Nghiên cứu về lập kế hoạch sản xuất vỏ điện thoại số lượng lớn

NGHIEN CUfU - TRAO D I NGHIEN CU-U V6 LAP KE HOACH S A N X U A T V6 DIEN THOAI S6 LUONG L&N RESEARCH ON MAKING THE MANUFACTURE PLAN FOR PHONE COVERS WITH LARGE QUANTITY Tuwng Ngpc TiiS TS Hoang Minh Thuan' 'Hpc vien Cap hpc, Truong Dji hpc Su pham Ky thuat Himg Yen 'Truong Cao ding Cong nghiep va Xay dung TOM TAT ^ Trong bdi Viet nay, nhom tdc gia gioi thieu vi each thuc lap M hoach san xuk vo tien tho v&i s6 It^ang Ian Sti dmg hi thdng GSCM di Uy du lieu dat hang cua khach hang, kiim tra nan Itn: va nguyen vat lieu cung cdp cho ki hoach san xudt; Dua ban ki hoach hoan chinh vdphd bo ki hoach sdn xudt Tir kh6a: Lap ke hogch, ep nhifa, vo diin thoai ABSTRACT In this article, the authors introduce how to make the manufacture plan for phone covers with large quantity GSCM system has been used for extracting the clients • purchase order dat iesttng the quality and materials for production plan, providing the completed plan and allocation of production plan Keywords: Making plan, plastic injection, phone covers ISSN 0866-7056 TAP CHI CO KHI VI£T NAM, S6 nam 2015 www.cokhivietnam.vn NGHIEN CljrU-TRAOD(!)l + Kilm tra chit lupmg va cung c4p cho lap rap DAT VAN DE Voi su phat tri6n manh me ciia ng^nh Ca khi, cac cong nghe san xuSt hang loat dang rkt bien ling dung su phat trien ciia nganh Co noi chung va su phat tiikn cua cong nghe khuon mau noirieng,cac cong ty 16n da ap dimg va thu du9C tihi6u kit qua co Ipi viec kinh doanh vai san luang hang loat Ion Vi vay, cIn thiet CO nhiing tinh toan hoach dinh dk co thk su dung, phan bo phdm den voi nhiing dan dat hang ma nguai dung yeu cau cho lupng san pham san xuat la khong thira gay lang phi, khong thieu anh huong tai tien dp ciia nha san xuat, ben canh la mo hinh quan !y, phan phoi san xuat 2.1 Cong doan due phun chat deo Cong doan Injection (due phun): San phim ca ban vo plastic dugc tao tu chat dec, diic phun hoi khuon khong c6 mau sac rue nhu phim nhung la cong doan chinh va rdt quan trpng bai cong doan quyet dinh nang luc san xuat (Capacity) San pham diic phun dupe tao tii chat deo nguyen chat dong mau Vi vay, nguyen vat lieu chinh can phai chii y den cong doan la nhua (Resin) Viec kiem tra nhua la cong viec rat quan trpng qua trinh ISp ke hoach Trong bai viet nay, nhom tac gia xay Ben canh viec kiem tra vat lieu thi ta phai dung phuong phap lap ke hoach ciing nhu quan ly san xuat (PPS) cac san pham plastic vo dien tinh toan nang luc san xuat ciia nha may Nang thoai ciia nha may cung cap cho lap rap de phan luc san xuat dupe tinh toan dira tren so lupng may moc (Machine), so lupng khuon (Mold), phoi cho thi truong theo nhu cau cua khach hang D6ga(Jig), CAC C N G DOAN TRONG QUA TRINH SAN XUAT Mpt san ph§m dien thoai lap rap hoan chinh gom nhieu phan cau Mot bp phan quan trpng nhat quyet dinh hinh thiic ciia mpt san pham dien thoai la phan vo Dien thoai co hinh d^g, kich thudc, dp ben ca hpc nhu the nao chi c§n quan sat phan vo la nguai tieu dung CO thS d^nh gia dupe phkn nao chat lupng cua san pham M6t vo plastic thong thuong se duprc san xuat tuan tu theo cac cong doan: + Due phun ap luc: San pham a dang so khai hinh hai nhu long va loi cua khuon + San bk mat: