Luận văn hoàn thiện công tác kế hoạch sản xuất tại công ty tnhh sản xuất phụ tùng yamaha motor việt nam

TRUONG DAI HOC KINH TE QUOC DAN ■ ■ -g-oGS Q DAI HOC KTQD TT THONG TIN THW VIEN PHONGLUANAN-TULIEU TRAN THI THANH VAN HOAN THIEN CONG TAC KE HOACH SAN XUAT TAI CONG TY ■ ■ ■ TNHH SAN XUAT PHU TUNG YAMAHA - MOTOR VIET NAM ■ ■ CHUYEN NGANH: KINH TE PHAT TRIEN fS 7J3/^ LUAN VAN THAC SY KINH TE • • Ngu'di hu’dng dan khoa hoc: TS BUI DUC TUAN HA NOI - 2013 LOI CAM DOAN Toi xin cam doan rang, ban luan van “Hoan thien cong tac ke hoach san xuat tai cong ty TNHH san xuat phu tung Yamaha-Motor Viet Nam” la cong trinh nghien cuu doc lap, chinh toi hoan Cac tai lieu tham khao va trich dan duoc su dung luan van deu neu ro xuat xu tac gia va duoc ghi danh muc cac tai lieu tham khao, cac so lieu deu duoc phep cong bo Toi xin chiu trach nhiem truoc phap luat ve loi cam doan Ha Noi, 31 thang 12 nam 2012 Ngudi thu’c hien Tran Thi Thanh Van MUC LUC • • TRANG PHU BIA LOI CAM DOAN MUC LUC DANH MUC BANG, HINH TOM TAT LUAN VAN LOI MO DAU CHUONG 1: TONG QUAN NGHIEN CUU VA LY LUAN CHUNG VE CONG TAC KE HOACH SAN XUAT VA PHUONG PHAP SAN XUAT TINH GON 1.1 Khai niem ve cong tac ke hoach san xuat doanh nghiep .5 1.2 Vai tro cua ke hoach san xuat hoat dong san xuat cua doanh nghiep 10 1.3 Noi dung cong tac ke hoach san xuat doanh nghiep 12 1.3.1 Lap ke hoach san xuat doanh nghiep 12 1.3.2 To chuc thuc hien ke hoach san xuat doanh nghiep 18 1.3.3 Theo doi va danh gia viec thuc hien ke hoach san xuat doanh nghiep 21 1.4 Phuong phap san xuat tinh gon - nhan to anh huong den cong tac ke hoach san xuat va yeu cau noi dung cong tac ke hoach san xuat dap ung phuong phap san xuat tinh gon 23 1.4.1 Tim hieu chung ve phuong phap san xuat tinh gon (Lean Manufacturing) 24 1.4.2 Yeu cau dat voi cong tac ke hoach san xuat doanh nghiep thuc hien phuong phap san xuat tinh gon 29 1.5 Cac nhan to khac anh huong toi ke hoach san xuat doanh nghiep 31 1.5.1 Nhung nhan to chu quan 31 1.5.2 Nhung nhan to khach quan 32 CHUONG 2: DANH GIA THUC TRANG CONG TAC kE HOACH SAN XUAt TAI CONG TY TNHH SAN XUAt PHU TUNG YAMAHA-MOTOR VUE T NAM 34 2.1 TTng quan vv c ong ty TNHH san xuat phu tung Yamaha-Motor VietNam 34 2.1.1 Lich su doi cua cong ty TNHH san xuat phu tung Ynmnan-Mrtrr Viet Nam .34 2.1.2 Co cau t0 chuc cua cong ty TNHH san xuat phu tung Ynmnan-Mrtrr Viet Nam 35 2.1.3 Thi truong san pham cua cong ty TNHH san xuat phu tung Ynmnan-Mrtrr Viet Naim 37 2.1.4 Tinh hinh san xuat kinh doanh cua cong ty TNHH san xuat phu tung YamahaMotor Viet Hnm gini daag 2006-2012 38 2.2 Thue trang cong ttic ke hooch san xuat cua cong tty TNJHH san xuat pha tung Ymmhan-Motor Viet Hnm 42 2.2.1 NOeu trngg ungg tcu ke OonuO sng uuat 42 2.2.2 POag tihO ungg tcu ke OonuO sng uuat uan ungg ty 46 2.2.3 DCgO gic uOugg ungg tcu ke OonhO sng uuat tni ungg ty 57 _ Q r X _ _ „ _ X _ X _ _ A CHUON'G 3: GIAI PHAP HOAN THIEN KE HOACH SAN XUAT TAI CONG TY TNHH SAN XUAt PHU TUNG YAMAHA-MOTOR VIET NAM 64 3.1 Qung diem Ooag tOieg ke OonuO sng uuat 64 3.2 HOugg tOuag loi/kOo kOag uan ungg ty NHHH sag uutt pOu tngg YnmnOn-Motor Viet Hnm kOi tOeu Oieg tOeo pOuogg pOCp sng uutt tigO gon 65 3.3 Ccu gini pOCp Ooag tOieg ungg tcu ke OonuO sng uuat 66 3.3.1 Hagg uco trigO uan doi ggu ucg bo lam ungg tCu lap ke OonuO sng uuat 66 3.3.2 Hoag tOieg quy trigO ke OonuO Oon sng uutt 69 3.3.3 Hoag tOieg pOuagg pOCp lap ke OonuO sng uuat: 73 3.3.4 Hoag tOieg Oe tOogg digO muu uay Oegg ke OonuO sdg uuat 75 3.3.5 Ket Oop ke OonuO sng uudt va ke OonuO Oe tru 82 3.3.6 Hagg uno gagg leu tOeo Ooi, dCgO giC uan bo pOag kehouOh va bo Ohgn lieg quan 85 3.3.7 Se Oo tro uan uCu pOogg bng trogg uogg ty 85 3.4 De sudt lo trigO Ooag tOieg ungg tCu ke OonuO sng uutt tOeo pOuagg pOCp sng uutt tigO gon 87 kEt lu Ain 90 tAi lieu tham khAo PHU LUC DANH MUC BANG, HINH VE I BANG Bang 1.1: Vi du bang