PMII lecture 4 ERP - Order Clarification and Configuration · Production Management II (Prof. Schuh), lecture 4 - ERP II - Order Clarification and Configuration 1 Contact: M. Lenders,
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Production Management II (Prof. Schuh), lecture 4 - ERP II - Order Clarification and Configuration
1Contact: M. Lenders, WZL 53B R. 503, tel. 80-27436, [email protected]
Assessment of demand Anonymous Inquiry Invitation to
tender
Order processing is dependent on the type of company
Order
Series manufacturer
(build-on-stock)
Variant manufacturer
Order-specific manufacturer
(build-by-order)
No order process or configuration process takes place in series production. Series manufacturer make use of a sufficiently largestock. (i.e. department stores, clothing industry).When an order has been accepted, the variant manufacturer chooses a solution from a number of solutions already designed. The variant manufacturer avoids producing in advance, thus avoiding order-related elements. The order-specific manufacturer is always confronted with a great number of order-specific elements which have to be combined with existing technical solutions and usually lead to significant configurational problems.
Production Management II (Prof. Schuh), lecture 4 - ERP II - Order Clarification and Configuration
5Contact: M. Lenders, WZL 53B R. 503, tel. 80-27436, [email protected]
with:specificationtimes for deliveryterms of deliveryprices
Warehouse
Order Processing
Concerning the demand of capital goods, a large proportion of the technical specifications is defined by the customers in the case of variants and order-specific production. For this reason, the order process between producer and supplier is often complex and time-consuming.
Production Management II (Prof. Schuh), lecture 4 - ERP II - Order Clarification and Configuration
6Contact: M. Lenders, WZL 53B R. 503, tel. 80-27436, [email protected]
Scheduling of Offers Taking the Capacity Requirements of Quotes Previously Submitted into Account
capa
city
(h/d
ay)
orders accepted
5.000
10.000
15.000
20.000
25.000capacity limit
t [calendar week]
capacity for further offers
20 21 22 23 24 25
theoretical capacity limit for offers (conversion rate 5:1)
quotes submitted
The above order scheduling method for companies (small lot or unit production) is known as the „pass-curve procedure“.The following conditions are taken into account: individual capacity requirements for different products, disposable capacity and theconversion rate or the number of orders planned/accepted. The theoretical capacity limit for offers is a result of the difference between the capacity limit and the orders accepted, taking the conversion rate into consideration. For the application of this method, the order processing must take place continually (no interruptions).
Production Management II (Prof. Schuh), lecture 4 - ERP II - Order Clarification and Configuration
9Contact: M. Lenders, WZL 53B R. 503, tel. 80-27436, [email protected]
differentiated evaluation•allocation of costs according to input involved
differentiated evaluation•allocation of costs according to input involved
analogical approach•
analogical approach•
analytical•calculation of individual parts
analytical•calculation of individual parts
estimation•estimation based on experience
estimation•estimation based on experience
knowledge-based•artificial intelligence•expert systems
knowledge-based•artificial intelligence•expert systems
statistical•deduce cost function
parametrical•cost function
statistical•deduce cost function
parametrical•cost function
f(x)=ax+bx2+...
E2B9621
estimation based on classification
Order calculation is often related to a high level of uncertainty. The production costs are supposed to be determined as exactly as possible, involving the lowest effort possible.The maximum costs permittable are defined by the markets. High prices lower the conversion rate, low prices reduce the profit. Knowledge concerning a company’s in-house production costs allows the determination of the price floor. The applicable methods and computer-aided means must be adjusted to the level of tolerance accepted and the order probability.
Production Management II (Prof. Schuh), lecture 4 - ERP II - Order Clarification and Configuration
10Contact: M. Lenders, WZL 53B R. 503, tel. 80-27436, [email protected]
Cost-per-kg-method Material cost method Calculation based on influencing factors
Calculation of individual parts
Basis: price per kg of similar products
Basis: cost structure of similar products
Basis: significant factors influencing the production costs
Basis: time value tables, wage rate, etc. of representative individual parts regarding costs
Determination of the price per kg of similar products
Determination of weight of the product to be calculated
Production costs = weight*price per kg
Determination of the cost structure of similar goods
Determination of material costs of the product to be calculated
Production costs= Σmaterial costs+% wages+%overhead costs
Cost analysis of similar products (determination of significant factors)
Generation of a cost function
Production costs= f(influencing factors)
Determination of representative new parts (regarding costs)
Determination of times, material prices wage rates, etc.
Production costs= Σproportion of material *material price + …
In offer preparation (including pricing), the production costs must be suitably familiar. If the calculated production costs exceed the actual production costs, competitive prices cannot be realized. The companies thenrun the risk of not receiving an order. In reverse, if the calculated production costs are lower than the actual production costs, unprofitable orders might be accepted.
