and many items can be ordered together. For example, supermarkets order by reviewing what is on
the shelf. Because there are so many transactions in a supermarket, they are expensive. Additionally, they sell one or two of
an item during each cash register transaction.

Continuous Review System :

Load : 특정 시기의 planned and actual order 처리를 위해 필요한 시간의 총합

Water Transportation : (이점) 비용 저렴, 큰 Capa (벌크화물, 저가치, 장거리 운송)

Distribution Warehouse : break down large lots into smaller items (expeditious move, handling - mix?)
Expeditious : 신속한 (expedite 재빠르게 처리하다)

MPS developing step : 1) develop preliminary MPS 2) Check the schedule against the capacity available 3) Resolve
differences between preliminary MPS and capacity available

Low level code : MRP 에서 BOM 의 하위단계 품목 코드

Inventory : 1) Raw Material 2) WIP 3) Finished Goods

Aggregate inventory management : cost-benefit effectiveness of carrying inventory

Item inventory management : management must establish Decision rules about inventory items

Objective of scheduling : Meet Delivery Data while utilizing manufacturing resources effectively

Purchasing cycle 1) 구매요구서 받고 2) 업체선정 3) 오더작성 4) 비용지출

TQM : 1) user 는 고객, 다음 프로세스 2) Daily monitoring by operator 3) defect -> stop & correct

Responsibility of a planner : 1) Reschedule due date of open order as required 2) reconcile errors and try to find their cause,
and solve critical material shortages by expediting or replanning.
Schedule Planned order -> by computer

Prelude : 도입부, 서곡

Functional Specification : 어떤 기능을 갖춰야하는지 (What to buy)

Process Specification : 공정 순서 명세서

Order qualifier - Minimum standard viable(독자생존 가능한)

Pegging : active where used information. In MRP/MPS, 아이템의 총수요와 할당량을 확인

(where-used : All parents where a component is used / pegging : parents in existing demand)

Particular Commodity : 특정 상품

ABC 분류에서 분류 기준은 재고비용, 재고비용이 큰 건 A 급 아이템 (L4L 사용)

L4L 은 상위 수요로부터 계산된 dependent 아이템에 대해 사용

Backflush : 완성품을 중심으로 BOM 확인하여 재고를 계산하여 감소시키는 방법

Zone System : Order picker only pick their own zone(area) (divided), marshaling area 에 모음

Tracking Signal = Total Errors / MAD (총 Error 에서 부호 상관없이 총합 / MAD = Bias 계산)

Blanket purchase order : long-term commitment to a supplier for material (=Standing Order)

Product Layout(=flow process layout) : 소규모 상품 집중 생산 (연속,반복생산, 수요 충분,Work Station 운영 고정)

EOQ 사용 조건 : end item, mts, 긴 life cycle, production run is limited

Invoice 처리 시 ) Purchase order 와 수량, 가격 일치여부, receipt, 수량 일치 여부

Product 종류 : commodities, standard products, items of small value, made-to-order items.

A is a characteristics of commodities, B is a characteristics of standard product, C is a characteristics of made-to-order
items. In items of small value, firm will negotiate a contact with a supplier widely.
가치 낮은 아이템(C)에 대해선 order 비용을 낮추는 것이 negotiate 목표

Buyer-planner : Buyer job, planner job 을 동시에 하는 사람, buyer, planner 각 사람보다 적은 부품을 다루지만 공급자와
정보, material 에서 섬세한 관계 형성 가능

FAS(Final Assembly Scheduling)

MPS minimum planning horizon : longest cumulative lead time (for purchasing required items)

ATO environment : Many different end items are made from a few standard components or modules.

ATP : 재고 + 예정생산량 - 다음 생산시점까지의 수요 합

JIT 7 waste : Process, Motion(movement), transportation, defects, waiting, overproduction, inventory

Quick Setup, Changeover 장점 : 생산 lead-time 감소, 품질 향상, WIP 감소

Quick Changeover 장점 : Improved Maintenance
Slow Time : 비수기

Release : 발주하다 (계약이 in place 될 때, 주문량은 release 에 따름)

Increasing batch size -> Reducing queue -> reducing LT -> Improving forecast accuracy -> better order-promising and due-
date performance

Work cell : 다양한 기계들이 생산단위에 비슷한 공정을 거치는 부품들을 생산하기 위해 함께 있는 것

Conformance(적합성) : Meeting the specified requirements (품질측면에서 생산의 주요 책임)

Input / Output Control : manage queue and lead times

Dispatching : Releasing orders to the shop floor (가용작업들을 선택하고 순서를 정함, 업무를 작업자들에게 할당)
Rules - FCFS, EDD, ODD, SPT

Available Capacity : ability of a resource to produce a quantity of output for a particular period

Cycle Counting 특징 : ABC 재고관리로 자주 카운팅하는 아이템이 있을 수 있다. A>B>C, 부분적인 생산 손실을
감소시킨다.
Cycle Count 목적 : 재고 error 확인 및 조치

MPS 목적 : 높은 고객 서비스 수준, 자원 효율적 사용, 효율적 재고 사용

FAS (Final Assembly Scheduling) : 효율적 최종 조립 달성

Central Storage (쉬운 관리) <-> Point of use Storage (자재 운반 감소, 보관비용 감소, 언제든 접근 가능)
POINT OF USE 는 재고로 관리하는 개념이 아니기 때문에 보관비가 감소함 - 자재 관리가 어려워진다.

