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ERP系统代表了现代先进的企业管理模式与管理解决方案,在实践过程中与企业的 信息化发展的战略紧密结合,能够提高企业管理效率,增强市场竞争力。而同样在国内 应用广泛的精益生产理论,其实施成本低,见效快,致力于为顾客创造价值,是一种追 求“零”浪费的先进生产管理方式。 本文以JT公司为例,综合运用文献分析法、案例研究法、专家访谈法,详细阐述 了站在精益视角ERP在JT公司生产管理应用方面存在的诸多问题:第一,生产计划不 精益,导致库存过多;第二,生产领料流程存在诸多问题;第三,设备备件无系统支持, 管理水平低;第四,产品可追溯性存在盲区。 文中论述了如何使用精益思想对ERP管理体系进行有效补充,结合制造企业的实 际情况来改进企业生产运营管理。针对这些问题,改进方案中使用了精益理论的诸多工 具和方法,例如:准时化生产(JIT),看板管理,零库存管理,全面生产维护(TPM), 价值流图,拉动式生产系统,持续改善等等。其中具体的改进方案如下:第一,ERP与 精益相结合改进生产计划,降低库存;第二,应用看板管理精益改进送料流程;第三, 备件纳入ERP系统,实现精益管控;第四,增强功能,实现ERP中产品追溯全面覆盖。 与此同时,还要就下述方面加强改进计划实施保障:高管层的参与、人员培训保障、绩 效考核支持、采用PDCA循环巩固成果。 企业可以把精益思想作为生产运营管理的核心思想,通过精益工具对ERP应用效 果不足的地方进行改善,实现ERP系统和企业精益运营管理完美的融合。文中“结合 精益思想对ERP系统实际应用进行改进的研究”,希望其不仅对JT公司的生产管理起 到提升的作用,同时也能对同类型的制造企业实施ERP应用的持续改进活动具有一定 的参考和借鉴价值。 关键词:生产管理;精益生产;ERP;运营管理;信息化 JT公司基于ERP系统的精益改进研究 -II- AStudyonImprovementofLeanProductionBasedonERPSysteminJT Corporation Abstract ERPsystemrepresentsthemodernadvancedenterprisemanagementmodeand managementsolution.Intheprocessofpractice,itiscloselycombinedwiththeenterprise's informationdevelopmentstrategy,whichcanimprovetheenterprisemanagementefficiency andenhancethemarketcompetitiveness.Theleanproductiontheory,whichisalsowidely usedinChina,haslowcostandquickeffect,andiscommittedtocreatingvaluefor customers. TakingJTcompanyasanexample,thispapercomprehensivelyusesthemethodsof literatureanalysis,casestudyandexpertinterviewtoelaborateonmanyproblemsexistingin thepracticalapplicationofERPsysteminJTcompany'sproductionmanagementunderlean perspective:First,theproductionplanisnotlean,resultinginexcessiveinventory;Second, therearemanyproblemsintheproductionmaterialpickingprocess;Third,thereisnosystem supportforequipmentspareparts,andthemanagementlevelislow;Four,Thereisablind spotinproducttraceability. ThispaperdiscusseshowtouseleanthinkingtoeffectivelysupplementtheERP managementsystemandimprovetheproductionandoperationmanagementcombinedwith theactualsituationofmanufacturingenterprises.Inviewoftheseproblems,manytoolsand methodsofleantheoryareusedintheimprovementplan,suchasJIT,Kanbanmanagement, zeroinventorymanagement,totalproductionmaintenance(TPM),valueflowchart,pull productionsystem,continuousimprovement,etc.Thespecificimprovementplanisasfollows: First,ERPandleanarecombinedtoimproveproductionplanandreduceinventory;Second, Kanbanisappliedtomanageleanmaterialpickingprocess;Third,sparepartsare incorporatedintoERPsystemtoachieveleanmanagementandcontrol;Fourth,functionsare enhancedtoachievefullcoverageofproducttraceabilityinERP.Atthesametime,weshould strengthentheimplementationguaranteeoftheimprovementplaninthefollowingaspects: theparticipationofseniormanagement,personneltrainingguarantee,performanceappraisal support,PDCAcycletoconsolidatetheresults. Enterprisescantaketheleanideaasthecoreideaofproductionoperationmanagement, improvethepooreffectofERPapplicationthroughleantools,andrealizetheperfect integrationofERPsystemandenterpriseleanoperationmanagement.Inthispaper,"Research ontheimprovementofthepracticalapplicationofERPsystemincombinationwiththelean 大连理工大学专业学位硕士学位论文 -III- idea",IhopeitwillnotonlyimprovetheproductionmanagementofJTcompany,butalso havecertainreferencevaluefortheimplementationofERPapplicationcontinuous improvementactivitiesinthesametypeofmanufacturingenterprises. KeyWords:ProductionManagement;ERP;LeanProduction;OperationManagement; Informatization JT公司基于ERP系统的精益改进研究 -IV- 目录 摘要.............................................................................................................................I Abstract..............................................................................................................................II 1绪论..............................................................................................................................1 1.1本文研究的背景和意义....................................................................................1 1.1.1研究背景.................................................................................................1 1.1.2研究意义.................................................................................................1 1.2文献综述............................................................................................................2 1.2.1国内外研究现状.....................................................................................2 1.2.2研究现状简要评述.................................................................................3 1.3研究的内容与思路方法....................................................................................4 1.3.1本文的研究内容与研究思路.................................................................4 1.3.2本文的研究方法.....................................................................................5 1.3.3本文的论文框架.....................................................................................6 2理论背景......................................................................................................................7 2.1ERP系统及其特点...........................................................................................7 2.1.1ERP系统概述........................................................................................7 2.1.2ERP系统应用效果及其特点................................................................7 2.2精益生产理论及相关工具................................................................................8 2.2.1精益理论与精益目标.............................................................................8 2.2.2精益生产的理论工具.............................................................................9 3JT公司生产管理现状及ERP应用存在问题分析..................................................12 3.1JT公司概况.....................................................................................................12 3.2JT公司生产管理现状.....................................................................................12 3.2.1JT公司主要产品..................................................................................12 3.2.2JT公司的生产管理软硬件资源..........................................................13 3.2.3JT公司生产管理概况..........................................................................15 3.3JT公司生产管理中ERP应用存在的主要问题...........................................16 3.3.1生产计划不精确导致库存过多...........................................................18 3.3.2生产领料流程存在诸多问题...............................................................20 3.3.3无系统支持备件管理水平低下...........................................................21 3.3.4产品追溯性上存在盲区.......................................................................23 大连理工大学专业学位硕士学位论文 -V- 4JT公司基于ERP系统的精益改进方案..................................................................28 4.1改进方案设计的总体思路、原则和预期效果..............................................28 4.1.1改进方案的总体思路...........................................................................28 4.1.2改进方案的制定原则...........................................................................28 4.1.3改进方案的期望效果...........................................................................29 4.2JT公司基于ERP系统的精益改进方案...........