Supply Chain Management and Advanced Planning: Concepts, Models, Software, and Case Studies

by Hartmut Stadtler (Editor), Christoph Kilger (Editor)

Overview

Supply Chain Management, Enterprise Resources Planning (ERP), and Advanced Planning Systems (APS) are important concepts in order to organize and optimize the flow of goods, materials, information and funds. This book, already in its fourth edition, gives a broad and up-to-date overview of the mentioned concepts, especially those underlying APS. Special emphasis is given to modeling supply chains and implementing APS successfully in industry. Understanding is enhanced by several case studies covering a wide range of industrial sectors. The fourth edition contains updated material, rewritten chapters and additional case studies.

Product Details

ISBN-13:	9783642093920
Publisher:	Springer Berlin Heidelberg
Publication date:	12/01/2010
Edition description:	Softcover reprint of hardcover 4th ed. 2008
Pages:	556
Product dimensions:	6.10(w) x 9.25(h) x 0.24(d)

About the Author

Prof. Dr. Hartmut Stadtler is professor of Business Management at the University of Hamburg. Formerly, he held a chair at Darmstadt University of Technology (1990–2004). From 1987–1990 he was employed as a consultant in the field of production management. He has published numerous articles about operations and supply chain management in international journals like International Journal of Production Research, Management Science, Operations Research, OR Spectrum and Production and Operations Management. He has been department editor for the Zeitschrift für Betriebswirtschaft and a member of the editorial board of the International Journal of Production Research.

Dr. Christoph Kilger is partner at Ernst & Young Advisory and head of Supply Chain & Operations in Germany, Switzerland and Austria. Before, he served for 13 years as a member of the executive board of J&M Management Consulting AG, Mannheim. At J&,M Christoph was responsible for the consulting practices, human resources and knowledge and quality management. From 1996—1999 he worked as project manager with KPMG Consulting. He has in-depth experience in supply chain transformation programs, APS implementations, product life cycle management, manufacturing, logistics and IT. Christoph holds a PhD in computer science from the University of Karlsruhe and is regularly giving lectures at the Karlsruhe Institute of Technology (KIT). He is the responsible organizer of the yearly conference Supply Chain Days Heidelberg.

Prof. Dr. Herbert Meyr worked at the department of Production and Logistics at the University of Augsburg from 1994–2003, at the Vienna University of Economics and Business Administration from 2003–2006 and at the Technical University of Darmstadt from 2007–2011. After finishing his PhD thesis about “Simultaneous Lot sizing and Scheduling for Continuous Production Lines” in 1999, he changed his research interest to model buildingand integration aspects of supply chain planning. He currently holds a chair for Supply Chain Management at the University of Hohenheim, Stuttgart, Germany.