ke hoach san xuat mot nhom hang cua cong ty TNHH san xuat phu tung Yamaha-Motor Viet Nam 16 Bang 1.2: Bang so sanh phuong phap san xuat tinh gon voi phuong phap san xuat hang loat 28 Bang 2.1: Ke hoach va thuc te luong pham ban hang cua cong ty hai quy dau nam 2012 41 Bang 2.2: Don hang trung ky cua cong ty TNHH san xuat phu tiing Yamaha- MotorViet nam 47 Bang 2.3: Ke hoach san xuat chi tiet 30K-1W cong doan tien banh rang theo 49 Bang 2.4: Ke hoach va thuc te san xuat cua ma hang 30K-1W tai cong doan tien banh rang 19/09/2012 va 20/09/2012 50 Bang 2.5: Ke hoanh va thuc te san xuat cua ma hang 30K-1W tir 17/09 den 22/09 nam 2012 54 Bang 2.6: Ke hoach va thuc te san xuat cua ma hang 52M-AM tir 17/09 den 22/09 nam 2012 .54 Bang 2.7: Ty le kiem ke tir nam 2006 den nam 2011 cua Cong ty TNHH san xuat phu tung Yamaha-motor Viet Nam 62 II HINH Hinh 2.1: So co cau to chuc cong ty TNHH san xuat phu tung Yamaha-Motor 35 Viet Nam 35 Hinh 2.2 : Do thi bieu thi san luong pham san xuat giai doan 2006-2011 39 Hinh 2.3: Do thi bieu hien doanh thu va lpi nhuan sau thue cua cong ty giai doan 2006-2011 40 Hinh 2.4: So to chuc bo may ke hoach san xuat 42 Hinh 2.5: Quy trinh ke hoach san xuat cua cong ty TNHH san xuat phu tung Yamaha-Motor Viet Nam 45 Hinh 2.6: So qua trinh san xuat cua ma hang 30K-1W 55 Hinh 3.1: Quy trinh cong tac ke hoach san xuat moi 72 TRUONG DAI HOC KINH TE QUOC DAN ôS^(G8 â ÊOô^ TRAN THI THANH VAN HOAN THIEN CONG TAC KE HOACH SAN XUAT TAI CONG TY ■ ■ ■ X A TNHH SAN XUAT PHU TUNG YAMAHA - MOTOR VIET NAM ■ ■ CHUYEN NGANH: KINH TE PHAT TRIEN TOM TAT LUAN VAN THAC SY HA NOI - 2013 i LOI MO DAU Tinh cap thief cua de tai Doi voi mot doanh nghiep san xuat nhu Cong ty TNHH Yamaha Viet Nam thi hoat dong san xuat la hoat dong chinh cua doanh nghiep Chinh vi the, viec quan ly san xuat cho hieu qua, loi nhuan cao, tiet kiem chi phi, va dam bao nhu cau cua khach hang la nhung yeu cau chinh cua doanh nghiep Trong do, cong tac ke hoach san xuat la mot nhung cong tac quan nhat nham dam bao nhung yeu cau tren Bo phan ke hoach san xuat phai dam bao san xuat dap ung nhu cau cua khach hang, tan dung nang luc san xuat, toi uu hoa cac muc dich ve chi phi, phoi hop hoat dong voi cac bo phan khac cua doanh nghiep nham thuc hien duoc cac muc tieu tren Doi tuong nghien cuu cua de tai De tai tap trung nghien cuu cong tac ke hoach san xuat cua cong ty TNHH san xuat phu tung Yamaha Viet Nam voi tam: Quy trinh ke hoach hoa san xuat cua cong ty, tu viec lap ke hoach san xuat den to chuc thuc hien ke hoach san xuat va t r r \ r kiem soat san xuat qua trinh thuc hien, cung voi la cac ly thuyet ve ke hoach san xuat va triet ly san xuat tinh gon hoat dong san xuat cua doanh nghiep Muc tieu nghien cuu De tai phan tich, lam sang to hon nhung van de ly luan co ban ve cong tac ke hoach san xuat doanh nghiep san xuat voi nhung yeu cau cua phuong phap san xuat tinh gon Ben canh do, phan tich va danh gia thuc trang cong tac ke hoach san xuat cua doanh nghiep san xuat, nham dua nhung uu diem, han che, ket qua dat duoc, va tim nguyen nhan cua su yeu kem cong tac ke hoach san xuat cua doanh nghiep nham dap ung nhung muc tieu cua phuong phap san xuat tinh gon Tu do, kien nghi mot so giai phap nham hoan thien va nang cao hieu qua cua cong tac ke hoach san xuat doanh nghiep san xuat nham dap ung muc tieu cua phuong phap san xuat tinh gon Pham vi nghien cuu Luan van chi tap trung nghien cuu cong tac ke hoach san xuat cua cong ty ii TNHH san xuat phu tung Yamaha-Motor Viet Nam tren co so dap ung muc tieu va yeu cau cua phuong phap san xuat tinh gon (Lean Manufacturing) De co dupc nhung phan tich cu the, chi tiet, luan van nghien cuu cu the cong tac ke hoach san xuat dien hinh tai phan xuong san xuat so Phan thuc trang luan van di sau phan tich cong tac ke hoach san xuat tai phan xuong so giai doan 2006-2012, va \ r