CPIMBSC考试教材BasicsofSupplyChainManagementAPICSCPIM

CPIM BSC考试教材-Basics of Supply Chain Management APICS CPIM BASICS OF SUPPLY CHAIN MANAGEMENT APICS CPIM Certification Course Study Guide Institute of Manufacturing Resource Management of India Copyright ? by IMRMI All rights reserved by IMRMI>. No portion of this publication may be reproduced in whole or in part>. Foreword First, let me thank Mr>. Anakala Vijay Bhaskar Reddy, CPIM, and Mr>. Pradeep V>. Khetan, CPIM for giving me the opportunity to write this foreword>. I feel honoured and flattered>. It is my mission, vision and dream to see my country, India, attain back the leadership position in the world>. I am quite confident that we as a nation will do it>. Towards achieving this mission, I found APICS body of knowledge quite powerful>. I decided to bring this body of knowledge to India, when I took my APICS certification exams in 1985 in the US>. The APICS certification programme started in India in 1992>. The beginning was tough>. Mr>. Anand Mahindra may not remember, but I am still grateful to him for sponsoring senior managers of Mahindra & Mahindra and Mahindra Ugine in this programme, as the first few APICS certification candidates>. Then came the support of BaaN Company>. Mr>. S>. Ramanathan, then heading BaaN, was (and is) our well-wisher>. We received a lot of support from Arthur Anderson (Accenture now)>. I have not forgotten the support I received from Mr>. J>. A>. Choudhary, who was the chairman of STPI, Hyderabad at that time>. I know that I am forgetting many names but the whole success is attributed to lots and lots of people who provided their selfless support to this programme and to me>. I am also thankful to each and everyone at APICS head quarters in USA, who gave us tremendous support at every step>. Last but not the least, I must thank my wife Shashi, CPIM herself and my brother-in-law Pradeep Khetan, CPIM, who became responsible for running this show, for holding this torch tight and making progress under all adverse conditions>. Even though, the programme was highly appreciated from day one, I felt that the cost was little high for an average Indian, which I saw as an impediment in achieving our mission and propagating this body of knowledge at a bigger level>. Therefore we tried to keep the cost as low as possible>. A significant part of the cost was spent in study material that is imported at a high cost>. I always wanted that the study material be made available at a cost that my fellow Indians could easily afford>. This was possible if an Indian author developed the study material>. I wanted to write a book on APICS body of knowledge myself, but my busy schedule never permitted me to make my dream a reality>. The same is true for most APICS certified professionals who lead lives of meeting project deadlines and constantly under pressure>. One day, in the year 2002, Mr>. Deepak Shikarpur of Computer Society of India, encouraged us to develop some indigenous material on APICS body of knowledge that CSI could use to impart supply chain management domain knowledge to young and budding IT professionals of India>. This will help them in taking their services up in the value chain globally>. I knew that this task was difficult>. So, we invited the individuals with the missionary zeal to come forward and help us in developing this material>. Many came forward and provided their invaluable time and knowledge>. Among them, it is worth praising few individuals for their selfless dedication and commitment: Ms>. Renu Lata Rajani, CPIM Mr>. Anakala Vijay Bhaskar Reddy, CPIM Mr>. Satyendra Pal, CPIM Mr>. Ismail Dawood Patel, CPIM Mr>. Mahiyar Faredoon Adajania, CPIM Mr Shashank Deshpande, CPIM Mr M V U Nageshwara Sharma, CPIM Mr Zubair Haroon Safdar, CPIM Mr Vijay Sambhaji Chavan, CPIM Mr T Venkata Krishna, CPIM Mr Ranjit Gangadharan, CPIM Mr>. R V Ramakrishnan Mr C Ravindran, CPIM, CIRM This material is the result of their contribution and effort>. I must once again mention here that these individuals are highly successful in their lives and are very busy>. In spite of that, they have taken out time to fulfill their duty towards the society>. Please join me in saluting these men and thanking them for the gift of knowledge they have given to their fellow professionals>. I am sure that this material will be quite useful for all supply chain management professionals whether they are appearing