Production Management II (Prof. Schuh), lecture 4 - ERP II - Order Clarification and Configuration
11Contact: M. Lenders, WZL 53B R. 503, tel. 80-27436, [email protected]
Potentials of Systematic Order Clarification and Configuration
Product configurators aim at reducing the information deficit in the order clarification process. Associated configurators support the early concretion of orders.
Production Management II (Prof. Schuh), lecture 4 - ERP II - Order Clarification and Configuration
13Contact: M. Lenders, WZL 53B R. 503, tel. 80-27436, [email protected]
„Product configuration denotes the combination of products or system solutions based on standardized component parts and on configuration rules stored in a data base in accordance with specifications of customers.“
Product Configuration
Definition
source: Schuh 2001
Production Management II (Prof. Schuh), lecture 4 - ERP II - Order Clarification and Configuration
14Contact: M. Lenders, WZL 53B R. 503, tel. 80-27436, [email protected]
Criteria for classification/differentiation: Where is the comprehensive configurational knowledge located?
3 Methodological Approaches of Product Configurators
body of rules and regulations (complex dependencies, preclusions, validations and calculations); configuration of customer without help of sales;
rule-based configurators
- intermediate stage -configuration by customer and/or sales person (complex products (e.g. machine tools), limited combinatory variety
interaction-based configurators
sales and engineering knowledge, for cases when configurational variety is extremely large, extremely complex objects (e.g. planning of industrial plants); illustration in the system is neither realizable nor advisable
knowledge-based configurators
source: Schuh 2001
Production Management II (Prof. Schuh), lecture 4 - ERP II - Order Clarification and Configuration
23Contact: M. Lenders, WZL 53B R. 503, tel. 80-27436, [email protected]
8 9 8 2 1 1 0 1 0 1 0 6 A 1 0 3 0 1 1 A B Z Y L . K U R B E L G E H A E U S E 18 9 8 2 1 1 0 2 0 1 0 6 A 1 0 3 1 5 4 B S P R I T Z D U E S E 18 9 8 2 1 1 0 3 0 1 0 6 A 1 0 3 1 7 1 B D I C H T F L A N S C H 18 9 8 2 1 1 0 3 0 1 0 3 8 1 0 3 1 7 1 E D I C H T F L A N S C H 18 9 8 2 1 1 0 3 0 1 0 3 8 1 0 3 1 7 1 B D I C H T F L A N S C H 18 9 8 2 1 1 0 4 0 1 0 6 A 1 1 5 1 2 5 R O L L E N K E T T E 18 9 8 2 1 1 0 5 0 1 0 6 A 1 1 5 1 3 0 K E T T E N S P A N N E R 18 9 8 2 1 2 0 1 0 1 0 6 A 1 0 5 0 2 1 F K U R B E L W E L L E 18 9 8 2 1 2 0 2 0 1 0 6 A 1 1 5 1 2 1 K E T T E N R A D 18 9 8 2 1 2 0 2 0 1 0 6 A 1 0 5 2 0 9 K E T T E N R A D 18 9 8 2 1 2 0 3 0 1 0 5 0 1 0 5 1 8 9 B G E B E R R A D 18 9 8 2 1 2 0 4 0 1 0 2 6 1 0 5 6 3 5 A A N L A U F S C H E I B E 18 9 8 2 1 2 0 5 0 1 0 6 B 1 0 5 5 6 1 H A U P T L A G E R 18 9 8 2 1 3 0 1 0 1 0 6 A 1 1 5 1 0 5 B O E L P U M P E 18 9 8 2 1 3 0 2 0 1 0 6 A 1 1 5 2 5 1 S A U G L E I T U N G 18 9 8 2 1 3 0 3 0 1 0 6 B 1 0 3 6 2 3 E S C H W A L L W A N D 18 9 8 2 1 3 0 4 0 1 0 6 A 1 0 3 6 3 4 F U E H R U N G S R O H R 18 9 8 2 1 4 0 1 0 1 0 3 4 1 0 5 7 0 1 P L E U E L L A G E R 18 9 8 2 1 4 0 1 0 1 0 3 4 1 0 5 7 0 1 B P L E U E L L A G E R 18 9 8 2 1 4 0 2 0 1 0 6 A 1 0 7 0 6 5 A B K O L B E N M I T R I N G E 18 9 8 2 1 4 0 3 0 1 0 2 7 1 0 5 4 0 1 C P L E U E L S T A N G E 18 9 8 2 1 4 0 3 0 1 0 2 7 1 0 5 4 0 1 J P L E U E L S T A N G E 18 9 8 2 1 5 0 1 0 1 0 3 8 1 0 3 6 0 1 M O E L W A N N E 18 9 8 2 1 5 0 2 0 1 1 J 0 9 0 7 6 6 0 B S E N S O R 18 9 8 2 1 5 0 4 0 1 0 6 A 9 0 6 4 3 3 L I M P U L S G E B E R 18 9 8 2 1 5 0 4 0 1 0 6 A 9 0 6 4 3 3 G I M P U L S G E B E R 18 9 8 2 1 6 0 1 0 1 0 3 0 9 0 5 3 7 7 C K L O P F S E N S O R 18 9 8 2 1 7 0 1 0 1 0 5 8 1 0 3 3 8 3 K Z Y L I N D E R K O P F D I C H T . 