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1、BRITISH STANDARD BS 5192-1: 1993 Guide to production control Part 1: Introduction Licensed Copy: sheffieldun sheffieldun, na, Fri Dec 01 13:41:58 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 5192-1:1993 This British Standard, having been prepared under the direction of the Quality, Management and S
2、tatistics Standards Policy Committee, was published under the authority of the Standards Board and comes into effect on 15 February 1993 BSI 08-1999 The following BSI references relate to the work on this standard: Committee reference QMS/33 Draft for comment 91/89476 DC ISBN 0 580 21128 2 Committee
3、s responsible for this British Standard The preparation of this British Standard was entrusted by the Quality, Management and Statistics Standards Policy Committee (QMS/-) to Technical Committee QMS/33, upon which the following bodies were represented: British Computer Society British Production and
4、 Inventory Control Society Chartered Institute of Management Accountants EEA (the Association of Electronics, Telecommunications and Business Equipment Industries) Institute of Logistics and Distribution Management Ministry of Defence Nottingham University PERA International (Production Engineering
5、Research Association) University of Bradford University of Manchester Institute of Science and Technology Amendments issued since publication Amd. No.DateComments Licensed Copy: sheffieldun sheffieldun, na, Fri Dec 01 13:41:58 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 5192-1:1993 BSI 08-1999i Co
6、ntents Page Committees responsibleInside front cover Forewordii 0Introduction1 1Scope1 2References1 3Definitions1 4The production control function6 5Relationship between production control and other functions7 6The impact of technology on production control10 7Characteristics of manufacturing organi
7、zations 14 8Choosing the right production control system for the business15 9Implementing and maintaining the system18 10Alternatives to complex production control systems18 Figure 1 Stages of production control8 Figure 2 Closed loop system9 Figure 3 Relationship between production control and other
8、 functions9 Figure 4 Development of computerized applications in manufacture10 Figure 5 Manufacturing resource planning (MRP II)11 Figure 6 Shape of bills of material16 List of referencesInside back cover Licensed Copy: sheffieldun sheffieldun, na, Fri Dec 01 13:41:58 GMT+00:00 2006, Uncontrolled Co
9、py, (c) BSI BS 5192-1:1993 ii BSI 08-1999 Foreword This Part of BS 5192 has been prepared under the direction of the Quality, Management and Statistics Standards Policy Committee. The prime objective of production control is to help a company become more competitive and profitable. An effective prod
10、uction control function endeavours to fulfil this objective by keeping a balance between satisfying sales demand, achieving high plant utilization and maintaining low investment in stocks and work-in-progress. An optimum balance between these often conflicting objectives will only be achieved by a p
11、roduction control system designed to meet the specific needs of the company and run by well trained and dedicated staff. BS 5192 is published in six Parts and gives comprehensive guidance in those areas that are considered essential for effective production control. The Parts are as follows: Part 1:
12、 Introduction: Scope of the guide, purpose of production control, relationship to other functions, technological changes, choosing the system to fit the business; Part 2: Production programming: Relationship to corporate and business programmes, planning techniques, Master Production Scheduling, Cap
13、acity Planning; Part 3: Ordering methods: The various types of ordering and stock control systems, comparing the advantages of each for particular applications; Part 4: Dispatching (shop-floor control): The methods of shop floor production control and documentation involved and the increasing influe
14、nce of computers; Part 5: The relationship between production control and other management functions: The production control information flows in the organization, their generation, presentation, use and maintenance; Part 6: Computer aided production control: The application of computer software to
15、the production control function. Throughout this standard use of the pronouns he, him and his is intended to be non-gender-specific. A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application. Co
16、mpliance with a British Standard does not of itself confer immunity from legal obligations. Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, pages 1 to 18, an inside back cover and a back cover. This standard has been updated (see copyright date) and may
17、 have had amendments incorporated. This will be indicated in the amendment table on the inside front cover. Licensed Copy: sheffieldun sheffieldun, na, Fri Dec 01 13:41:58 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 5192-1:1993 BSI 08-19991 0 Introduction The six Parts of BS 5192 provide an overvi