Operation Time : setup + operation, Total Manufacturing LT : queue + setup + operation(run) + wait + move

Firm Planned Order (FPO) : planned order frozen in quantity and time (정해지면 컴퓨터가 자동 변경 x)

SOP 목적 : Build Teamwork, 변화 효과적 관리, 비즈니스 플랜 지원, 계획 현실성 확보, 제품 재고, 백로그 관리, 성과측정

Obsolete Inventory : 유행 지난 재고

Finite Loading : 필요량 이상 생산하지 않는 것 (DBR MTO 환경) - Forward - WIP inv 상승
Infinite Loading - MTS 환경 - Backward - WIP Inv 감소

Total Employee Involvement : Supervisor”s role = Coaching, (다른 환경 정리)

Intrinsic forecasting : 기업 내부 과거 데이터 사용, (다른 환경 정리)

Bypass : 우회하다, 건너뛰다

Kanban System = Two-bin system

CR = Remain / Process Time

MRP 메인 목적 : 1) 자원 소요량 계산, 2) 주문 우선순위 최신상태로 유지

Back-order : 재고가 부족하여 주문 처리를 due date 까지 못하게 된 것

Routing : Operation, Sequence, Work Centers, Tooling Necessary, Standard Setup and run times (Material flow X)

Capacity : Common Unit - cars, barrels Variety of Products - Time

Product-focused layout : Fixed flow of work / flow operation (good inventory movement / bad labor, machine)
process layout : intermittent operation
project layout : fixed location operation

Delivery Lead Time : customer order -> delivery

Cumulative Lead Time : longest planned length of time
Demand Lead Time : potential Customers are willing to wait for the delivery of a good

DRP : logic, translate MRP to distribution system, 다양한 수요를 예측하여 central supply, operation 에 수요정보 전달

Quality Cost
internal failures, external failures, appraisal costs, and prevention costs
Appraisal : 정형 평가와 품질 감사와 관련된 비용
process loss : 프로세스 상의 생산성을 떨어뜨리는 손실

Scheduling 시 필요한 정보 : 양, 기한, 총 생산시간 (total 세부시간)

Decentralized Distribution System (Pull) - Central Supply Organization Role : Respond to Demand from DC
Each distribution center places order to central supply organization

Centralized Distribution System (Push) - central supply organization Role : determine when to replenish stock at DC,
coordinate among DC, forecast demand at each DC

Truck : Moving Small Quantities to widely dispersed markets

Train : Moving Large Quantities
Ship :
Air :

Input Rate(rope) : controlled by release of orders to the shop (if order release speed is faster than producing, input
rate(queue, WIP, LT) will increase)

Factor of 2 : x2

MPS = Anticipated Build Schedule

Fast Moving : 회전율이 빠른

Working stock - 작업용 재고, reserve stock - 보관용 재고 / 보관 시 분리

Demand Management include (Forecasted Requirements, service parts requirements, branch warehouse requirements, inter-
plant orders, order entry and order promising

Backflushing : 재고를 생산품 BOM 기준으로 계산하여 처리하는 방법 (생산 LT 가 작을 때 최적)

Deterioration : 손상

Cycle stock(Lot-Size Stock) is one of the two main conceptual components of any inventory
순환재고 (발주량에 따라 주문해서 생기는 재고)

MRP
Exploding : process of multiplying the requirements
Offsetting : process of placing the exploded requirements (상쇄하다, 리드타임에 맞춰 놓는 것)

JIT Quality : by operator, they stop when find defects

Value added : materials > labor

Rated capacity(standard time required) : 4(machine) * 40(shift hours) * 0.9(utilization) * 0.9(efficiency)

Demonstrated capacity(average capacity) : historical data / period

Forecasting Method
Qualitative - Quantitative (Intrinsic - Historical Data(Moving Average, Exp Smoothing, 회귀), Extrinsic - (집 - 가구)

Interruption : 중단

Carrying costs : capital cost, storage cost, risk cost, ownership cost
risk cost: Obsolescence , Damage, Deterioration , Pilferage

days of supply = Inventory on hand / average daily usage

Drum(Path) - Buffer(Inventory) - Rope(Release Time)

1 MAD - 60% 2 MAD 90% 3 MAD 98%

Ownership - Transaction Channel, Goods&Service - Distribution Channel

Consignment - 위탁

Shelves - 선반 (Reorder - Shelves = Replenishment)

CRP - Open shop order, planned order(MRP), routing, time standard, lead times, center capacities
Shop order - 생산, 및 주문에 필요한 정보, open order - 입고예정량

MRP - offset (수요발생과 LT 만큼 떨어뜨리는 것 생산지시 내리는 것)

PP -> (Feasibility Check) -> Resource Plan

Deplete : 고갈시키다, 감소시키다

Inventory Velocity - Raw Material 재고부터 finished goods sold 까지의 시간

Decouple : 분리시키다 (공급 수요 분리 - 재고)

Transportation Consolidation in physical distribution = Break Bulk

POQ - Period-order quantity = EOQ / average weekly usage

Backlog : 주문잔고 (밀린 일) monitor - queue, lead time performance

Input rate : release order to shop floor 증가 - queue, wip, lead time 증가,
Output rate : work center capacity

Sequencing for short term planning of actual jobs to be run in each work center

Breaching the organization”s secret : 기밀위반

Poke-yoke : 행동 제한 (품질실패 예방)

Jidoka : 불량 발생 시 Stop - 품질 유지를 위한 행동
Andon : 신호등 (문제 해결될때까지 정지)

MUDA : waste (가치를 생산하지 않는 것)

MURI : overburden (과부화)
MURA : unevenness (불규칙성) - 표준화되어있지 않은 것 (과도한 변동)

Hoshin (대책) : 4 가지 vision statement, 이를 기반으로 목표와 작업계획 5 년단위

PAB(Projected Available Balance) : Demand Time Fence 안에서 수요는 변하지 않음 - 이로 계산, 그 외 max 로 계산

Cost of goods sold = 50% material, 20~60% inventory

Order entry : 주문접수? 처리?