NGHIEN c i i u - T R A O D O I
NGHIEN CO'U THIET LAP PHAN MEM LAP KE HOACH SAN XUAT TRONG MAY C6NG NGHIEP
DESIGNING SOFTWARE PROGRAM FOR MANUFACTURING PLANNING ESf GARMENT INDUSTRY
TS. Nguyen Thi Le Trudng Dai hpc Su pham Ky thuat Hung Yen T 6 M TAT
Cong tdc lap ke hogch sdn xudt cho don hdng sdn phdm may co vai tro rdt quan trgng v&i viic ndng cao ndng sudt lao dgng, ddm bdo chdt lugng sdn phdm vd thai hgn giao hdng trong may cong nghiip. Bdi bdo ndy gi&i thieu kit qud nghien ciru thiet lap chuang trinh phdn mim lap ke hogch cho cdc cong dogn sdn xudt chinh trong doanh nghiep may, gom: Trdi, cdt vdi, may, hodn thien sdn phdm. Dua tren cdc dit lieu don hdng, diiu kiin sdn xudt, chuang trinh cho phep tinh todn ke hogch sdn xudt long the vd chi tiet phu hgp v&i dieu kiin vd ndng luc sdn xudt cua doanh nghiep.
Chuang trinh phdn mim ADP. Garmentl.l ho trgr qud trinh lap ki hogch sdn xudt trong doanh nghiep may da duac thiit lap vd thu nghiem tren mgt so dan hdng sdn xudt tgi Xi nghiep May xudt khdu Thanh Tri vd Cong ty Dit may Hd Ngi
Tir Ichoa: Phdn mim lap ki hogch sdn xudt; May cong nghiep; Ki hogch may.
ABSTRACT
Production planning plays an important part in operator productivity improving, guarantee of product quality and delivery deadline in garment industry. This article introduces the results of the research and development of planning software program for the main stages of production in garment enterprises including spreading, cutting fabric, sewing and finishing products. Based on the order data, production conditions, the program allows for the calculation of the overall production plan and further processing in accordance with the production conditions and capacity ofthe enterprise. ADP. Garment 1.1 supports the production planning process in garment enterprises have been established and tested on a number of orders at Thanh Tri Garment Export Enterprise and Hanoi Textile Garment Company.
Keywords: Production planning software, industrial garment, sewingplan.
ISSN 0866 - 7056
TAP CHi CO KHf VIET NAM, Sd 6 nam 2017 www.coldiivietnam.vn
NGHIEN c i i u - T R A O D 6 | I . D A T V A N D E
Lap ke hoach sdn xuat cho don hang trong cdng nghiep may la xac dinh cdc cdng viec vdi khdi lupng cu thd can thuc hien, tuang img vdi thdi gian can thiet vd cdc dieu kien phuc vu di kem cho cac cdng doan de dat dupc sdn lupng va dap iing diing thai gian giao hdng.
Lap ke hoach sdn xudt Id cdng viec quan trpng, cd anh hudng true tiep den nang sudt lao ddng, chdt lupng san phdm vd thdi han giao hang.
Tai cac doanh nghiep may Viet Nam hien nay, ke hoach sdn xudt thuc hien chu ydu dua vao kinh nghiem, thudng duac hieu dan gian nhu la san lupng giao cho cdc ddy chuyen san xuat tuang iing vai thdi gian giao hang, chua day du de tao dieu kien thudn lgi cho tridn khai, qudn ly vd dieu hdnh sdn xudt hidu qua, chua xdc dinh cac muc tieu cu the cho ttmg cdng doan sdn xuat vdi thdi gian, nang sudt, sdn lupng tuong iing. Cdc phdn mem da dupc phat trien bdi Gerber, Lectra, Optitex,...
Tap trung vdo hd tra thiet ke my thuat va ky thuat san phdm may [3], [4]. Mdt sd phdn mem dupc phdt trien de tinh miic thdi gian lao dpng cho nguyen cdng san xudt sdn pham may, kiem soat nang sudt nhu [5], [6].
Nghien ciiu nay, nham thiet lap phan mem ADP.Garmentl.l hd tra qua trinh lap kd hoach sdn xudt, gidm thieu thdi gian, sd nhan vien lap kd hoach va tang khd nang quan ly nhd may, gdp phan nang cao hieu qud sdn xuat trong may cdng nghiep.
2. PHlTONG PHAP NGHIEN ClTU Phdn mdm lap kd hoach sdn xudt cho dan hang sdn phdm may duac thidt lap vdi dii lieu ddu vdo, dau ra va md dun chiic nang.