r •> nhung kien nghi giai phap se dupc de suat de ap dung thoi gian tuong lai, sau nam 2012 Phuong phap nghien cuu Tac gia lua chon nhung muc tieu va nguyen tac cua phuong phap san xuat > ? > r tinh gon qua trinh nghien cuu de tai lam nen tang chinh de hoan thien ke hoach san xuat cua cong ty TNHH san xuat phu tung Yamaha-Motor Viet Nam r r i Luan van su dung nghien cuu dien hinh o phan xuong san xuat so de phan tich cong tac ke hoach san xuat cua cong ty TNHH san xuat phu tung Yamaha-Motor Viet Nam Luan van su dung phuong phap thu thap va xu ly thong tin thuc te tu ngudn thdng tin thu cap cua cong ty TNHH san xuat phu tung Yamaha-Motor Viet Nam, va cac ngudn khac, phan tich va tong hop thdng tin de thuc hien muc tieu nghien cuu cua de tai Bo cuc cua luan van Ngoai phan mo dau, ket luan, muc luc, danh muc bang bieu, phu luc va danh muc tai lieu tham khao, noi dung chinh cua luan van dupc chia lam chuong: Chuong 1: Tong quan nghien cuu va ly luan chung ve cong tac ke hoach san xuat va phuong phap san xuat tinh gon (Lean Manufacturing) Chuong 2: Danh gia thuc trang cong tac ke hoach san xuat tai cong ty TNHH san xuat phu tung Yamaha Viet Nam Chuong 3: Giai phap hoan thien cong tac ke hoach san xuat tai cong ty TNHH san xuat phu tung Yamaha Viet Nam iii CHITONG 1: TONG QUAN NGHIEN CUU VA LY LUAN CHUNG VE CONG TAC KE HOACH SAN XUAT VA PHUONG PHAP SAN XUAT TINH GON 1.1 Khai niem ve cong tac ke hoach san xuat doanh nghiep Cong tac ke hoach san xuat cua doanh nghiep nen hieu bao gom cac noi dung: (1) soan, lap ke hoach san xuat vdi muc dich sap xep toi uu cac he thong a a r a y r nguon lire nham nham dat muc tieu kinh te da de ra; (2) to chtrc, thuc hien ke hoach san xuat, bao gom su phoi hop giua bo phan ke hoach va cac bo phan lien quan, su dung cac giai phap su dung nguon luc de dat duoc ke hoach de ra; (3) theo doi, kiem tra, dieu chinh, danh gia tinh hinh thuc hien ke hoach r r r 1.2 Vai tro cua ke hoach san xuat hoat dong san xuat cua doanh nghiep Tren thuc te, luon co sir sai lech giua du bao va thi truong noi ma doanh nghiep co mat, vi vay ke hoach phai duoc xay dung dua tren nang luc san xuat, va cac phan tich danh gia du bao nhu cau cua san pham tren thi truong Ke hoach san xuat dupe dieu chinh linh hoat cho thich ung vdi moi su bien dong cua moi truong kinh doanh, dac biet la su bien dong cua nhu cau Qua do, lam cho cac chuc nang san xuat tro mot nhan to quan dam bao sir cong cua doanh nghiep Tom lai, ke hoach san xuat hieu qua se dem lai cac loi ich: Giam nguon lire gay lang phi thbi gian va cai tien dong chay san pham; giam chi phi luu kho bang each giam muc ton kho an toan, ton kho cong doan; toi uu hoa viec su dung trang thiet bi va nang luc san xuat toi da; toi uu hoa nguon nhan luc; cai tien van chuyen san pham, dich vu dung luc kip thbi 1.3 Noi dung cong tac ke hoach san xuat doanh nghiep Noi dung cua cong tac ke hoach san xuat bao gom: Lap ke hoach san xuat, thuc hien ke hoach san xuat, theo doi va danh gia thuc hien ke hoach san xuat 1.3.1 Lap k§ hoach san xuat doanh nghiep Lap ke hoach la budc dau tien ke hoach hoa san xuat Bude quyet dinh ke hoach hanh dong, cac hoat dong nham dat tinh kinh te, so lupng, quyet dinh ve may mbe, su uu tien san xuat mot each toi uu Noi dung bao gom: Lap 82 + Xay dung tieu chi danh gia doi voi muc phuc tap cua cong viec sua chua + Xac dinh muc sua chua doi voi tung thiet bi dieu kien cu the + KiSm tra va phan tich qua trinh thuc hien dinh muc Trong qua trinh phat trien cua cong ty thi ky thuat, cong nghe va td chuc sua chua khong ngung duqc hoan thien Vi vay dinh muc sua chua se duqc rut ngan r \ dam bao cho san xuat lien tuc it bi gian doan va can duqc cap nhat 3.3.5 Ket hop ke hoach san xuat va ke hoach du' trie Hang du tru he thong san xuat va cung ung nham muc dich de phong nhung bat trac co the xay qua trinh san xuat va