基于SAP ECC的补货计划优化模型研究及系统实现

【作者】 李皓；

【导师】 戴伟辉；

【作者基本信息】 复旦大学 ， 软件工程， 2009， 硕士

【摘要】 SAP是全球应用最广泛的ERP系统,其MRP的基本原理是将市场需求或经营计划具体化为主生产计划,然后参照主生产计划,结合库存、工艺路线、物料清单等数据,制定出生产计划或采购计划。对于波动过大的市场需求,MRP运算出的补货计划也会有波动过大的问题。这一问题在中国汽车行业尤为明显。中国汽车市场需求波动巨大,无法对汽车的销售情况作出准确的预测。另一方面,国外强势零部件供应商要求中国整车制造厂提供的补货计划不可波动过大,且实际采购量与之前提供的补货计划预测的偏差要限定在一定范围内。根据MRP基本原理,市场需求的波动引起零部件补货计划的波动,因而传统的MRP补货计划无法解决中国汽车行业补货计划的特定需求,存在不足之处。该问题的难点在于市场需求的波动与补货计划的平滑存在矛盾,其次市场需求变化势必引起补货计划的调整,如果强制不作调整则容易引起缺货或库存积压。本文结合中国汽车整车制造厂对补货计划的特定要求,提出了需求平滑与偏差控制的算法,需求平滑的算法基于提前补货周期的方法实现了平滑补货计划的作用,偏差控制的算法则将实际采购量与历史预测计划采购量的偏差控制在一定范围内。基于SAP ECC对于MRP的算法实现,将需求平滑与偏差控制的功能集成在补货计划中,提出了补货计划的优化模型。使得通过该模型计算得出的补货计划在满足安全库存与正常生产需求的同时,满足了国内汽车行业对于补货计划的特殊要求,解决了传统MRP算法在中国汽车行业应用的不足之处。基于补货计划优化模型,设计并开发B/S架构下Struts框架的基于SAP ECC补货计划系统;通过运行在单独服务器上的C++程序,模块化并实现补货计划优化模型的核心算法;设计了补货计划系统的工作流、用户操作界面及数据库结构;为了保证补货计划优化算法能够从SAP ECC中获取核心计划基础数据,分析并实现了补货计划与SAP ECC的关键集成技术;最后分析了系统测试及实际应用情况,结果表明,补货计划系统对波动的市场需求能够有效地降低补货计划的离散度,并可以在满足安全库存与正常生产需求的前提下有效控制实际采购量和历史补货计划之间的偏差,该系统的实现可以解决中国整车制造厂在补货计划方面遇到的特殊困难。更多还原

【Abstract】 SAP is the most world-wide ERP system. The basic principle of MRP is to turn market demand into MPS. Plan order or purchase plan is built according to MPS, inventory, route and BOM. There is an issue that replenishment plan fluctuates when demand is not smooth.This issue is obvious in vehicle industry. Chinese vehicle markrt demand is fluctuating and hard to forecast accurately. With the wave of market demand, vehicle plant’s MPS (master production schedule) is fluctuating and need adjustment frequently. On the orther hand, strong foreign parts vendor ask Chinese vehicle plant to provide smooth replenishment plan and proper purchase order which should be in a certain range around former replenishment plan. According to the principle of MRP, market demand fluctuation causes MPS to fluctuate, then it has the same effect on MRP, So traditional MRP can’t cope with the conflict of Chinese vehicle industry replenishment plan. The key of the problem is the conflict between conflicting market demand and smooth replenishment. Change of damand leads to adjustment of replenishment, or it leads to lack of stock or over stock.Considering the special replenishment plan requirement of Chinese vehicle industry, the concept of demand leveling and variation control is issued which can be helpful to get smooth replenishment plan and control the variation between forecast plan and actual purchase order. Based on SAP ECC, replenishment optimization model is issued, integrated with variation control and demand leveling. It helps to meet the requirement of safety stock while it also helps domestic vehicle industry to meet the special requirement. It solves the special problem of traditional MRP.With B/S Struts, replenishment plan system is designed and built based on SAP ECC. C++ realizes the core principle. Work flow, user interface and database are designed. Interface between SAP ECC and replenishment plan is analysed to make sure to get base data from SAP ECC. The result of test and application of this system shows that this system makes good effect on demand leveling and variation control. It helps to solve the MRP problem of domestic vehicle industry.更多还原