Dir liiu ddu vdo:
Don hang: Ten khach hang, ten don hang, san phdm, sd sdn pham ciia don hdng L, sd sdn pham du phdng (sdn xudt them) L . .
Dieu kien san xudt: Sd phdn xudng, sd day chuydn cua mdi phan xudng, thdi gian ldm viec cua 1 ca sdn xudt T^, thdi gian dimg T^, sd cdng nhdn lam viec true tidp tren day chuydn S, thdi gian dinh miic gia cdng 1 sdn phdm T ^ , hieu sudt lam viec tren chuyen, hieu sudt H^, i
=1,2, ...,n (n Id sd ngay may). Trongdd, Hied the chpn mac dinh sdn trong chuang trinh hodc dua cdc gia tri vdo theo tinh hinh thuc td cua doanh nghiep, thdi gian san xuat (tir ngdy...ddn ngay) n ngay, ngdy giao hdng, sd ngdy nghi (chu nhdt, ngay Id) 1.
Ddu ra: Kdt qud ddu ra cua chuang trinh dupc the hien vdi 3 ndi dung;
- Cdc thdng sd tdng the cho qua trinh san xuat bao gdm: Ten don hang, ma sd, sd luong sdn phdm, sd day chuyen san xuat N, thdi gian sdn xudt (sd ngdy, tir ngay... den ngdy...), sd ngay may (t), san lupng giao cho timg chuyen, tdng sdn lugng cac chuyen cdn dat theo timg ngay, ngay ket thuc dan hang, ngdy giao hang va thdng tm them neu can thiet.
- Bieu dd san xudt dan hang tdng the cho cac khdu tir trdi vdi, cat, may va hodn tdt sdn phdm, giao hang. Thdng tin nay giiip cho cdc can bd qudn ly cdp trung nam dupc ke hoach tdng the vd dieu phdi khi cdn thiet.
- Kd hoach san xudt chi tiet cho chuyen may bao gdm: Ten ddy chuyen may, sd luang lao ddng tren chuyen, dan hang sdn xudt, thdi gian san xudt cho timg chuyen, sdn luong giao cho timg ngdy tuang ling vdi cac mdu vd cd sd, tdng san luong giao cho day chuyen, cac ngay nghi neu cd. Bdng ke hoach chi tiet dupc the hien cho tat cd cdc ddy chuyen may don hdng.
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NGHIEN CO'U-TRAO D 6 |
2.1. Chile nang nhap du li^u
Don hang va didu kien san xuat cua doanh nghiep vdi cdc thdng sd nhu tren dupc nhfip vdo phdn mdm qua chiic nang khai bao.
Cdc thdng tm cua sdn phdm dupc nhdp va kiem tra cheo, sau khi chinh xdc vd ddy du thdng tin cua cdc muc theo ydu cdu thi dupc luu vao co sd dii lieu. Cdc thdng tin cua don hang, dieu kien sdn xudt cd the thay ddi theo yeu cdu cua ngudi dung, ddm bdo ludn cap nhdt. Ke hoach may dupc thiet lap tren nguyen tac chia sd san pham cho cac chuyen sao cho thdi gian kdt thlic tren cac chuyen la gidng nhau de thuan lpi cho qudn ly san xuat, sd lan thay man cua ma hang tren mdt chuyen la it nhat.
2.2. Xac dinh cac thdng s6 dd Idp kl hostch san xuat
Cdng suat trung binh cua ddy chuyen may dupe xdc dinh:
^_(T^-Tj).3600.S.H,^
Thdi gian san xudt trung binh tren 1 day
thudng la 1 ngay, ndu khdng nhdp, phan mem se chpn mac dinh la 1 ngay). Thdi gian trd cua thdi gian hoan tat so vdi thdi gian may la n^^^j,^, keithuc ("l^^c nhap tiiy theo don hang, ndu khdng nhap, phdn mem chpn mac dinh Id 1 ngdy). Sd ngay nghl trong dip sdn xuat don hang la n^ ^^^^^
(dupc nhdp vdo tuy theo thdi gian cu the sdn xuat don hang tai doanh nghiep).
chuyen/ngay: T = (T ^ - T^).3600.S.H,^
Trong dd: T,^^^^ ^^ la thdi gian sdn xudt tren 1 chuydn.
Thdi gian san xudt cdn thidt cua don
^' donhana *- d n ' ' sn
Trong do: T^^
dan hang (giay).