phan phoi De dam bao hieu qua toi uu cua san xuat, cac doanh nghiep can ap dung cung ung dung thdi diem Luqng du tru dung thdi diem la luqng du tru toi thieu can thiet giu cho he thong san xuat hoat dong binh thudng Voi phuong thuc td chuc cung ung va du tru dung thdi didm de dam bao luqng hang hoa duqc dua den noi co nhu cau dung luc, kip thdi cho hoat dong cua bat ky noi nao cung duqc lien tuc (khong som qua cung khdng muon qua) De dat duqc luqng du tru dung thdi diem, cac nha quan tri san xuat phai tim cach giam nhung bien ddi cac nhan to ben va ben ngoai cua qua trinh san r xuat gay Trong dieu kien nhat dinh, du tru qua cao se lam tang chi phi dau tu vao du tru, du tru thap se ton kem chi phi viec dat hang, chuyen ddi lo san xuat, bo lo co hoi thu lqi nhuan Ddi voi cong ty, ap dung phuong phap Lean Manufacturing vao san xuat ndn viec ket hop giua ke hoach san xuat va ke hoach du tru la vo cung quan Du tru luqng bao nhieu? Du tru nao? Va nao thi dung luqng du tru la cau hoi ma cac nha quan ly can tra ldi de nham vua thu duqc lqi nhuan lai vua giam duqc chi phi 83 He thong luong dat hang co dinh thiet lap cac don hang vdi cung so luong cho mot loai vat lieu vat lieu duoc dat hang, luong du tru giam cho den muc gidi han nao se duoc tien hanh dat hang, tai thdi diem luong hang lai duoc tinh bang each udc luong so luong vat lieu mong doi duoc su dung giua thdi gian chung ta dat hang den nhan duoc 16 hang khac cua loai vat lieu Viec kiem tra du tru don gian nhat la ung dung kieu he thong hai ngan Trong kieu he thong hai ngan, tung loai vat lieu duoc giu hai ngan cua nha kho Khi su dung, vat lieu d ngan ldn duoc dung cho den het, thdi diem don hang moi duoc gui di va luc vat lieu ngan nho duoc su dung het, tuc la luong du tru da du dung cho den nhan duoc vat tu mdi, ca hai ngan vat lieu deu day va chu ky lap lai Khi cac nha quan tri san xuat phai quyet dinh so luong cua mot vat lieu de dat hang he thong dat hang co dinh, khong co cdng thuc don gian nao ap dung cho moi tinh huong day, luan van xin su dung mo hinh luong dat hang theo 16 san xuat (POQProduction Order Quantity) Gia thiet cua mo hinh: - Nhu cau hang nam, chi phi ton tru va chi phi dat hang cua mot loai vat lieu co the udc luong duoc - Khong su dung du tru an toan, vat lieu duoc cung cap theo muc dong nhat (p), vat lieu duoc su dung d muc ddng nhat (d) va tat ca vat lieu duoc dung het toan bo don hang ke tiep ve den - Neu het du tru thi su dap ung khach hang va cac chi phi khac khong dang ke - Khong co chiet khau theo so luong - Muc cung cap (p) ldn hon muc su dung (d) Cdng thicc tinh: Du tru toi da = Muc tang du tru x Thbi gian giao hang 84 Qmax = (p-d) X _ P Du tru toi thieu: (Qmin) = Du tru trung binh = Vi *(Du tru toi da + Du tru toi thieu) Qtb Qmax 1/2 x _ Qmin = Chi phi ton tru hang nam = Du tru trung binh x Phi ton tru don vi hang nam Ctt 1// = x (p-d) x _ P x h Chi phi dat hang hang nam = So don hang/nam x Chi phi mot don dat hang Cdh = D _ Q X S T6ng chi phi du tru = Chi phi ton tru hang nam + Chi phi dat hang hang nam TC = CT + Cdh Mo hinh POQ cho lo san xuat, huu dung cho viec xac dinh kich thuoc don hang n£u mot vat lieu duoc san xuat o mot giai doan cua quy trinh san xuat, ton tru kho va sau gui qua giai doan khac san xuat hay van chuyen den khach hang Mo hinh cho ta thay cac don hang duoc san xuat o muc dong nhat (p) giai doan dau cua chu ky du tru va duoc dung o muc dong nhat (d) suot chu ky Ke hoach san xuat va ke hoach du tru lien quan truc tiep den doanh nghiep san xuat Ke hoach san xuat quyet dinh ke hoach du tru va ke hoach du tru anh huong toi ke hoach san xuat Viec tinh toan luong du tru can thiet ca ve pham va nguyen vat lieu giup cho cac nha ke hoach va nha quan ly co the kiem soat duoc hoat dong san xuat va hoat dong cung ung va nang luc san xuat cua doanh nghiep 85 r 3.3.6 Nang cao nang