Aggregate and Sales Planning
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Transcript of Aggregate and Sales Planning
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McGraw-Hill/Irwin Copyright 2009 by The McGraw-Hill Companies, Inc !ll rights reser"e#
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Sales and Operations Planning
The Aggregate Operations Plan
Examples: Chase and Levelstrategies
OBJECTIVES
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1-4
Process planning
Strategic capacityplanning
Sales and operations(aggregate) planning
Salesplan
Aggregateoperations
plan
Supply networkplanning
Forecasting anddemand management
Master sc eduling
Material re!uirements
planning
"rder sc eduling
#e icle capacityplanning
#e icle loading#e icle dispatc ing
$are ousereceipt
planning
$eeklywork%orcesc eduling
&aily work%orcesc eduling
Manu%acturing 'ogistics Ser ices
'ongrange
Mediumrange
S ortrange
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Sales and "perations Planning Acti ities
Long-range planning * Greater than one year planning hori on * !s"ally per#ormed in ann"al in$rements
%edi"m-range planning * Six to eighteen months * !s"ally &ith &ee'ly( monthly or )"arterly
in$rements
Short-range planning * One day to less than six months * !s"ally &ith &ee'ly or daily in$rements
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, e Aggregate "perations Plan
%ain p"rpose: Spe$i#y the optimal$om*ination o# * prod"$tion rate +"nits $ompleted
per "nit o# time, * &or'#or$e level +n"m*er o# &or'ers, * inventory on hand +inventory
$arried #rom previo"s period, Prod"$t gro"p or *road $ategory
+Aggregation, This planning is done over an
intermediate-range planning period o# to1. months
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alancing Aggregate &emandand Aggregate Production .apacity
0
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10000
Jan Feb Mar Apr May Jun
45005500
7000
10000
8000
6000
0
2000
4000
6000
8000
10000
Jan Feb Mar Apr May Jun
4500 4000
90008000
4000
6000
S"ppose the #ig"re tothe right represents#ore$ast demand in"nits
/o& s"ppose thislo&er #ig"re representsthe aggregate $apa$ityo# the $ompany tomeet demand
0hat &e &ant to do is*alan$e o"t theprod"$tion rate(&or'#or$e levels( andinventory to ma'ethese #ig"res mat$h "p
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ey Strategies %or Meeting &emand
Chase
Level
Sta*le &or'#or$e
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Aggregate Planning 5 amples7 8nit &emand and .ost &ata
Materials $5/unitHoldin !osts $1/unit per "o#Mar inal !ost o sto!%out $1#25/unit per "o#Hirin and trainin !ost $200/&or%er 'ayo !osts $250/&or%er 'abor (ours re)uired #15 (rs/unit*trai (t ti"e labor !ost $8/(our +e innin in,entory 250 units-rodu!ti,e (ours/&or%er/day 7#25
-aid strai (t (rs/day 8
S"ppose &e have the #ollo&ing "nit
demand and $ost in#ormation:.e"and/"o Jan Feb Mar Apr May Jun
4500 5500 7000 10000 8000 6000
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Jan Feb Mar Apr May JunDays/mo 22 19 21 21 22 20Hrs/worker/mo 159.5 137.75 152.25 152.25 159.5 145Uni s/worker 10!3.33 91".33 1015 1015 10!3.33 9!!.!7
#/worker #1$40" 1$21! 1$344 1$344 1$40" 1$2"0
-rodu!ti,e (ours/&or%er/day 7#25-aid strai (t (rs/day 8
.e"and/"o Jan Feb Mar Apr MayJun
4500 5500 7000 10000 8000
6000
Given the demand and $ost in#ormation *elo&( &hatare the aggregate ho"rs2&or'er2month( "nits2&or'er( anddollars2&or'er3
7#25 22
7#25 0#15 48#
84# 22 106 #22 8(rs $8 $1408
.ut-and-,ry 5 ample7 &eterminingStraig t 'a:or .osts and "utput
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. ase Strategy(;iring < Firing to meet demand)
J anDays/mo 22Hrs/worker/mo 159.5Uni s/worker 1$0!3.33#/worker #1$40"
J anDeman% 4$500&e'. in). 250*e re+. 4$250,e+. workers 3.997Hire%Fire% 3-orkore 4
n%in' in)enory 0
Lets ass"me o"r $"rrent &or'#or$e is 4&or'ers5
irst( $al$"late net re)"irements #orprod"$tion( or 7899- 89;7 89 "nits
Then( $al$"late n"m*er o# &or'ersneeded to prod"$e the netre)"irements( or7 892196 5 ; 5
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J an Feb Mar Apr May JunDays/mo 22 19 21 21 22 20Hrs/worker/mo 159.5 137.75 152.25 152.25 159.5 145Uni s/worker 1$0!3 91" 1$015 1$015 1$0!3 9!7#/worker #1$40" 1$21! 1$344 1$344 1$40" 1$2"0
Jan Feb Mar Apr May JunDeman% 4$500 5$500 7$000 10$000 "$000 !$000&e'. in). 250
*e re+. 4$250 5$500 7$000 10$000 "$000 !$000,e+. workers 3.997 5.9"9 !."97 9."52 7.524 !.207Hire% 2 1 3Fire% 3 2 1-orkore 4 ! 7 10 " 7n%in' in)enory 0 0 0 0 0 0
>elo& are the $omplete $al$"lations #or the remainingmonths in the six month planning hori on
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Jan Feb Mar Apr May Jun
Deman% 4$500 5$500 7$000 10$000 "$000 !$000&e'. in). 250*e re+. 4$250 5$500 7$000 10$000 "$000 !$000,e+. workers 3.997 5.9"9 !."97 9."52 7.524 !.207Hire% 2 1 3
Fire% 3 2 1-ork ore 4 ! 7 10 " 7n%in' in)enory 0 0 0 0 0 0
Jan Feb Mar Apr May Jun ossMaeria #21$250.00 #27$500.00 #35$000.00 #50$000.00 #40$000.00 #30$000.00 203$750.00abor 5$!27.59 7$2"2.7! 9$2!".97 13$241.3" 10$593.10 7$944."3 53$95".!2Hirin' os 400.00 200.00 !00.00 1$200.00Firin' os 750.00 500.00 250.00 1$500.00
?:69(79.56:
>elo& are the $omplete $al$"lations #or the remaining months inthe six month planning hori on &ith the other $osts in$l"ded
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'e el $ork%orce Strategy (Surplus and S ortage Allowed)
J anDeman% 4$500&e'. in). 250*e re+. 4$250-orkers !