Id thdi gian sdn xudt
Trong dd: P la cdng sudt trung binh cua day chuyen (san pham/ca), T^ la thdi gian ldm viec cua mdt ca (gid), T^ la thdi gian diing trong mdt ca lam viec (gid), S la sd cdng nhdn ldm viec true tiep tren day chuyen (ngudi). H^^
Id hieu sudt trung binh cua day chuyen.
Thdi gian dinh miic hoan thanh tai lieu la n^^ij^^ (nh|p vao theo dinh miic thdi gian cua tling cdng ty). Thdi gian cdn thiet de giao hang la n j^^^^^ (dupc nhdp vdo tiiy theo ma hang, ii
Sd ngay san xuat can thiet neu trien khai may tren 1 ddy chuyen: N , ^ -. =T, ^. fl^^ .
Sd ddy chuyen may can thiSt de thuc hien sdn xudt don hang Id N: So sanh Nsxlchuyen vdi sd ngay san xudt la [n - n^.^.^^
~ "giaohang ^ ^oanlalkelthuc ~ "nghile ~ \-^ ~ ^ l " " ! ' "}
- H^ - Hj]. Trong dd, Hj, H^,..., H^ Id hieu suat lam viec cua day chuyen may tir ngay thii nhdt ddn ngdy thir 5.
Ndu N , , . : < l n - n , , - n . , . -
"hoantatketthu. ^ ^nghile ^ ^^ ' ^f^Z " ^^3 " " 4 " ^ 5 ]
thi don hang nay se duac trien khai sdn xuat tren N = 1 day chuyen. Tinh todn kd hoach san xudt cu the cho timg ngay cua chuyen nay ddi vai ma hang.
giaohang
- ( 5 - H , - H , - H 3 - H , - H J ,
N = roundup [(L + L )/P.[n - n_„,.
' » - \ . I. - n ., - ( 5 - H , - H , - H ,
giaonang noajitatkellh)ic ngbile ^ \ 2 i
- H^ - H J ] neu phdn thdp phdn cua gia tri nhdn dupc ldn ban 0,1.
N = rounddown [(L + L^^)lP.[n - n^^,^
~ "giaohang "" 'HMnlalkephiic ~ "nghile ~ ( ^ " " l " " l " " 3
- H^- Hj]] neu phdn th^p phdn cua gia tri nhdn dupc nhd hon hoac bdng 0,1.
Thdi gian may cdn thidt thyc td tren cac
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day chuySn may la t (ngay):
t = Roundup [(L + L^ )/P.N + 5 - H - H - H , - H , - H J ( n g a y )
San luong giao cho timg chuyen: L - roundup (L +L^ )/N vai j = 1, 2 , . . . , N 2,3. Lap ke hoach chi tidt cho day chuy&n may
Tu dil lieu ve ngay bdt ddu sdn xudt, sd ngay xay dung tdi Heu, sd ngay fre cdt (trudc may), ngay giao hang va nghi Id, xac dinh ngay ddu tien md cac ddy chuyen bat dau may don hang nay, xac dinh thii, ngay, thdng, nam cu die. Chuong trinh gan ty ddng khi so sdnh ngay ddy chuyen may sdn xuat vdi thu trong tudn, neu gap chu nhdt thi tu ddng cdch ngay nghi.
Hieu sudt ldm viec cua day chuydn may j theo thdi gian sdn xuat dan hang la H^
- cua ngay thii i may dan hang. Gid tri H^
cd the nhdp true tiep hoac chpn H^ mac dinh.
Khi dd, sdn lupng giao cho day chuyen may thli j theo tirng ngay duoc xdc dinh: P^ = H^
X P, vdi i = 1, 2, ..., t-1; j - 1, 2,..., N. San lupng giao cho chuyen j sdn xudt trong ngdy cudi (ngdy thu t) la:
S^.
v d i j = 1,2,...,N.Neu sdn pham da timg san xudt thi hieu suat lam viec cho 3 ngdy ddu (H,, H^, H^) dupc nhap vao tu bdn phim hodc lya chpn che dp mac dinh. Tii ngdy thii 4 ddn hdt thdi gian gia cdng don hang se su dung mdt gid trj hieu suat dn dinh. Neu loai san phdm mdi la chua timg san xudt, tien hdnh nhdp hieu sudt lam viec cho cdc ddy chuyen trong 5 ngdy ddu (H,, H^, H3, H^, Hj) tir ban phim hoac lya chpn chd dp mac dinh. Tir ngay thii 6 ddn hdt thdi gian gia cdng se sii dung mdt gid tri hieu sudt dn dinh. Sd sdn phdm ddy chuyen may phai san xudt timg ngdy dupc tinh chi tiet tren bang 2.1.