lire theo doi, danh gid cua bo phan ke hoach va bo phan lien quan Trong cong tac ke hoach san xuat cua cong ty, cong tac theo doi ke hoach la mot cdng tac yeu kem nhat Vi the, ma tinh trang san xuat Ion xon, luong ton kho chenh lech qua nhieu cong doan, hoac giua cac ma hang phai chenh lech Ion thi bo phan ke hoach moi phat hien Vai trd theo doi ke hoach san xuat quan nhat la cua bo phan doc cong nhung bo phan lai co vai trd rat md nhat hoat dong san xuat Ngudi doc cdng can lien tuc theo ddi, nam bat tinh hinh san xuat cua tung cdng doan va thuc hien viec don doc thuc hien ke hoach giua cac cdng doan va chinh la ngudi nam quyen chu dong, tac dong va thuc day trao doi thdng tin giua cac cdng doan vdi De lam tot vai trd nay, ngudi doc cdng can hieu rd ve san xuat, ke hoach san xuat, can nhan thuc duoc viec thuc hien ke hoach san xuat nham dam bao duoc muc tieu cua cdng ty Nhu vay, doc cdng chinh la ngudi ho trq tot nhat cho bo phan ke hoach san xuat neu nhu ho phat huy duqc het tac dung va hieu duqc tam quan cua ke hoach san xuat Hoat dong theo ddi ke hoach san xuat, danh gia thuc te va ke hoach se giup cho bo phan ke hoach can doi duqc san xuat, dua quyet dinh can lam gi de dam bao muc tieu cua ban giam doc va muc tieu cua ke hoach san xuat Ddi vdi quy md san xuat ldn, hoat dong theo ddi ke hoach san xuat yeu kem, se dan den rat nhieu lang phi san xuat thira, tang cao chi phi san xuat thieu ma viec lai bi phat hien qua cham che Do do, hoat dong theo ddi ke hoach la hoat dong thudng xuyen, quan nhu hoat dong lap ke hoach, va tham chi la duqc thuc hien gap nhieu lan, bdi nhung tac dong khach quan san xuat ma ke hoach san xuat khdng the ludng truoc duqc 3.3.7 Sic ho tret cua cac phong ban cong ty Rd rang, su ho trq tich cue cua phong ban la rat can thiet viec ap dung 86 Lean Manufacturing cong Vi Lean Manufacturing la mot phuong phap huu hieu quan ly san xuat chu khong phai gianh rieng cho bo phan ke hoach san xuat Do do, cac bo phan khac cong ty can: Ddi voi bo phan ky thuat: Phai lien tuc cai tien ve may moc, rut ngan thoi gian thiet lap may va thoi gian chuyen doi may, cai tien lap trinh san xuat Doi voi muc tieu nay, bo phan ky thuat giup nang cao nang luc san xuat cua xuong, va hO tro bo phan ke hoach cac van de rui ro ky thuat lien quan toi may moc va san pham lam cham tien thuc hien ke hoach san xuat Tu do, gop phan han che su lang phi dung may, giam gia san pham Ho cung la nguoi dam bao chat luong san pham cong doan rieng Bo phan ky thuat cung voi bo r r r r a phan chat luong se phai cai tien hoat dong san xuat nham nang cao chat luong san pham, khac phuc su co, va dap ung yeu cau cang cao cua khach hang, > r r dam bao yeu cau tiet kiem cua ban giam doc Ddi vdi bo phan chat luang: Dam bao duoc muc tieu ve chat luong san pham Chat luong san pham chinh la yeu to quan trong san xuat, bo phan chat luong danh gia chat luong va dua quyet dinh can thiet de dam bao san xuat lien tuc khong gian doan, ho tro bo phan ke hoach san xuat dua quyet dinh thay dOi ke hoach chi dao san xuat san pham gap van de chat luong Ben canh do, bo phan se sua hang loi, danh gia nguyen vat lieu dau vao, thuc hien cac bien \ r r \ r phap yeu cau doi voi nha cung cap ve chat luong nguyen vat lieu Ddi voi bo phan bao duang: Day la bo phan chiu trach nhiem khac phuc su r r ? co xay voi may moc, va bao duong he thong may de dam bao tinh an toan cua may moc qua trinh su dung va su on dinh ve chat luong cua san pham vein de quan la bo phan can lap ke hoach bao duong may moc co su lien he voi bo phan ke hoach san xuat Tu truoc, bo phan luon hoat dong doc lap, va khong co su thong tin voi bo phan ke hoach, dan den rat nhieu ke hoach san xuat bi dinh tre, bi dung, va cham tre ma bo phan ke hoach khong nam bat duoc thong tin Nguyen nhan chinh la nang luc san xuat du thua, viec dung may khong anh 87 huong