for APICS certification or not>. I wish them all the best>. Ravindra K>. Tulsyan, CFPIM CIRM President Institute of Manufacturing Resource Management of India Authors Renu Rajani, CPIM Author : Chapter 4 (Design) Chapter 7 (Execution and Control) Chapter 8 (Performance Measurement) Renu Rajani is Principal Consultant and head of Software Testing Business at vMoksha Technologies for the last 2 years>. Earlier she worked for KPMG Management Consulting India for 5 years in the areas of Supply Chain Management, eBusiness, Business Process Reengineering, IT Strategy, IT Outsourcing and Enterprise Resource Planning>. Renu is on the Executive Committees of Bangalore Management Association, Indian Institute of Materials Management (Bangalore Branch) and Operations Research Society of India>. She is an #99ff99'>MBA from Purdue University, USA, a B>.Tech in Computer Science and Holds CFA, ACS (Inter), CFP, CPIM, CSTE and PMP Professional Certifications Renu Rajani can be reached at HTUrenurajanivsnl>.comUTH Anakala Vijay Bhaskar Reddy, CPIM Author : Chapter 6 (Planning) Chapter 12 (Physical Distribution) Vijay Bhaskar Reddy is currently working with the R&D Division of Baan Info Systems India as a functional Engineer for Baan ERP and Baan E-enterprise Products>. He is with Baan Since Nov 1999 and has contributed to the functional areas of Baan ERP Order Management (Sales and Purchase), Warehousing, Enterprise Planning, Manufacturing, iBaan e-Sourcing and iBaan e-Procurement>. Prior to joining Baan, Vijay served the Indian Navy for three years>. He was commissioned in the Indian Navy in 1995>. In his tenure in the Navy, he contributed to the areas of Materials Management, Refit coordination and Staff duties>. He is a graduate of Industrial and Production Engineering from Nagarjuna University, Andhra Pradesh, and is Certified in Production and Inventory Management (CPIM) by American Production and Inventory Control Society (APICS) Vijay can be reached at HTUvijaybhaskarreddyhotmail>.comUTH Dedication : To my parents (Late) Shri A>. Guruva Reddy and Smt>. A>. Rama Lakshmi>. Satyendra Pal, CPIM Author : Chapter 9 (Fundamentals of Inventory Management) Chapter10 (Inventory Management) Chapter 11 (Purchasing) Satyendra has been working in Supply Chain Management field for more than six years>. His experience spreads across Industry, Product and Management Consulting>. He is an alumnus of NITIE, Mumbai and is Certified in Production and Inventory Management (CPIM) by American Production and Inventory Control Society (APICS) Satyendra Pal can be reached at HTUsatyendraconsultant>.comUTH Dedication : To my wife Poonam Pal for her support during the preparation of the course material>. Ismail D>. Patel, CPIM Author : Chapter 3 (Demand Planning) Chapter 5 (Capacity Management) Tumu Venkata Krishna, CPIM Co-Author : Chapter 5 (Capacity Management) Ismail D>. Patel has 13 years of professional experience in Manufacturing and Supply Chain Management>. His experience in the manufacturing area includes Production planning and control, Process control, Productivity improvement, Automation, Time Study, Method Study, Waste elimination, ISO 9000 QMS documentation and training>. His experience in the Supply Chain Management area includes Vendor Selection, Vendor Management, Production part approval process (PPAP), Vendor audit and performance rating, Vendor Improvements, Acceptance Sampling plans, Master scheduling, Inventory management, Stores management, Vendor Capacity Planning, Material Requirement Planning (MRP), Kanban Scheduling>. Professional courses to his credit include “ISO 9001 Internal Auditor”, “Six Sigma Black Belt”, “Technical Leadership Program (TLP) from GE (USA)”, “Strategic Cost Manage-ment”, “Activity Based Costing”, “TOC” and “Logistic and Operations Management”>. He is an Industrial Engineering Graduate, holds a Diploma in Materials Management, has done his specialization in Operations Management from (Godrej S>.P>. Jain Institute of Management Science) and is Certified in Production and Inventory Management (CPIM) by American Production and Inventory Control Society (APICS) Ismail D>. Patel can be reached at HTUidp611hotmail>.comUTH - Venkata Krishna has 6 years of professional experience in various aspects of Supply Chain and Financial Management>. He is presently working as Product Analyst with Oracle and is responsible for Financials and Financial Intelligence