Bdng 2.1. Ke hogch sdn lugng theo ngdy ciia ddy chuyen may:
Ngay Thli nhat
Thli 2 Thli 3 Thi 4 Thli 5 Th4 6 ^ t - 1
Thut
So lirtfng theo ngay vol san pham quen thuQC P „ = H , , x P , j = I,2,...,N
P r H a " ' ' ,
• ' j i ' H . / P i P 4 r ( ' - l ) J - P ,
"rL,- TP,
Sd lugng theo ngay vol san phdm khdng quen thuoc P = H , x P , 1 = 1 , 2 , . . . , N
P, = H,. X P P, = H, X P
3l 3j J
P = H, x P,
-Ij 4j j '
P.i = H5i''P, P e r ( ' - l ) J - P ,
tl J ^ ^ , 1=1
ISSN 0866 - 7056
TAP CHi CO KHI VlfiT NAM, Sd 6 nam 2017
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3. KET QUA VA BAN LUAN
Giao dien chinh cua chuong trinh cho phep dang nhdp he thdng. Sau do, khai bao don h va dieu kien sdn xudt bang each chpn cdc mit chirc nang nhu tren hinh.
« > k i i _ t i » * ^ ^ l
I "
Hinh 1. Giao dien khai bdo chinh vd khai bdo cdc thdng tin vi dan hdng
iinabkibplib*^^
Hinh 2. Giao diin nhdp thdng tin so sdn phdm theo mdu vd ca cua don hdng Khai bdo cho don hang bang each dien thdng tin vao cdc d du lieu dau vao. Cac thdng tin ddu vdo dupc kiem tra trudc khi dua vao ca sd du lieu de dam bao chinh xdc. Sau dd, chuydn sang khai bao chi tiet cho mdu va cd cua don hang. Trong cac cira sd ndy, khai bdo ten mau, ten co, sd lupng sdn phdm theo mau va ca. Ket thuc, chuyen sang khai bao dieu kien sdn xudt don hang vdi cdc thdng tin tren giao dien hinh 2.
Hinh 3. Giao diin nhdp thong tin diiu kiin sdn xudt vd ldp ke hogch dan hdng
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NGHIEN Ciiu - TRAO DOI
Sau khi da nhap thdng tin vS thai gian sdn xudt cua mpt ca, thdi gian dimg, tidn hanh nhap thdng tin cho cdc chuydn cua phan xudng, gdm ten chuyen, sd lupng cdng nhan tren chuyen. Can cir vao thdi gian san xudt cu the cua cdng ty ma ngudi dung khai bao cho hpp ly cac thdng tin ve sd ngdy nghi trong sudt thdi gian sdn xudt, thai gian gia cdng mdt san pham tren ddy chuyen may. Dua tren thdi gian dinh miic xay dung tai lieu vd thdi gian hodn tdt sdn phdm sau may theo yeu cau cua don hang de xdc dinh thdng tin cdn lai. Neu khdng dua du lieu ciia cdng ty, chuang trinh mac dinh chpn thdi gian xdy dung tai lieu ky thuat la 2 ngay, thai gian hodn tat sdn phdm ket thiic sau khi may la 1 ngdy. Hieu sudt lam vide cua day chuyen may cd the dupc nhap vao tuy theo dac diem thuc te cua doanh nghiep. Neu khdng nhap dil lieu ndy, chuong trinh se mac dinh chpn gid tri hieu sudt lam viec tuy theo loai sdn
phdm san xuat la quen thudc hay mdi la. Neu sdn pham la loai san ph&n quen thudc, gid tri cua hieu sudt lam viec dupc chpn tuong ling la:
H, - 0,3; H^ - 0,5; H^ = 0,8; H^^^ - 1. Ndu sdn phdm Id loai mdi, gia tri hieu suat dugc chpn la:
Hj - 0,2; H^ = 0,5; H^ - 0,7; H^ = 0,9; H^^,= 1.
Sau khi nhap day dii dii lieu, chpn cira sd ket qud, chpn mpt trong 3 tac dpng (thdng tin don hang, bieu dd ke hoach sdn xudt hoac ke hoach may), chuong trinh se tu ddng thuc hien qua trinh tinh todn can thiet va de nghi ngudi su dung luu lai ket qud vdl ten da dinh tuy theo chiic nang (donhang[tendonhang];bieudosx[tendonhang]
hoac kehoachsx[tendonhang]) dudi dang tep Excel va chpn dudng dan luu ket qua. De xem va in ket qud lap ke hoach san xuat, md cac tep dii lieu da dupc ghi vdi ten don hdng theo dudng dan vd chpn may in phu hpp.