tdi xuat hang, va hon the nua ke hoach san xuat cung chua duoc coi r \ r t Nhung nang luc san xuat thap hon nhu cau ban hang thi day chinh la diem ma cong ty can thay doi each nhin nhan Ke hoach bao duong may moc anh huong toi nhu cau su dung may va anh huong tdi tien thuc hien ke hoach cung nhu ke hoach san xuat Su can thiet thong tin lien lac giua ke hoach san xuat va ke hoach bao dudng, sua may de dam bao thuc te sat ke hoach nhat, nguon luc dam bao duoc ke hoach san xuat theo ke hoach bao duong Ddi vdi bo phan mua ban: Bo phan mua ban phai dap ung day du yeu cau cua ban ke hoach san xuat, ho tro can nhung thong tin ve san pham va ho tro nhung don hang can gap f r t r Ddi vdi bo phan van chuyen: Bo phan van chuyen cung co ke hoach van chuyen cho toan bo hoat dong cua cdng ty vdi ben ngoai va t£r ngoai vao cdng ty Vi the, ke hoach van chuyen phai dap ung duoc ke hoach san xuat va ke hoach giao hang Day la bo phan quan trong viec dap ung nhu cau khach hang dung han, dung so lupng, dung dia diem Ke hoach san xuat cd hoan tot la can su ho tro, thong tin cua tat ca cac r a a phdng ban cdng ty Tat ca moi hoat dong ca cac phdng ban deu nham phuc vu san xuat va thuc hien ke hoach san xuat tot nhat Cac bo phan cung vdi bo phan ke hoach luon theo doi, thuc hien ke hoach san xuat nham muc tieu chung: Giam lang phi, tang nang suat, tang chat lupng theo nhu muc tieu cua phuong phap Lean 3.4 De suat Id trinh hoan thien cdng tac ke hoach san xuat theo phiro’ng phap san xuat tinh gon Luan van dua mot de suat lo trinh de ap dung triet de muc tieu phuong phap Lean Manufacturing cdng tac ke hoach san xuat doi vdi cdng ty TNHH san xuat phu tung Yamaha-Motor Viet Nam la: Bu’d’c 1: Xay dung quy trinh ke hoach hoa chuan cho bo phan ke hoach san xuat 88 Cong ty da lam duoc buoc nhung chua yeu cau cao van de thuc hien theo quy trinh nay, va nhieu nhan vien moi cong ty cung chua nam het duoc nhung nhiem vu, cung nhu chinh sach lam viec, do, qua trinh lam viec ho khong bi mac loi lam sai quy trinh Trong qua trinh nay, ban giam doc cung can dua nhung muc tieu cu the ma ban giam doc mong muon dat duoc tung thoi ky, ngan han, dai han Vi moi mot giai doan thi can phai chap nhan van de ton tai de dat duoc muc tieu nao Lean Khong phai luc nao moi dieu kien deu tot de dam bao dat duoc day du cac muc tieu Lean Buoc 2: Xay dung quy trinh thuc hien ke hoach Day la buoc quan va chi ro trach nhiem cua nguoi thuc hien ke hoach r r r t se dam bao duoc chenh lech giua ke hoach va thuc te la nhd nhat Cung voi do, r r > ' > nguoi thuc hien ke hoach biet ro cong viec can lam, can phai co hoat dong nao neu khong theo duoc ke hoach va can phai thong tin voi nhung co trach nhiem Moi hoat dong thuc hien ke hoach phai ro rang, thi nguoi lao dong moi hieu vai trd quan cua ho hoat dong san xuat Dong thoi, cac doc cong, va truong nhom moi thay ro vai trd cua ho viec dieu phoi ke hoach truc tiep qua trinh san xuat r r r Buoc 3: Phd bien noi dung ve phuang phap san xuat tinh gon doi vdi toan the nhan vien, cong nhan cong ty Day la buoc dau tien de tac dong vao nhan thuc cua toan the nhan vien, cong nhan cua cong ty Khien cho ho hieu ve phuong phap nay, thay doi nhan thuc ho ve cong viec de ho biet minh can lam gi va thuc hien ke hoach san xuat chinh la dam bao thuc hien tot muc tieu cua cong ty Tuy rang, cong ty ap dung mot so muc tieu, cung nhu phuong phap Lean Manufacturing, nhung la su ap dat cua bo phan quan ly, ma nguoi thuc hien ke hoach lai khong he hieu hoat dong ke hoach san xuat Va do, ho nhan thay su vo 89 ly cac quyet dinh san xuat va ke hoach san xuat cua bd phan ke hoach Va ca nhan vien ky thuat quan ly tung cdng doan cung khong the hieu tai lai phai dung day chuyen cho mot ma hang, ma hang khac dang ton nhieu va chua duoc lam het Vi vay, thay ddi nhan thuc, thdng bao ve muc dich can lam la dieu quan doi voi