Professional Documents
Culture Documents
Instructor Guide
Table of Contents
Participant Workbook Page
Table of Contents
Session 1Introduction to Supply Chain Management
Introduction to Manufacturing..............................................................................
1-9
Role of Manufacturing.................................................................................................................
1-9
Global Citizenship.......................................................................................................................
1-11
1-15
Business Environment.................................................................................................................
1-23
1-27
Manufacturing Environments.......................................................................................................
1-27
1-33
1-35
1-45
1-45
1-47
1-51
Performance Measures...............................................................................................................
1-53
1-55
1-57
Objectives of Manufacturing........................................................................................................
1-57
1-57
1-59
1-61
1-61
1-61
1-63
1-65
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2-7
Marketing Management...............................................................................................................
2-7
2-11
Demand Planning........................................................................................................................
2-11
Characteristics of Demand...................................................................................
2-13
2-13
Sources of Demand.....................................................................................................................
2-13
2-15
Forecasting.............................................................................................................
2-19
2-19
Principles of Forecasting.............................................................................................................
2-21
2-23
Forecasting Techniques........................................................................................
2-25
Qualitative Techniques................................................................................................................
2-25
2-25
2-27
2-27
Exponential Smoothing...............................................................................................................
2-35
Seasonal Forecast......................................................................................................................
2-39
2-43
Bias.............................................................................................................................................
2-43
2-43
2-45
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Table of Contents
Participant Workbook Page
3-7
Priority Planning.........................................................................................................................
Planning Horizon and Level of Detail.........................................................................................
3-7
3-7
3-9
3-9
3-11
3-37
Purpose.....................................................................................................................................
3-37
3-37
3-39
3-39
3-41
3-41
3-43
3-47
3-49
3-49
3-51
3-51
3-53
3-53
Objectives..................................................................................................................................
Inputs.........................................................................................................................................
Relationship to the Production Plan...........................................................................................
Developing a Master Schedule..................................................................................................
Projected Available Balance......................................................................................................
Preliminary MPS........................................................................................................................
Planning Horizon........................................................................................................................
Time Fences and Zones............................................................................................................
Aggregating the Master Schedules............................................................................................
Rough-Cut Capacity Planning....................................................................................................
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iii
4-7
Nature of Demand......................................................................................................................
4-7
4-7
Objectives of MRP.....................................................................................................................
4-9
4-11
Planning Software......................................................................................................................
4-13
Bill of Material.......................................................................................................
4-15
Introduction................................................................................................................................
4-15
4-15
4-17
4-17
Parent-Component Relationship................................................................................................
4-17
4-19
Planning Bill...............................................................................................................................
4-23
4-25
4-27
4-29
4-29
4-29
4-31
4-37
4-41
4-47
4-49
4-49
Order Control.............................................................................................................................
4-51
4-53
4-55
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Table of Contents
Participant Workbook Page
5-7
5-7
5-7
Capacity Management........................................................................................
5-9
5-9
5-11
5-11
5-13
5-21
5-25
5-27
Introduction..............................................................................................................................
Key Inputs...............................................................................................................................
CRP Process...........................................................................................................................
5-27
5-27
5-33
5-41
Objectives................................................................................................................................
Functions.................................................................................................................................
Information Requirements.......................................................................................................
Data Requirements.................................................................................................................
5-41
5-43
5-45
5-47
Scheduling..........................................................................................................
5-49
Introduction..............................................................................................................................
Scheduling and Loading Techniques......................................................................................
Bottleneck Scheduling.............................................................................................................
5-49
5-49
5-53
Implementation...................................................................................................
5-55
5-55
5-55
Control.................................................................................................................
5-57
5-57
5-59
5-61
5-67
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6-7
What is Inventory?...................................................................................................................
6-7
6-9
6-11
6-11
6-13
Functions of Inventory.............................................................................................................
6-15
Inventory Objectives................................................................................................................
6-17
Inventory Costs..................................................................................................
6-21
Item Costs...............................................................................................................................
6-21
Carrying Costs.........................................................................................................................
6-23
Ordering Costs........................................................................................................................
6-25
Stockout Costs........................................................................................................................
6-29
Capacity-Related Costs...........................................................................................................
6-29
6-33
6-33
Balance Sheet.........................................................................................................................
6-35
Income Statement...................................................................................................................
6-37
6-39
6-43
Inventory Valuation..................................................................................................................
6-45
6-47
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Participant Workbook Page
7-7
7-7
7-9
7-13
7-21
7-25
7-27
7-29
Safety Stock............................................................................................................................
7-35
7-43
7-47
7-55
ABC Principles........................................................................................................................
7-55
ABC Classification...................................................................................................................
7-57
ABC Process...........................................................................................................................
7-57
Sample Calculation.................................................................................................................
7-59
7-63
7-65
7-65
Cycle Counting........................................................................................................................
7-67
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vii
8-7
8-7
8-9
Purchasing Objectives...........................................................................................................
8-11
Purchasing Activities..............................................................................................................
8-11
Physical Distribution..........................................................................................
8-29
8-29
8-29
8-31
8-33
8-37
8-37
8-39
8-39
8-41
8-43
8-45
8-45
Transportation....................................................................................................
8-49
Introduction..............................................................................................................................
8-49
8-55
8-55
8-65
Warehousing.......................................................................................................
8-71
Purpose of Warehousing.........................................................................................................
8-71
8-71
8-73
8-75
Global Distribution...................................................................................................................
Influence of Marketing.............................................................................................................
Interface with Production and Finance....................................................................................
Other Factors: Distribution Channels ......................................................................................
Objectives................................................................................................................................
Distribution Inventory Planning Systems.................................................................................
Push System...........................................................................................................................
Reverse Logistics......................................................................................................
Basic Transportation Modes....................................................................................................
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Table of Contents
Participant Workbook Page
9-7
9-7
Objectives................................................................................................................................
9-7
9-9
9-11
9-13
9-15
9-15
Lean................................................................................................
9-17
House of Toyota......................................................................................................................
9-17
9-17
Waste......................................................................................................................................
9-19
9-21
Pull Systems............................................................................................................................
9-21
Work Layouts..........................................................................................................................
9-23
Process Flexibility....................................................................................................................
9-25
9-27
9-29
9-31
9-33
Supplier Partnerships..............................................................................................................
9-35
9-37
Product Quality........................................................................................................................
9-37
Quality-Related Costs.............................................................................................................
9-41
9-43
Six Sigma................................................................................................................................
9-57
Summary.................................................................................................................................
9-63
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ix
10-7
10-7
Types of Constraints...............................................................................................................
10-9
Problem-Solving Tools............................................................................................................
10-9
General Applications..........................................................................................
10-11
VATI Analysis..........................................................................................................................
10-11
10-13
10-27
Throughput Accounting...........................................................................................................
10-29
Critical-Chain Method..............................................................................................................
10-31
Distribution..............................................................................................................................
10-33
Appendix
Progress Check Answer Sheet.........................................................................
Bibliography..............................................................................
Course Evaluation..............................................................................................
A-1
A-2
A-3
2013 APICS