ro%uion !$3"0n%in' in)enory 2$130urpus 2$1306ora'e
Lets ta'e the same pro*lem as*e#ore *"t this time "se theLevel 0or'#or$e strategy
This time &e &ill see' to "sea &or'#or$e level o# 6 &or'ers
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>an Fe: Mar Apr May >un&emand )?+99 +?+99 /?999 19?999 2?999 6?999eg@ in(@ =+9 =?139 =?1)9 1?=39 -=?629 -1?399et re!@ )?=+9 3?3/9 )?269 2?//9 19?629 /?399$orkers 6 6 6 6 6 6Production 6?329 +?+19 6?949 6?949 6?329 +?2995nding in(entory =?139 =?1)9 1?=39 -=?629 -1?399 -1?+99Surplus =?139 =?1)9 1?=39S ortage =?629 1?399 1?+99
ote? i% we recalculate t is s eet wit / workerswe would a e a surplus
>elo& are the $omplete $al$"lations #or the remainingmonths in the six month planning hori on
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>an Fe: Mar Apr May >un)?+99 +?+99 /?999 19?999 2?999 6?999
=+9 =?139 19 -419 -3?419 -1?6=9)?=+9 3?3/9 )?269 2?//9 19?629 /?399
6 6 6 6 6 66?329 +?+19 6?949 6?949 6?329 +?299=?139 =?1)9 1?=39 -=?629 -1?399 -1?+99=?139 =?1)9 1?=39
=?629 1?399 1?+99
>an Fe: Mar Apr May >unB2?))2 B/?=46 B2?96) B2?96) B2?))2 B/?629 B)2?999@9931?499 =/?++9 39?)+9 39?)+9 31?499 =4?999 121?=+9@99
=?139 =?1)9 1?=39 +?+99@993?3+9 1?6=+ 1?2/+ 6?2+9@99
?:71(699599
Belo" are the complete calculations for theremaining months in the six month planninghori'on "ith the other costs included
/ote( total$osts "nderthis strategyare less thanChase at? 69579.56
'a:or MaterialStorageStockout
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Cuestion owl
Sales and Operations Planninga$tivities are "s"ally $ond"$tedd"ring &hi$h planning time hori on
a5 Long-range
*5 =ntermediate-range$5 Short-ranged5 @eally short-rangee5 /one o# the a*ove
%ns"er( b) Intermediate*range +i)e), - to
./ months0
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Cuestion owl
0hi$h o# the #ollo&ing are Prod"$tionPlanning Strategies $an involve trade-o##s among the &or'#or$e si e( &or'ho"rs( inventory( and *a$'logs3
a5 Chase strategy
*5 Sta*le &or'#or$e-varia*le &or' ho"rs$5 Level strategyd5 All o# the a*ovee5 /one o# the a*ove
%ns"er( d) %ll of the abo e
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Cuestion owl
0hi$h o# the #ollo&ing are $onsideredrelevant $ostsB in the AggregateProd"$tion Plan3
a5 Costs asso$iated &ith $hanges in theprod"$tion rate
*5 =nventory holding $osts$5 >a$'ordering $osts
d5 >asi$ prod"$tion $ostse5 All o# the a*ove
%ns"er( e) %ll of the abo e
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Cuestion owl
0hi$h o# the #ollo&ing AggregatePlanning Te$hni)"es $an *e per#ormed"sing simple spreadsheets3
a5 C"t-and-try*5 Linear programming
$5 Transportation methodd5 All o# the a*ovee5 /one o# the a*ove
%ns"er( a) Cut*and*try +The other t"o in ol e morecomplex computational effort than simple
spreadsheets)0
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End o# Chapter 16
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