Tools>. Before joining Oracle, he worked as Product Owner in Baan for 2 years>. Prior to Baan, he worked with Strabus Software Soluitions where he was instrumental in defining and designing the Production Activity and Control and Capacity Management products for automobile OEMs>. Venkata Krishna has done his #99ff99'>MBA in Systems and Finance from Osmania University and is Certified in Production and Inventory Management (CPIM) by American Production and Inventory Control Society (APICS) Venkata Krishna can be reached at HTUkrishnavtyahoo>.comUTH Dedication : To all my Teachers>. M F Adajania, CPIM Author : Chapter 2 (Management Approaches) M F Adajania is a Senior Manager in the Production Department of Godrej and Boyce>. He has 14 years of experience in the production function and is well versed with different enabling techniques viz>., ISO 9001, ISO 14001>. TQC, JIT, SCM, ERP, PLM having helped implement them at various stages>. He is a Mechanical Engineering Graduate from College of Engineering, Pune and is Certified in Production and Inventory Management (CPIM) by American Production and Inventory Control Society (APICS) M F Adajania can be reached at HTUmahiyarvsnl>.comUTH Shashank Deshpande, CPIM M>.V>.U>. Nageshwara Sharma, CPIM Co-Authors : Chapter 1 (Business Concepts) Shashank Deshpande has 17 years of professional experience in various aspects of Supply Chain Management>. He is presently working with Pidilite Industries Limited as Logistics Manager and is responsible for Finished Goods Distribution, Sales Administration and Warehouse Management>. He has in-depth experience in Inbound and Outbound Logistics, C&FA Management and Inventory Control>. He has successfully implemented IT enabled process improvements and ISO9002 standards>. Prior to Pidilite Industries Limited, he has worked with Cadbury for 12 years, Larsen and Toubro for 3 years and 2 years with RPG Cables>. He has published articles on various aspects of Supply Chain Management in “Logistics vision” an Indian Express Publication and the topics include VMI, New Products Launch Process, ABC (Activity Based Costing) of Logistics, S&OP (Sales and Operations Planning), Supply Chain Efficiencies in Retailing, etc>., Shashank Deshpande can be reached at HTUdeshpihotmail>.comUTH - M>.V>.U>. Nageshwara Sharma has 8 years of professional experience in various aspects of Supply Chain Management>. He is presently working as Product Analyst with Oracle and is responsible for Warehouse Management Systems (WMS)>. Before joining Oracle, he worked as Product Consultant for Baan for 5 years>. He was instrumental in defining and designing the e-procurement and strategic sourcing products in Baan>. Prior to Baan, he worked with MICO where he gained in-depth experience in Inbound Logistics and Inventory Control areas>. Nageshwara Sharma had done his BE (Hons) in Metallurgical Engineering from NIT Jaipur, his PGDIE from NITIE Mumbai and is Certified in Production and Inventory Management (CPIM) by American Production and Inventory Control Society (APICS) Nageshwara Sharma can be reached at HTUmvunsharmahotmail>.comUTH Reviewers Mr>. M V U Nageshwara Sharma, CPIM Reviewer : Chapter 6 (Planning) Mr>. Zubair H Safdar, CPIM Reviewer : Chapter 9 (Fundamentals of Inventory Management) Chapter 10 (Inventory Management) Mr>. A Vijay Bhaskar Reddy, CPIM Reviewer : Chapter 11 (Purchasing) Chapter 12 (Physical Distribution) Mr>. Vijay S Chawan, CPIM Reviewer : Chapter 8 (Performance Measurement) Mr>. T Venkata Krishna, CPIM Reviewer : Chapter 5 (Capacity Management) Mr>. Ranjit Gangadharan, CPIM Reviewer : Chapter 7 (Execution and Control) Mr>. R V Ramakrishnan Reviewer : Chapter 4 (Design) Mr>. C Ravindran, CPIM, CIRM Reviewer : Chapter 3 (Demand Planning) A special mention of Thanks to Mr>. Vijay S Chawan (chapter 8) Mr>. Zubair H Safdar (chapters 9, 10) For their involvement in enhancing the content for the chapters indicated, in addition to the reviews>. Contents Session 1>. Business Concepts 1 1>.1 Definition of Supply Chain 2 1>.2 Elements of Supply Chain 3 1>.3 Organizational Dynamics 41>.4 Impact of Market Environment 5 1>.5 Manufacturing Process Choices 7 1>.6 Production Environment 81>.7 Financial Statements 11 1>.8 Costs Analysis 13 1>.9 Key Terminology 16 1>.10 Practice Questions 17 Session 2>. Management Approaches 20 2>.1 Objectives of MRP II 21 2>.2 Principles and Characteristics of MRP II 23 2>.3 Objectives