IHdNGnNOOrNHANG
Mkigni mat Sjido : JicS i
Hinh 4. Thong lin vd ke hogch may dan hdng SM2011
rtm/joi^mkntmwt
«,'> A'n u!h iitA jyat A.'Ji Mn j.'.'i *'J> a'* WA a'* L.'* U.'D »
Hinh 5. Bieu do ki hogch sdn xudt don hdng SM2011 ISSN 0866 - 7056
TAP CHI CO KHI VIET NAM, So 6 nam 2017
NGHIEN CU'U-TRAODOI
De dung phdn mem nay trong ldn sir dung ddu tien, ngudi dimg phai tao mdt tai khodn sit dung vdi password, khai bdo cdc thdng tin can thiet. Cac thdng tin ndy cd the thay ddi va dupc luu vao CO sd dii lieu. Cira sd "quan ly ngudi dimg" cho phep xem danh sach n ^ d i dimg, them ngudi dling (tao tai khoan mdi) va xda ngudi dimg. De tao mdt tai khodn mdi, dien ddy du cac thdng tin yeu cau va chpn niit "them mdi". De cap nhdt hoac xda mpt tai khoan cd sin, chpn mdt tai khodn tii danh sach va thyc hien cac thay ddi theo yeu cau. Menu cd nhdn cung cho phep thay ddi mat khdu cua ngudi dimg khi can thiet.
Hinh 6. Danh sdch nguai sir dung chuang trinh vd tgo tdi khodn su dgng mai Chuong trinh dam bdo tinh bao mat
thdng tin san xuat nhd tinh nang kiem tra ten truy cap, mat khau va cd the tro giiip khi can thidt.
Vdi chuong trinh dupc thiet lap nhu tren, cdng tac lap ke hoach san xudt duoc tien hdnh ty ddng vd cho kdt qua phii hop vdi yeu cau ciia don hang va dieu kien san xudt cua doanh nghiep. Cac kdt qua luu lai d dang tep Excel de de dang sir dung trong qud trinh sdn xudt. Chuong trinh dupc thu nghiem tren mdt sd don hang sdn xuat tai Cdng ty Det may Hd Npi vd cdng ty may xuat khau Thanh Tri cho thay, ke hoach sdn xudt chi tiet Id kha thi, phii hpp vdi dieu kien ciia doanh nghiep.
4. KET LUAN
Chuong trinh jphan mem ADP.
Garmentl.l da duac thiet lap tren ngdn ngu C#, cho phep lap ke hoach san xudt cho cac cdng doan tir chudn bi san xudt, trdi cat vdi, may va hoan tat san pham vdi day du thdng tin cdn thidt, ndi dung phu hop, chinh xac, cu the va kha thi trong dieu kien cua doanh nghiep may. Thdi gian lap ke hoach sdn xuat cho mpt don hang cd dp phiic tap trung binh Id 10 phiit.
Ket qud ciia lap ke hoach sdn xuat dupc lim giii dudi dang tep Excel thuan lpi cho qua trinh
sir dung. Cdc bdo cdo cd cdu tnic vd ndi dung don gidn, de hieu, phii hpp vai yeu cdu cua cac doanh nghiep may Viet Nam. Chuong trinh da dupc dua vao ap dung vdi 5 dan hang tai Cdng ty May xuat khdu Thanh Tri va Tdng Cdng ty Det may Ha Npi va dupc ddnh gid Id ddp img tdt yeu cdu ciia san xudt.
Chuang trinh da thiet l|.p cd y nghia thyc tidn, thdn thien va de sir dung, gdp phdn ndng cao hieu qua sdn xuat tai cdc doanh nghiep may. •!*
Ngdy nhdn bai: 05/6/2017 Ngdy phdn bien: 15/6/2017 Tai lieu tham khao:
NguySn Van Nghien, Qudn ly sdn xudt, NXB. Bai hgc Qu6c gia Ha Ngi, 2001.
D6 Van Phiic; Qudn ly doanii nghiep, NXB, Bach khoa Ha Npi, 2006.
Harold Can, Barbara Latham; TTie Technology of Clothing manufacture; Blackwell Scientific Pubhcations, second edition, 1994
H. Eberle; H. Hermeling; M. Homberger; R. Kilgus;
D Menzer; W. Ring; Clothing technology, from fibre to fashion, Veriag Europa-Lehrmittel; Fourth Edition.
2003.
Catherme Fairhurst, Advances in apparel production.
Woodhead Publishing in Textiles: Number 69, 2008.
Jacob Solinger, Apparel manufactunng handbook.
Van Nostrand Reinhold Company, 1988.
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