18 9 8 2 1 7 0 2 0 1 0 6 A 1 0 3 3 5 3 P Z Y L I N D E R K O P F 18 9 8 2 1 7 0 3 0 1 1 0 1 0 0 0 0 6 3 A A Z U E N D K E R Z E 18 9 8 2 1 7 0 4 0 1 0 5 0 1 2 1 1 1 3 C T H E R M O S T A T / K U E H L W A S S E R R E G L . 18 9 8 2 1 7 0 5 0 1 0 6 A 1 1 5 4 0 5 A H O E L F I L T E R H A L T E R 18 9 8 2 1 7 0 6 0 1 0 6 A 1 0 3 6 6 3 B E I N F U E H R T R I C H T E R 18 9 8 2 1 7 0 7 0 1 0 6 A 1 0 3 2 2 7 A T E N T L U E F T U N G 18 9 8 2 2 1 0 1 0 1 0 5 8 1 0 3 5 5 5 B A B S C H I R M T E I L 18 9 8 2 2 1 0 2 0 1 0 6 A 1 0 3 4 6 9 S Z Y L I N D E R K O P F H A U B E 18 9 8 2 2 1 0 3 0 1 0 5 8 1 0 3 3 6 5 T R A N S P O R T L A S C H E 18 9 8 2 2 1 0 4 0 1 0 2 6 1 0 3 4 8 5 O E L V E R S C H L U S S D E C K . 18 9 8 2 2 1 0 4 0 1 0 2 6 1 0 3 4 8 5 A O E L V E R S C H L U S S D E C K . 18 9 8 2 2 1 0 6 0 1 0 6 A 9 1 9 0 8 1 A O E L D R U C K S C H A L T E R 18 9 8 2 2 1 0 6 0 1 0 6 A 9 1 9 0 8 1 A O E L D R U C K S C H A L T E R 18 9 8 2 2 1 0 7 0 1 0 2 8 1 1 7 0 2 1 B O E L K U E H L E R 18 9 8 2 2 1 0 8 0 1 0 6 A 1 1 5 5 6 1 B W E C H S E L F I L T E R 18 9 8 2 2 2 0 1 0 1 0 6 B 1 0 9 1 1 1 Z A H N R I E M E N R A D 18 9 8 2 2 2 0 1 0 1 0 6 A 1 0 5 2 6 3 D Z A H N R I E M E N R A D 18 9 8 2 2 2 0 2 0 1 0 5 8 1 0 3 7 2 8 A B E F E S T I G U N G S T E I L 18 9 8 2 2 2 0 3 0 1 0 6 A 1 2 1 1 3 2 D W A S S E R S T U T Z E N 18 9 8 2 2 2 0 4 0 1 0 7 8 9 1 9 5 0 1 C T E M P E R A T U R G E B E R 18 9 8 2 2 2 0 5 0 1 0 6 B 1 0 9 2 4 3 D S P A N N R O L L E 18 9 8 2 2 2 0 6 0 1 0 6 A 1 3 1 0 9 8 M K O M B I V E N T I L 18 9 8 2 2 2 0 7 0 1 0 6 A 1 3 3 0 6 2 C D R O S S E L K L A P P E N S T U . 18 9 8 2 2 2 0 8 0 1 K R A F T S T . S A M M E L L T G . 18 9 8 2 2 3 0 1 0 1 0 6 B 1 0 9 4 7 7 R I E M E N S P A N N E R 18 9 8 2 2 3 0 2 0 1 0 6 B 1 0 9 1 1 9 A Z A H N R I E M E N 18 9 8 2 2 3 0 2 0 1 0 6 B 1 0 9 1 1 9 B Z A H N R I E M E N 18 9 8 2 2 3 0 3 0 1 0 6 B 1 0 9 2 4 4 U M L E N K R O L L E 18 9 8 2 2 3 0 4 0 1 0 6 A 1 0 9 1 4 7 E A B D E C K T E I L 18 9 8 2 2 3 0 5 0 1 0 6 A 1 0 9 1 0 8 K Z A H N R I E M E N S C H U T Z 18 9 8 2 2 3 0 6 0 1 0 2 7 1 3 3 7 8 4 C W I N K E L S C H L A U C H 18 9 8 2 2 3 0 6 0 1 0 6 A 1 3 3 7 8 4 H W I N K E L S C H L A U C H 18 9 8 2 2 4 0 1 0 1 0 6 A 2 5 3 0 3 3 A J A B G A S K R U E M M E R 18 9 8 2 2 4 0 2 0 1 0 6 A 1 4 5 7 0 2 F A B G A S T U R B O L A D E R 18 9 8 2 2 4 0 4 0 1 0 6 A 1 3 3 2 0 1 C D S A U G R O H R 18 9 8 2 2 5 0 1 0 1 0 6 B 9 0 5 1 1 5 H Z U E N D S P U L E 18 9 8 2 2 5 0 1 0 1 0 6 C 9 0 5 1 1 5 C Z U E N D S P U L E 18 9 8 2 2 5 0 2 0 1 0 6 B 1 1 5 6 1 1 C O E L M E S S S T A B 18 9 8 2 2 5 0 3 0 1 0 6 A 1 4 5 5 3 6 H S T U E T Z S T R E B E 18 9 8 2 2 5 0 3 0 1 0 6 A 1 4 5 5 3 6 K S T U E T Z S T R E B E 18 9 8 2 2 5 0 7 0 1 0 6 A 1 4 1 0 3 1 Q K U P P L U N G S S C H E I B E 18 9 8 2 2 5 0 9 0 1 0 5 8 9 0 5 3 7 9 T E M P E R A T U R F U E H L E R 18 9 8 2 2 5 1 0 0 1 0 6 A 1 0 5 2 6 6 P 2 - M A S S . S C H W U N G R A D 1
engine type 4711
cylinder head
crank shaft
oil pump
parts list motor type 4711
parts list approx. 230 positions and approx. 70 primary entries
fuelcubic capacity
# cylinders# valves
KWHPNm
exhaust gas
gearing