Tang dp tham mi va dp b ^ CO hpc ciia vo Hinh 2: Sdnphdm vo plastic chua qua san ISSN 0866 - 7056 TAP CHI CO KHi VIET NAM, S6 nam 2015 www.cokhivietnam.vn NGHIEN CUfU-TRAOD6| 2.2 Cdng doan son be mat 2.3 C6ng doan lap r a p , Cong doan lap rap pham (Final Assembly): C6ng d o ^ cu6i cung truoc ragt san pham duac xudt thi truong tieu thu Cong doan rIt quan trpng boi le tit ca cac linh ki?n se dupe lip rap tai day (bao g6m ca phin vo), cong do^n san pham se duac san CO kem theo cac cong doan kiem tra chit lupng, hoac ISn, co thi dupe phii, ma tiiy thupc vao chay ung dung, phin mlm, tij day dupe xuit chat lupng va gia tri ciia san pham Tuy nhien, di khap cac thi truong va phan phoi toi tay ngu6i cong doan thuong c6 nang luc san xuat rat tieu dung cao, vi vay, ta mac dinh cong doan du nang luc de dap ling dupe ke hoach san xuat Cong doan son be mat (Coating): Sau nhan dupe hang chuyen len tir cong doan ep phun, bp phan son phii co nhiem vu hoan thien be mat cua san pham Hinh 5: Sdnphdm hoan thien CAC mS6C T I E N HANH L ^ P HO4.CH TRfeN H E T H O N G id 3.1 Nhu c^u cua khach hang va vi^c phan bi k^ hoach Viec lap k l hoach san xuat dSu dupe quan ly va theo doi bang he thfing theo mot chuoi He tb^ng qiik t4 Duiteig, input «!ci 1^ , , \ He ibong li> kc Hctli6iigi{iiiDly i=> iiaachmnill J iaiixiiit,pbiniii& linh liinlirinmil Hinh 6: He thong theo doi chuoi ctia viec lap kehoftch Hinh 4: Dong khay vd cung cdp cho lap rap Viec lap ke hoach san xuit bit ngu6n tu Yeu t6 Ian nhlt cua cong do^n son ma nhu c4u cua khach hang Nhu ciu nay, chuyln ta can quan tam la hieu sudt (Yeild) cua qua tai toi cong ty, nha m i y theo thong tin nhan dug«; trinh Day co thi coi la ylu t6 quan trpng, bai tii bp ph$n tiSp thi (marketing) hay bp phjn dat hieu suat cao tuang duang voi hi$u qua san xuat hang (Oder) Tit ea cac don dat hang tit khach t6t M^c dii vay, d l dat dupe hieu suit toan cong hang (nguoi tieu diing, cac nha mang, cac dia doan cao la mot cong viec At kho khan va vai phuong ) deu dupe cac nha quan ly phan anh m6i mpt cong doan khac thi hieu suit lai len tren he th6ng Viec lap kS hoach san xuit vo khac nhau, do can phai quan ly chat che dien thoai cung cip cho lip rap dku dupe quan viec lap kl hoach ly bang he th6ng tu yeu eiu cua khach hang TAP CHI CO KHf VIET NAM, S6 nam 2015 www.cokhivietnam.vn NGHIEN CUTU-TRAO Ddi De lap duoc kl hosich san xuit ta phai cua nha may san xuat Vi yeu to hieu suat quan ly dii Ueu don dat hang ciia khach hang ma lupng san phim dau vao (Input) bao gio bai yilt nay, nhom tac gia su dung h? thdng ciing Ion hon lupng san pham dau (Output) GSCM dl liy dii lieu dat hang cua khach hang Voi dii lieu thu thap dupe tu he th6ng bao g6m cac thong tin: Ten nhung phin dat hang, khach hang, so lupng, mau sic, san pham Tat ca duac mo ta rat ro rang theo tiing tuin (ta goi la SOP cua tuin) SOP co tac dung se moc n6i lien ket va sinh dii lieu dl lam ke hoach tren chinh he th6ng (Demand data) Hay noi each khac: Demand Data = SOP cua tudn Hinh 8: Ki hoach cda nhd may Co the bieu dien bang cong thiic: Ou^ut (Final Assembly) = Yeild x Input (Injection) Output: La pham, don vi tinh la Tu he thong nay, ta tai du lieu vl may va pes (Chiec) quan ly tren file Excel ca nhSn , Yeild: La chi so phan tram, hieu qua ciia cong doan son Input: La san pham dau vao chua qua son, dan vi tinh la pes (Chiec) Tu luang yeu cau cua ben lip rap tharih lupng ke hoach can lam ciia ben nha may san xuat vo dien thoai NhiSm vu tiep theo la bo tri may moc, khuon mlu (Mold), kiem tra tinh trang nguyen vat lieu (Nhua), dua ke hoach de dua vao bp phan san xuit lam theo Du lieu hang tuin la cho ta cai nhin ting quat vl don dat hang, day la lucmg cong viec ma nha may phai lam tiing tuan Nguoi lap ke hoach phan b6 nhiing s6 timg tuan cho dap ling dupe nang luc san xuat, vat lieu, toi uu hoa may moc va tat ca van de lien quan So lupng may d§ san xuat anh huong nhilu nhit toi viec lap kl hoach san xuit, vi nlu khong co may ta khong thi lip khuon va sii dung dupe lupng nhua kho va cac nha quan ly tinh toan dupe s6 luang nhan cong cin thilt 3.2 Quy d6i san lirong Khi ke ho^ch ciia bp phan lap rap dugc hoan thanh, ta quy doi ke hoach ciia bp phan kl hoach ciia nha may san xuat vo dien thoai dl tu ta du doan dupe ke hoach Hinh 9: May ep nhyca JSW ISSN 0866 - 7056 TAP CHf CO KHf VIET NAM, S6 nam 2015 www.coldiivietnam.vn NGHIEN ClifU - TRAO 061 3.3 Ki^m tra v^t lif u Idhi llip ke hoach san xuit Cong viec kilm tra nhua dupe kilm soat bing Excelfileket hop voi cac he thong Ci day, bp phan mua hang cap nhat dii lieu tren he thdng ERP Tren He thong co cac thong tin vl lupng ton kho cua tiing ma (code) nhua va lupng nhira Hinh 10: Khuon chudn hi cho sdn xudt cin thilt dl tao tiing san pham Day la cac y^u to can thiet de kiem soat luang vat lieu kho Khuon mau diing de san xuat can dupe CO du dl dap ling ke hoach san xuat hay khong quan ly, thuong la bang cac Tool Excel vi linh Su dung cac T- Code de co the vao tung hoat hon cac truong hpp hong hoac sua khuon (Mold) Nguai lap ke hoach co the ty dieu chiic nang ERP: chinh cho thuan tien viec quan ly T- Code giup ta kiem soat lupng nhua Doi voi tung mau dien thoai (Model) lai kho ciia cac ma nhira hien hanh, khac thi ta co nhiing loai khuon khac Idem tra ca cay lien ket giiia cac ma Idem tra Tung loEii khuon khac lai c6 chu ky bao dupe ca lupng nhua can thiet cho san pham duong ciing nhu nang luc san xuat khac lai viia biet (check) dupe lupng nhua ton kho Nang luc san xuit ciia khuon dupe tinh theo san Nhupc diem cua T-code la chi kiem tra duac lupng khuon co the tao thai gian timg ma neng biet: De tinh dupe nang luc (Capa) cua khuon nao d6 nguai ta quan tam tai thoi gian khuon Dl tinh dupe lucmg nhua cin thilt thi ta van hanh ngay, ylu t6 s6 long khuon CO the ap dung qui tic: (Cavity), chu ky khuon (Cycle time) QuMitity Requirements ^ Unit x Input (Injection); Ta CO the tinh nang luc cua khuon (mold) theo cong thiic: Quantity Req la lupng nhua cdn thiet de dap ling duoc kl hoach (g); Capa Mold = Operation rate x Cavity: Cycle Time Unit la lupng nhua cin thilt cho m6i san phim (g); Capa Mold la lupng san phim khuon tao vong ngay, don vi la chile Nhu vay, de c6 cai nhin t6ng quat, ta c6 the quy doi true tiep tu san lupng pham de Operation rate la thai gian khuon van tinh toan dupe lupng nhua cin thilt Ta co the hanh c6 trir di thai gian bao duang, sua tinh theo quy tic: chiia khuon, don vi tinh la s Operation rate = 24H x 3600 x (85~90)% = 75600 (liy 88%) Quantity Requuements = Unit x Output (Final Assy): Yeild Dilu kien nhua dam bao kl hoach la lupng ISSN 0866 - 7056 TAP CHi CO KHi VIET NAM, S6 nam 2015 www.cokhivietnam.vn NGHIEN CUTU - TRAO D O I nhua yen cau nho hon lupng nhua t i n kho N I U tit ca cac ylu t l v l may moc, khuon mau va nhua deu dap ling thi cong viec lai cua nguai ISp k l hoach la phan b6 san lupng cac may cho may lip duoc khuon phu hpp va san lupfng phu hop voi nang luc ciia khuon 3.4 Lalp ke hoach tren cong cu Excel va hf thong, ban giao san xuat - Model: Ten model, mau sac, chung loai - San lupng yeu cau - Thai gian bat diu va hoan ke hoach - Vat tu yeu cau Khi he thdng van hanh ke hoach hoan thi tat ca cac thong tin tren he thong se dupe chuyen len mpt he thong trung gian ERP va xii ly , • •—"nrnr^rj "^ ••^••••••* Tat ca cac cong viec phan bo len cac may deu dupe nguoi lap ke hoach (planner) thuc hien tren Excel Cong viec sap xep tren he thong nguoi ta gpi la Fine Tunning , ^ : 11 M • F -t- f - i • ^ "4"4sr» -rr. .L^„'^' -^=^"- ; S^s^ ^ffg'jrtfT^si ' -~~*— - ^ — : H ^ E M SESSii^ " " " ^ Hinh 12: DU lieu trin hi thdng ERP • : " - ' • " -^ -^w ERI* la he thing trung gian co chiic nang chuyln hoa thong tm giiia cac he thing Cac he thong deu dupe lien ket voi he thong Hinh 10: Man hinh thao tdc phan bo ki hoach vdo cdc mdy sdn xudt Sau phan phoi xong vao cac may (Line), nguoi quan ly ke hoach lam thao tac phat hanh k l hoach (Release) tren he thong Khi he thing nhan thong tin se ty dpng chay tinh toan dii lieu kS hoach Cac thong tin tinh toan se dupe chuyln qua he thdng va bp phan san xuat nhan k l hoach san xuit tren he thong cua rieng ho He thfing quan ly san xuat ciing dupe moc noi va nh^n thong tin tu ERP, qua trinh trao d i i tif ERP din he thing san xuat dupe gpi la Interface Nhan thong tin tir ERP, MES (he thing ciia san xuat) ciing phan anh day dii cac thong tin lien quan den ke hoach Bp phan san xuat co trach nhiem theo doi va xii ly he thong de dam bao dupe lupng ke hoach da dat ir anfti'^ilM Hinh 11: He thong hodn Cac thong tin quan trpng can c6 bao gom: Hinh 13: Ki hoach o tren he thong sdn xudt ISSN 0866 - 7056 TAP CHi CO KHi V I | T NAM, S l nam 2015 www.cokhivietnam.vn NGHIEN CUfU - TRAO Ddi Bp phan san xuit can cii vae day di chuin bi may mec, khuon, nh^a, nhan luc dS dam bio san xuat Sau hoan san xuit thi bp phgn san xuat co trach nhiem bao cao va thong tin len bp ph|n lap k i hotich Hinh 14: Bao cao sdn xudt tren h^ thong KET LUAN Tren cp so Itei viec true tiSp va tim hiiu quy trinh san xuit vo nhua dien thoai, nhom tac gia da di v4o th\ic tien lap ke hojch san xuit Cach ki8m tra nang luc va nguySn vat Heu cung cip cho ke hoach san xuat, gop phan dua ban k i hoach hoan chinh • Ngay nhan b4i: 25/6/2015 Ngay phan bien: 14/7/2015 Tai li^u tham khao: S p r i n ^ g e ^ n O O * ! * ' "" " " " ' ^ °f P ™ " - ' ™ -heduling "Handbook of Production Scheduling, ^ " ' ' s r ° " ' * ^ ^ " " " ^"^^"^ ' " ' " ' ^ ' * ' ' ^ ' '^''"""''y- '^'- M - ' r i a l Management, [4] http://dip vn/web/sanpham aspx [5] http://www ecounterp com vn/ [6] http://www perfect, com vn/manufacturing-resource-plaimng.html ISSN 0866-7056 TAP CHi CO KHI VIET NAM, S6 nam 2015 www.cokhivietnam.vn