Table of Contents

Preface   Hartmut Stadtler   Christoph Kilger     V
Introduction   Hartmut Stadtler     1
References     5
Basics of Supply Chain Management
Supply Chain Management - An Overview   Hartmut Stadtler     9
Definitions     9
Building Blocks     11
Origins     24
References     33
Supply Chain Analysis   Christopher Surie   Michael Wagner     37
Motivation and Goals     37
Process Modeling     39
Performance Measurement     48
Inventory Analysis     56
References     62
Types of Supply Chains   Herbert Meyr   Hartmut Stadtler     65
Motivation and Basics     65
Functional Attributes     66
Structural Attributes     69
Example for the Consumer Goods Industry     71
Example for Computer Assembly     75
References     80
Advanced Planning   Bernhard Fleischmann   Herbert Meyr   Michael Wagner     81
What Is Planning?     81
Planning Tasks Along the Supply Chain     86
Examples of Type-Specific Planning Tasks and Planning Concepts     92
References     106
Concepts of Advanced Planning Systems
Structure of Advanced Planning Systems   Herbert Meyr   Michael Wagner   Jens Rohde     109
References     115
Strategic Network Design   Marc Goetschalcks   Bernhard Fleischmann     117
The Planning Environment     117
Strategic Network Design Models     120
Implementation     126
Review of Models in the Literature     127
Strategic Network Design Modules in APS Systems     129
Conclusions     130
References     131
Demand Planning   Christoph Kilger   Michael Wagner     133
A Demand Planning Framework     133
Demand Planning Structures     135
Demand Planning Process     141
Statistical Forecasting Techniques     144
Demand Planning Controlling     149
Additional Features     154
References     159
Master Planning   Jens Rohde   Michael Wagner     161
The Decision Situation     162
Model Building      168
Generating a Plan     176
References     179
Demand Fulfilment and ATP   Christoph Kilger   Herbert Meyr     181
Available-to-Promise (ATP)     182
Structuring of ATP by Product     184
Structuring of ATP by Time     188
Structuring of ATP by Customer     188
Order Promising     194
References     198
Production Planning and Scheduling   Hartmut Stadtler     199
Description of the Decision Situation     199
How to Proceed from a Model to a Production Schedule     200
Model Building     203
Updating Production Schedules     209
Number of Planning Levels and Limitations     211
References     215
Purchasing and Material Requirements Planning   Hartmut Stadtler     217
Basics of Material Requirements Planning     217
Generation and Timing of Uncritical Orders     219
Quantity Discounts and Supplier Selection     224
References     228
Distribution and Transport Planning   Bernhard Fleischmann     231
Planning Situations     231
Models     237
References      245
Coordination and Integration   Boris Reuter   Jens Rohde     247
Coordination of APS Modules     248
Integration of APS     251
Supply Chain Event Management     260
References     261
Collaborative Planning   Christoph Kilger   Boris Reuter   Hartmut Stadtler     263
Introduction     264
Types of Collaborations     267
A Generic Collaboration and Collaborative Planning Process     275
Software Support     281
References     282
Implementing Advanced Planning Systems
The Definition of a Supply Chain Project   Christoph Kilger     287
Supply Chain Evaluation     289
Supply Chain Potential Analysis     297
Project Roadmap     303
References     306
The Selection Process   Christoph Kilger   Ulrich Wetterauer     309
Creation of a Short List     310
APS Requirements     316
Implementation and Integration     318
Post-implementation Effort and Support Model     321
References     323
The Implementation Process   Ulrich Wetterauer   Herbert Meyr     325
The APS Implementation Project     325
Modelling Phases of an APS-Project     341
References     346
Actual APS and Case Studies
Architecture of Selected APS   Herbert Meyr   Heidrun Rosic   Christian Seipl   Michael Wagner   Ulrich Wetterauer     349
AspenTech - aspenONE     349
i2 Technologies - i2 Six.Two     353
Oracle - JDEdwards EnterpriseOne Supply Chain Planning     358
SAP - SCM     362
References     366
Strategic Network Design in the Chemical Industry   Jochen Haberle   Christoph Kilger     367
Case Description     367
Objectives of the Project     369
Framework for Strategic Network Design     370
Setting Up the Baseline Model     374
Alternative Scenarios     378
Results and Lessons Learned     380
Computer Assembly   Christoph Kilger     381
Description of the Computer Assembly Case     381
Scope and Objectives     385
Planning Processes in Detail     387
Results and Lessons Learned     397
References      398
Oil Industry   Mario Roitsch   Herbert Meyr     399
Supply Chain Description and Typology     399
Requirements for Planning     401
Description of the (Ideal) Planning System     402
Modeling and Implementation of APS     406
Modules in Detail     408
Results and Lessons Learned     414
SCM in a Pharmaceutical Company   Tanguy Caillet     415
Case Description     415
Objectives of Project     418
Planning Processes     421
Results and Lessons Learned     429
Demand Planning of Styrene Plastics   Boris Reuter     431
Description of the Supply Chain     431
The Architecture of the Planning System     432
Model Building with SAP APO Demand Planning     434
The Demand Planning Process of the Styrene Plastics Division     439
Results and Lessons Learned     443
References     444
Food and Beverages   Michael Wagner   Herbert Meyr     445
Case Description     445
Aim of the Project     451
Model Building in Oracle's Strategic Network Optimization      451
Implementing the Master Planning Model     455
Results and Lessons Learned     461
References     462
Scheduling of Synthetic Granulate   Marco Richter   Volker Stockrahm     463
Case Description     463
Objectives     465
Modelling the Production Process in APO PP/DS     465
Planning Process     476
Results and Lessons Learned     477
Event-Based Planning for Standard Polymer Products   Matthias Lautenschlager     481
Current Situation and Definition of Problem     481
Solution Concept     483
Results and Lessons Learned     494
Conclusions and Outlook
Conclusions and Outlook   Hartmut Stadtler   Christoph Kilger     497
Summary of Advanced Planning     497
Further Developments of APS     498
Management of Change Aspects     500
Scope of Supply Chain Management     501
References     502
Supplement
Forecast Methods   Herbert Meyr     505
Forecasting for Seasonality and Trend     505
Initialization of Trend and Seasonal Coefficients     511
References     515
Linear and Mixed Integer Programming   Hartmut Stadtler     517
Linear Programming     517
Pure Integer and Mixed Integer Programming     521
Remarks and Recommendations     525
References     527
Genetic Algorithms   Robert Klein     529
General Idea     529
Populations and Individuals     530
Evaluation and Selection of Individuals     532
Recombination and Mutation     534
Conclusions     535
References     536
Constraint Programming   Robert Klein     537
Overview and General Idea     537
Constraint Satisfaction Problems     538
Constraint Propagation     539
Search Algorithms     541
Concluding Remarks     542
References     543
Index     545
About Contributors     553