18、ew of production control principles and good practice applied to manufacturing industry. It explains the relationship between production control and other functions of the business and the role of production control in implementing corporate and business plans at the manufacturing level. A number of
19、 techniques are described for planning, directing and regulating manufacture and provisioning material. Each technique is covered in sufficient detail to enable the reader to obtain a general understanding of how the technique functions, its purpose, applications, advantages and disadvantages. It is
20、 not feasible within the scope of these documents to describe techniques in detail. Readers are therefore advised to ensure that their staff have the relevant expertise or receive thorough training in the technique before proceeding to implement it. Expertise may be acquired by attending courses on
21、production control subjects which range from one day to a week or more in duration. Knowledge can also be acquired by referring to books and professional journals on the subject. Of standards on, or related to, production control NF X 50-310 1 published by AFNOR deserves mention, not least for its e
22、xtensive bibliography of other standards. In certain instances, particularly where there is a lack of in-house expertise, it will be advisable to obtain professional assistance from an external consultant. Advice can also be obtained from professional organizations such as those listed on the inside
23、 front cover. Manufacturing operations take many different forms, so it is essential to choose the right technique to suit the needs of the particular business. Although it is not possible to cover every situation, the guide explains in broad terms the suitability of each technique for particular ty
24、pes of manufacturing operation. 1 Scope This Part of BS 5192 provides an introduction to the objectives and concepts of production control. In addition, it provides introductions to the other Parts of BS 5192. 2 References 2.1 Normative references This Part of BS 5192 incorporates, by reference, pro
25、visions from specific editions of other publications. These normative references are cited at the appropriate points in the text and the publications are listed on the inside back cover. Subsequent amendments to, or revisions of, any of these publications apply to this Part of BS 5192 only when inco
26、rporated in it by updating or revision. 2.2 Informative references This Part of BS 5192 refers to other publications that provide information or guidance. Editions of these publications current at the time of issue of this standard are listed on the inside back cover, but reference should be made to
27、 the latest editions. 3 Definitions For the purposes of this Part of BS 5192, the definitions given in BS 3138 and BS 5191 apply, together with the following. NOTESince the publication of BS 5191:1975 many new terms have been introduced in the field of production planning and control as a result of
28、the significant developments in this area. It is envisaged that the terms defined in this clause will be incorporated in a revision of BS 5191, to be published in due course. 3.1 activity based costing (ABC) cost attribution to cost units on the basis of benefit received from indirect activities, e.
29、g. ordering, setting-up, assuring quality 3.2 architecture the design of the computers hardware, system software and communication systems on which the application software functions 3.3 assembly schedule the detailed schedule of time and sequence planned for the assembly of a product 3.4 base stock
30、 system an ordering method in which a fixed (or base) stock is established for every item. Any issue from stock is immediately followed by issuing a new order for the same quantity to the preceding processing stage; this in turn causes orders to be issued to all previous stages and finally to the ma
31、terial supplier NOTEBase stock control is a stock base, pull method of ordering. Licensed Copy: sheffieldun sheffieldun, na, Fri Dec 01 13:41:58 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 5192-1:1993 2 BSI 08-1999 3.5 big bang expression denoting an abrupt change from one system to another withou
32、t overlap or parallel running 3.6 batch quantity the number of components in a batch NOTEAnother term for batch quantity is run quantity. 3.7 call-off schedule a schedule which shows by period, e.g. week or month, the quantity to be delivered of goods listed in a blanket purchase order NOTEA typical
33、 call-off schedule would show the next four weeks as firm requirements and the following eight weeks as estimates. 3.8 capacity bill of material a bill of material which shows for each manufactured item the amount of capacity and type of resource needed to manufacture the quantity required to make o