viec thuc hien mot cai moi va can su hop tac cua moi ngudi Dac biet, bo phan ke hoach san xuat phai theo sat quy trinh va dam bao thuc hien de dat duoc muc tieu cua ban giam doc tirng thdi ky Buoc 4: Theo ddi qua trinh thuc hien ke hoach san xuat va dua ddi sach thuc hien Sau da ap dung cdng ty thi can theo ddi xem cac muc tieu da dat duoc den dau: Muc tieu ve ton kho nhu the nao? Muc tieu ve chat luong san pham sao? Muc tieu ve ket qua kiem ke the nao? Muc tieu ve dieu kien hoat dong cua may moc sao? Nhung danh gia, so sanh truoc va sau thuc hien, cung nhu qua trinh thuc hien se giup cho nhan vien va ban giam doc dua dupe nhung ddi sach phu hop vdi hoat dong san xuat cua cdng ty va phu hop vdi muc tieu cua cdng ty giai doan nao 90 KET LUAN Hoan thien cong tac ke hoach san xuat la cong viec can thiet khong the thieu duoc doi voi cac doanh nghiep hoat dong linh vuc san xuat san pham Chat < r ' r luong cua cong tac ke hoach san xuat anh huong truc tiep toi hieu qua san xuat kinh doanh cua doanh nghiep va quyet dinh su bai cua doanh nghiep r r r r Cong tac ke hoach san xuat la mot linh vuc rong lien quan va chi phoi tat ca cac hoat dong cua cac bo phan doanh nghiep bao gom tu bo phan ke hoach, cung ung, san xuat, tai chinh, ke toan, lao dong tien luong, xay dung co ban, ky thuat san xuat, quan ly chat luong v.v Moi doanh nghiep thuoc moi nganh, linh vuc san xuat kinh doanh khac co nhung dac trung rieng biet Cong tac ke hoach san xuat chiu tac dong cua cac dac diem, yeu to mang tinh dac trung cua linh vuc, nganh ma doanh nghiep co hoat dong san xuat kinh doanh bao gom dac tinh kinh te, ky thuat cua san pham, dac diem va tinh canh tranh cua thi trudng, dac diem ve cong nghe va quy trinh san xuat, dac diem ve nguon nhan luc, chien luoc va chinh sach cua moi doanh nghiep Cong ty TNHH san xuat phu tung Yamaha- Motor Viet Nam la cong ty kinh doanh thiet bi cong nghiep, hoat dong linh vuc san xuat co Trong qua trinh ton tai va phat trien nha may da trai qua nhieu giai doan thang tram, vi vay lanh dao nha may co nhan thuc dung dan ve vai trd va tam quan cua cong tac r r r r ke hoach san xuat Danh gia cong tac ke hoach san xuat cua Cong ty chung ta co the thay nhung uu diem noi bat la: Cong tac xay dung ke hoach san xuat cua nha may duoc tien hanh co bai ban va khoa hoc phu hop voi dieu kien thuc te, dap ung duoc nhu cau cua khach hang va thi trudng Tuy nhien, ben canh nhung uu diem van ton tai mot so han che nhu ton kho qua lon dan toi lang phi, chua can bang duoc san xuat, ap dung phuong phap san xuat moi chua triet de va lung tung "> r r Tren co so phan tich nhung uu diem va han che cong tac ke hoach san xuat cua cong ty, mot so giai phap nham hoan thien cong tac xay dung ke hoach 91 san xuat tai nha may bao gom: Nang cao trinh doi ngu can bd lam cong tac ke hoach san xuat, hoan thien quy trinh ke hoach hoa san xuat, hoan thien phuong phap lap ke hoach san xuat, hoan thien he thong dinh muc xay dung ke hoach san xuat, ket hop ke hoach san xuat va ke hoach du tru, nang cao nang luc theo doi danh gia cua bo phan ke hoach va bo phan co lien quan, su ho trq cua cac phong ban cong ty Luan van mdi chi de cap den mot so mat cong tac ke hoach san xuat tai cong ty TNHH san xuat phu tung Yamaha-Motor Viet Nam va khong tranh khoi nhung thieu sot, tac gia rat mong muon nhan duoc su gop y quy bau cua cac thay co khoa ke hoach va phat trien va cac quy vi Trong qua trinh nghien cuu va viet luan van toi da nhan duoc sir giup do, ung ho tu lanh dao va nhan vien Cong ty TNHH san xuat phu tung Yamaha-Motor Viet nam, cac thay co, ban hoc, dong nghiep, gia dinh va ban be Dac biet toi xin gui loi cam on chan den thay giao TS Bui Dire Tuan da huong dan va giup toi suot qua trinh nghien cuu va viet luan van TAI LIEU THAM KHAO I Tieng Viet Phan Chi Anh (2010), “Cai tien va doi mdi nganh san xuat che tao