region
…
Otto1,845
110150210EU4
B80
EU
…
…………
115157235EU3
B80q
Japan
…
…………
125170280
EU2B
MQ350
…
…
…………
132180…D4
…
…
…
…………
165225……
…
…
…
……………………
…
…
…
…………
………
…
…
…
charact. specifications
Parts list for entire product line 1,8l 5V turbo engine contains approx. 8000 positions!
Z Y L I N D E R K O P F DZ Y L I N D E R K O P FZ U E N D K E R Z E
K U R B E L W E L L E
H A U P T L A G E RO E L P U M P E
Production Management II (Prof. Schuh), lecture 4 - ERP II - Order Clarification and Configuration
31Contact: M. Lenders, WZL 53B R. 503, tel. 80-27436, [email protected]
The order clarification is the process of clarifying and specifying the customer requirements as completely as possible. The difficulties in the offering phase are based on the fact that usually not all customer requirements can be entirely specified. Whether or not an offer should be generated and an order should be accepted, can only be estimated based on experiences with similar products. Based on the information from the order clarification phase, an order selection can be performed under consideration of the profit margin, the demanded and the possible delivery date.
Order Clarification
The offer calculation is the calculation of the offer or quotation price. In order of increasing accuracy, the following methods can be deployed:- Estimation (experience-based)- Cost-per-kg- or material-cost-method- Calculation based on cost functions- Calculation broken down to individual partsWhile an estimation may require the least effort, it at the same time provides the lowest accuracy. A calculation broken down to individual components requires a large effort, but generates a quotation price with the maximum accuracy.
Offer Calculation
Source: Eversheim 1996
Production Management II (Prof. Schuh), lecture 4 - ERP II - Order Clarification and Configuration
32Contact: M. Lenders, WZL 53B R. 503, tel. 80-27436, [email protected]
A product structure is the structured composition of components to a product. Sub-assembly components and individual parts lead to structure steps by bundling those components and parts on a lower level in the product structure.
Product Structure
Product configuration means the composition of products or system solutions based on standardised components and on a knowledge base of predefined configuration rules. This composition of products happens according to customer specifications.
Product Configuration
Module Building Sets are characterised by one or few base elements, onto which modules of differing variety can be mounted over various assembly steps. This principle is a common basis for bill-of-material structures in the area of plant engineering and construction. The difference to a pure module approach lies in the existence of base elements, but not in the existence of and structuring into different modules as parts to be attached.
Module Building Set
Modules are parts to be attached, that enable a manifold combinability of components and an efficient creation of variety based on separate function, but unified product interfaces. The principle of modularisation is especially well suited to represent a high product variety with only limited effects on the product complexity.
Module
Source: Schuh 2001
Production Management II (Prof. Schuh), lecture 4 - ERP II - Order Clarification and Configuration
33Contact: M. Lenders, WZL 53B R. 503, tel. 80-27436, [email protected]