1、BRITISH STANDARD BS 5192-1: 1993 Guide to production control Part1: IntroductionBS 5192-1:1993 This British Standard, having been prepared under the direction of the Quality, Management and Statistics Standards Policy Committee, was published under the authority of the Standards Board and comes into
2、 effect on 15 February1993 BSI08-1999 The following BSI references relate to the work on this standard: Committee reference QMS/33 Draft for comment91/89476DC ISBN 0 580 21128 2 Committees responsible for this British Standard The preparation of this British Standard was entrusted by the Quality, Ma
3、nagement and Statistics Standards Policy Committee (QMS/-) to Technical Committee QMS/33, upon which the following bodies were represented: British Computer Society British Production and Inventory Control Society Chartered Institute of Management Accountants EEA (the Association of Electronics, Tel
4、ecommunications and Business Equipment Industries) Institute of Logistics and Distribution Management Ministry of Defence Nottingham University PERA International (Production Engineering Research Association) University of Bradford University of Manchester Institute of Science and Technology Amendme
5、nts issued since publication Amd. No. Date CommentsBS 5192-1:1993 BSI 08-1999 i Contents Page Committees responsible Inside front cover Foreword ii 0 Introduction 1 1 Scope 1 2 References 1 3 Definitions 1 4 The production control function 6 5 Relationship between production control and other functi
6、ons 7 6 The impact of technology on production control 10 7 Characteristics of manufacturing organizations 14 8 Choosing the right production control system for the business 15 9 Implementing and maintaining the system 18 10 Alternatives to complex production control systems 18 Figure 1 Stages of pr
7、oduction control 8 Figure 2 Closed loop system 9 Figure 3 Relationship between production control and other functions 9 Figure 4 Development of computerized applications in manufacture 10 Figure 5 Manufacturing resource planning (MRP II) 11 Figure 6 Shape of bills of material 16 List of references I
8、nside back coverBS 5192-1:1993 ii BSI 08-1999 Foreword This Part of BS5192 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 p
9、roduction 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
10、a production control system designed to meet the specific needs of the company and run by well trained and dedicated staff. BS5192 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: Part1
11、: Introduction: Scope of the guide, purpose of production control, relationship to other functions, technological changes, choosing the system to fit the business; Part2: Production programming: Relationship to corporate and business programmes, planning techniques, Master Production Scheduling, Cap
12、acity Planning; Part3: Ordering methods: The various types of ordering and stock control systems, comparing the advantages of each for particular applications; Part4: Dispatching (shop-floor control): The methods of shop floor production control and documentation involved and the increasing influenc
13、e of computers; Part5: The relationship between production control and other management functions: The production control information flows in the organization, their generation, presentation, use and maintenance; Part6: Computer aided production control: The application of computer software to the
14、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. Compli
15、ance 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, pagesi andii, pages1to18, an inside back cover and a back cover. This standard has been updated (see copyright date) and may have had
16、 amendments incorporated. This will be indicated in the amendment table on the inside front cover.BS5192-1:1993 BSI 08-1999 1 0 Introduction The six Parts of BS5192 provide an overview of production control principles and good practice applied to manufacturing industry. It explains the relationship
17、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 techniques are described for planning, directing and regulating manufacture and provisioning material. Each technique
18、 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 not feasible within the scope of these documents to describe techniques in detail. Readers are therefore advised to e
19、nsure 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 production control subjects which range from one day to a week or more in duration. Knowledge can also be acquired by
20、referring to books and professional journals on the subject. Of standards on, or related to, production control NF X50-3101 published by AFNOR deserves mention, not least for its extensive bibliography of other standards. In certain instances, particularly where there is a lack of in-house expertise
21、, 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 front cover. Manufacturing operations take many different forms, so it is essential to choose the right technique to su
22、it 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 types of manufacturing operation. 1 Scope This Part of BS5192 provides an introduction to the objectives and concepts of p
23、roduction control. In addition, it provides introductions to the other Parts of BS5192. 2 References 2.1 Normative references This Part of BS5192 incorporates, by reference, provisions from specific editions of other publications. These normative references are cited at the appropriate points in the
24、 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 BS5192 only when incorporated in it by updating or revision. 2.2 Informative references This Part of BS5192 refers to other publications that pro
25、vide 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 the latest editions. 3 Definitions For the purposes of this Part of BS5192, the definitions given in BS3138 and BS5191 apply
26、, together with the following. NOTESince the publication of BS5191:1975 many new terms have been introduced in the field of production planning and control as a result of the significant developments in this area. It is envisaged that the terms defined in this clause will be incorporated in a revisi
27、on of BS5191, 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.g.ordering, setting-up, assuring quality 3.2 architecture the design of the computers hardware, system software and communication
28、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 system an ordering method in which a fixed (or base) stock is established for every item. Any issue from stock is immediately foll
29、owed 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 material supplier NOTEBase stock control is a stock base, pull method of ordering.BS 5192-1:1993 2 BSI 08-1999 3.5 big bang expressio
30、n denoting an abrupt change from one system to another without 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 deliver
31、ed of goods listed in a blanket purchase order NOTEA typical 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 re
32、source needed to manufacture the quantity required to make one 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 (see3.64). 3.9 capacity requirements planning (CRP) a system that ca
33、lculates time-phased capacity requirements by resource type 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 re
34、ported to the MRP system. More sophisticated versions of CRP 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 o
35、ther systems to provide feedback of information between the 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 man
36、ufacturing and buying instructions. Purchasing and shop order systems feed back information about performance to the MRP system to enable corrective action to be taken, if necessary. (See also3.48.) 3.11 closed loop system a control system in which the planning and execution phases are linked so tha
37、t information about performance compared to plan is fed back 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
38、to customer order upon receipt of the order 3.13 computer 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 equi
39、pment 3.15 computer aided process planning (CAPP) the application 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 cont
40、rol software packages NOTEAnother term for CAPM is computer 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 link
41、s (e.g.between CAD and CAPP and between MRP and CAM) to a 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.B
42、S5192-1:1993 BSI 08-1999 3 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 subsequent control of production resources to individua
43、l 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 business. The transfer of structured business data by agre
44、ed 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, batch, on run out of old component (machine), or
45、as soon as a new component is available 3.23 expert system 1) 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 parameters programmed into it 3.24 explosion a br
46、eakdown 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 detail below MRP to assist in the scheduling/rebalancin
47、g 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 F
48、MC 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 rebalanced often, rapidly matching output to changes in demand NOTEFMC involves mixed-model sc
49、heduling, multi-skilled operators, standardization of equipment for quick changeover items, and design of the production line to allow workers to do more than one job and to cut down on transportation time between lines. 3.28 flexible programming a method of programming in which the year is divided into equal short time periods and new short term sales and production programmes are prepared at the beginning of each period NOTEFlexible programming makes it possible for production to follow changes in the market with minimum stocks. 3.29 flow control a te