of Just-in-time (JIT) 24 2>.4 Concepts of Waste and Value added activity 24 2>.5 Principles and Characteristics of JIT 25 2>.6 Objectives of Total Quality Management (TQM) 28 2>.7 Principles and Characteristics of TQM 29 2>.8 TQM Impact on System Design and Deployment 32 2>.9 Key Terminology 34 2>.10 Practice Questions 35 Session 3>. Demand Planning 38 3>.1 Marketplace a key driver 39 3>.2 Customer Expectations 40 3>.3 Customer Relationship 41 3>.4 Sources of Demand 41 3>.5 Kinds of Demand 41 3>.6 Forecast Management 43 3>.7 DRP Logic 51 3>.8 Key Terminology 52 3>.9 Practice Questions 53 Contents Session 4>. Design 56 4>.1 New Product Design and Introduction 57 4>.2 Process Design 58 4>.3 Manufacturing and Purchasing Lead Time 61 4>.4 Order Quantity / Lot Size / Batch 63 4>.5 Safety Stock and / or Capacity 65 4>.6 Bill of Materials (BOM) 66 4>.7 Item Master / Material Master 67 4>.8 Routing / Process 68 4>.9 Work Center / Flow Line 68 4>.10 Key Terminology 70 4>.11 Practice Questions 71 Session 5>. Capacity Management 74 5>.1 Definition of Capacity Management 76 5>.2 Objectives of Capacity Management 76 5>.3 Resources 78 5>.4 Measuring Available Capacity 79 5>.5 Factors affecting Capacity 79 5>.6 Capacity Measuring Units 79 5>.7 Ways of determining Capacity 81 5>.8 Determining Required Capacity 81 5>.9 Capacity Requirement Planning (CRP) 83 5>.10 Resolving the Differences 86 5>.11 Key Terminology 88 5>.12 Practice Questions 89 Session 6>. Planning 92 6>.1 Strategic Planning 95 6>.2 Business Planning 98 6>.3 Production and Resource Planning 100 6>.4 Sales and Operations Planning 116 6>.5 Master Scheduling 117 6>.6 Rough-Cut Capacity Planning 124 6>.7 Material Requirements Planning (MRP) 126 Contents 6>.8 Capacity Requirements Planning (CRP) 137 6>.9 MRP / CRP in Repetitive Production 141 6>.10 Basics of Final Assembly Scheduling (FAS) 143 6>.11 Key Terminology 144 6>.12 Practice Questions 146 Session 7>. Execution and Control 149 7>.1 Order Processing 150 7>.2 Order Promising 150 7>.3 Push / Pull Systems 150 7>.4 Scheduling Techniques 151 7>.5 Information Docket for Execution 155 7>.6 Priority Control 161 7>.7 Production Reporting 163 7>.8 Measuring Quality 166 7>.9 Process Variation 167 7>.10 Process Capability 167 7>.11 Process Control 167 7>.12 Sample Inspection 169 7>.13 Key Terminology 170 7>.14 Practice Questions 171 Session 8>. Performance Measurement 174 8>.1 General Principles of Performance Measurements 175 8>.2 Types of Measurements 183 8>.3 Accounting Based Measures 185 8>.4 Activity Based Cost Measures 185 8>.5 Productivity Measures 187 8>.6 Other Financially Based Measures 188 8>.7 Strategic Measures 189 8>.8 Performance Measuring Model 194 8>.9 MRP / CRP Performance Measurements 195 8>.10 Key Terminology 197 8>.11 Practice Questions 198 Contents Session 9>. Fundamentals of Inventory Management 201 9>.1 Introduction to Inventory 202 9>.2 Inventory Classification by Categories 205 9>.3 Inventory Classification by Functions 207 9>.4 Item Costs 208 9>.5 Carrying Costs 209 9>.6 Ordering Costs 209 9>.7 Stock out Costs 210 9>.8 Capacity Related Costs 210 9>.9 Cost Balancing 211 9>.10 Key Terminology 212 9>.11 Practice Questions 213 Session 10>.Inventory Management 216 10>.1 ABC Analysis 217 10>.2 Obsolescence of Inventory 219 10>.3 Accounting Principles 220 10>.4 Physical Inventory Control 222 10>.5 Quantity Based Replenishment System 225 10>.6 Time Based Replenishment System 227 10>.7 Order Quantity Considerations 228 10>.8 Economic Order Quantity (EOQ) 229 10>.9 Methods for Order Quantity Determination 233 10>.10 Demand and Supply Uncertainty 235 10>.11 Concept of Safety Stock 235 10>.12 Concept of Service Level 236 10>.13 Key Terminology 238 10>.14 Practice Questions 239 Session 11>.Purchasing 242 11>.1 Objectives and Importance of Purchasing 243 11>.2 Receiving and Analyzing notification of Need 244 11>.3 Establishing Specifications 245 11>.4 Selecting Suppliers 246 11>.5 Supplier Agreements 248 11>.6 Order Management 249 11>.7 Establishing Performance Criteria 250 Contents 11>.8 Key Terminology 252 11>.9 Practice Questions 253 Session 12>.Physical Distribution 256 12>.1 Introduction to Physical Distribution 257 12>.2 Distribution Channels 258 12>.3 Transportation 262 12>.4 Warehousing 265 12>.5 Distribution Inventory 268 12>.6 Materials Handling 272 12>.7 Protective Packaging 273 12>.8 Order Processing and Communication 275 12>.9 Interfaces 27