34、ne unit of the product NOTEA capacity bill of material that contains only details of capacity for key or critical resources is called a rough-cut capacity bill of material (see 3.64). 3.9 capacity requirements planning (CRP) a system that calculates time-phased capacity requirements by resource type
35、 in order to execute the production programme NOTE 1Where CRP is linked to a material requirements planning (MRP) system, information about open and planned orders is input from the MRP system to the CRP system and limitations in capacity reported to the MRP system. More sophisticated versions of CR
36、P take account of information about part completed open orders, provided from a shop order system. NOTE 2Another term for CRP is capacity planning. 3.10 closed loop material requirements planning an overall system in which MRP is linked to other systems to provide feedback of information between the
37、 planning and executing functions, thus closing the information loop NOTEProduction programmes are developed through the master production scheduling and CRP systems, and the programmes input to the MRP system which generates time-phased manufacturing and buying instructions. Purchasing and shop ord
38、er systems feed back information about performance to the MRP system to enable corrective action to be taken, if necessary. (See also 3.48.) 3.11 closed loop system a control system in which the planning and execution phases are linked so that information about performance compared to plan is fed ba
39、ck to the planning phase to enable corrective action to be taken, if necessary NOTEAnother term for closed loop system is feedback control system. 3.12 complete-to-order a type of manufacturing that, completes or configures lower-level items to customer order upon receipt of the order 3.13 computer
40、aided design (CAD) the application of computers in the interactive mode for design, draughting and storing designs 3.14 computer aided manufacture (CAM) manufacture in which computers are used to instruct and control production plant and equipment 3.15 computer aided process planning (CAPP) the appl
41、ication of computers in the interactive mode for the planning of manufacturing processes and operations and for the storing of process planning information 3.16 computer aided production management (CAPM) a collective term for production control software packages NOTEAnother term for CAPM is compute
42、r aided production control (CAPC). 3.17 computer integrated manufacture (CIM) manufacture in which various computerized systems are linked to provide an integrated manufacturing system NOTEDegrees of integration are possible, from simple links (e.g. between CAD and CAPP and between MRP and CAM) to a
43、 totally integrated factory. 3.18 database a data structure for accepting, storing and providing on demand data for multiple independent users NOTEThe database may be distributed across various storage media such as paper, magnetic tape, etc. Licensed Copy: sheffieldun sheffieldun, na, Fri Dec 01 13
44、:41:58 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 5192-1:1993 BSI 08-19993 3.19 dependent demand a demand directly related to, or derived from, the demand for other items or end products. Dependent demands are therefore calculated and not forecast 3.20 dispatching the detailed allocation and subs
45、equent control of production resources to individual work orders, necessary to complete orders in accordance with the production programme 3.21 electronic data interchange 1) General. The transfer of structured data in electronic form between computer systems in separate organizations. 2) In busines
46、s. The transfer of structured business data by agreed message standards in electronic form between computer systems in separate organizations. 3.22 engineering change control a procedure for planning and executing the introduction of a new bill of material, routing or process. It may be done by late
47、, batch, on run out of old component (machine), or as soon as a new component is available 3.23 expert system1) a computer program that uses the programming techniques of artificial intelligence, especially those techniques developed for problem solving, to interrogate data and deduce results within
48、 parameters programmed into it 3.24 explosion a breakdown of a bill of material into the total of each of the components required to manufacture a given quantity of a higher assembly or sub-assembly 3.25 finite production modelling a finite scheduling technique operating at a level of planning detai
49、l below MRP to assist in the scheduling/rebalancing of the shop floor in which computer based techniques are usually applied 3.26 flexible machine centre (FMC) usually an automated system, usually comprised of computerized numerical control machines with robots loading and unloading parts conveyed into and through the system NOTEThe purpose of an FMC is to provide quicker throughput, changeovers, setups, etc., to manufacture multiple products. 3.27 flexible manufacturing system (FMS) a manufacturing process designed so that the production line may be re