tai Nhat Ban”, Dai hoc Tong hap Quoc gia Yokohama (Dien dan Nang Suat Chat Luong Viet Nam 28-30/10/2010) Ngo Thang Loi (2009), Giao trinh ke hoach hoa phat trien, NXB DHKTQD Nguyen Van Nghien (2001), Quan tri san xuat, NXB Dai hoc Quoc gia, Ha Noi, Bui Due Tuan (2005), Giao trinh ke hoach kinh doanh, NXB Lao Dong Xa Hoi, Ha Noi Le Due Tien (2010), chat luong cong tac ke hoach san xuat cac doanh nghiep vua va nhd d Viet Nam Dia chi: http://www.saga.vn/Kvnangquan.lv/Kehoaeh-Chienluoc/19032.saga (so 29/03/2010) Tai lieu ke hoach cua cong ty TNHH san xuat phu tung Yamaha-Motor Viet Nam II Tieng Anh Anil Kumar va Suresh (2006), Production and operations managerment, New Age International Leansigmavn HMQ - From Wikipedia, Lean Manufacturing (San xuat tinh gon) la gi? Dia chi: http://www.vinamain eom/2012/l l/lean-manufacturing-san- xuat-tinh-gon-la-gi.html Stephen c Graves (1999), Manufacturing planning and control, Massachusetts Institute of technology PHU• LUC • Phu• luc • 1: Hinh anh mot • chi tiet dau bo Nguon: Ban ky thuat- Cong ty TNHH san xuat phu tung Yamaha-Motor Vipt Nam Phu luc 2: Hinh anh mot chi tiet banh rang Nguon: Ban ky thuat- Cdng ty TNHH san xuat phu tung Yamaha-Motor Viet Nam Phu• lu• c 3: Hinh anh mot • chi tiet true • Nguon: Ban ky thuat- Cdng ty TNHH san xuat phu tung Yamaha-Motor Viet Nam Phu• lu• c 4: Hinh anh mot • chi tiet vanh duc a r Nguon: Ban ky thuat- Cdng ty TNHH san xuat phu tung Yamaha-Motor Viet Nam Phu luc 5: Bang ton kho cong doan cua ma hang 30K-1W Ngay: 19-09-2012 Ton kho cong doan Ma san pham Bo30K 30K-1W Qua trinh san xuat Truoc cong Sau cong Tong ton cong doan doan doan - -Luang xuat hang theo Luang ton kho nhap tu YPMI 19/9 20/9 21/9 22/9 24/9 25/9 1500 1400 1300 1500 1500 1500 10000 Bo 4200 4200 2700 1300 -1500 -3000 -4500 Thanh pham 1000 5200 3700 2300 1000 -500 -2000 -3500 Nhiet luyen 756 5956 4456 3056 1756 256 -1244 -2744 5956 6901 7401 4456 5401 5901 3056 4001 4501 1756 2701 3201 256 1201 1701 -1244 -299 201 -2744 -1799 -1299 Tao banh rang lan Tao banh rang lan Tien 945 500 149 r r r Nguon: Bo phan ke hoach san xuat cua cdng ty TNHH san xuat phu tung Yamaha-Motor Viet Nam Phu luc 6: Bang ton kho cdng doan cua md hang 52M-AM Ton kho cong doan rri Ma hang Qua trinh san xuat r Tru’d’c cong doan Sau cong doan a Tong ton cdng doan 20/9 19/9 Xuat hang theo 100 Thanh pham 52M AM 823 Do size Do on mai Nhiet luyen Mai rang Tao banh rang Tien lan Tien lan 21/9 560 Phoi y 22/9 24/9 100 100 25/9 26/9 27/9 28/9 100 100 100 823 823 823 823 723 723 723 723 623 623 523 523 523 523 423 423 323 323 223 223 823 823 823 823 723 723 723 723 623 623 523 523 523 523 423 423 323 323 223 223 823 823 723 723 623 523 523 423 323 223 823 823 723 723 623 523 523 423 323 223 823 823 723 723 623 523 523 423 323 223 823 823 723 723 623 523 523 423 323 223 823 1383 823 1383 723 1283 723 1283 623 1183 523 1083 523 1083 423 983 323 883 223 783 r r r Ngudn: Bo phan ke hoach san xuat cua cdng ty TNHH san xuat phu tung Yamaha-Motor Viet Nam Phu luc 7: Bang ton kho cong doan cua ma hang 30K-AM Ton kho cong doan Ma hang Qua trinh san xuat Xuat hang theo Du tru thuc te Thanh pham Do size Do on Mai 30KAM Nhiet luyen Mai rang Tao rang Tien lan Tien lan Phoi Trudc cong doan Sau cong doan 15000 4000 5865 1847 1692 1587 ■y r Tong ton kho cong doan 15000 6261 6261 6261 6261 13973 15665 15665 15665 15665 17252 r 19/9 20/9 21/9 22/9 24/9 25/9 1500 1700 1700 1500 1500 1500 4261 4261 4261 4261 11973 13665 13665 13665 13665 15252 2261 2261 2261 2261 9973 11665 11665 11665 11665 13252 161 161 161 161 7873 9565 9565 9565 9565 11152 -1839 -1839 -1839 -1839 5873 7565 7565 7565 7565 9152 -3939 -3939 -3939 -3939 3773 5465 5465 5465 5465 7052 -5739 -5739 -5739 -5739 1973 3665 3665 3665 3665 5252 r Nguon: Bo phan ke hoach san xuat cua cong ty TNHH san xuat phu tung Yamaha-Motor Viet Nam