Heizer 13 Aggregate Planning 2016
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Transcript of Heizer 13 Aggregate Planning 2016
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Aggregate AggregatePlanning Planning Chapter 13Chapter 13
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Learning ObjectivesLearning Objectives
When you complete this chapter youWhen you complete this chapter youshould be able to:should be able to:
1.1. e!ine aggregate planning e!ine aggregate planning ".". #denti!y optional strategies !or#denti!y optional strategies !or
developing an aggregate plandeveloping an aggregate plan
3.3. Prepare a graphical aggregate planPrepare a graphical aggregate plan
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Learning ObjectivesLearning Objectives
When you complete this chapter youWhen you complete this chapter youshould be able to:should be able to:
$.$. %olve an aggregate plan via the%olve an aggregate plan via thetransportation method o! lineartransportation method o! linear
programming programming
&.&. 'nderstand and solve a yield'nderstand and solve a yield
management problemmanagement problem
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e!initione!inition
Aggregate planning is the process o! developing( analy)ing( Aggregate planning is the process o! developing( analy)ing(and maintaining a preliminary( appro*imate schedule o! theand maintaining a preliminary( appro*imate schedule o! theoverall operations o! an organi)ation.overall operations o! an organi)ation.
+he aggregate plan generally contains targeted sales !orecasts(+he aggregate plan generally contains targeted sales !orecasts( production levels( inventory levels( and customer bac,logs. production levels( inventory levels( and customer bac,logs.
+he term aggregate implies that the planning is done !or a+he term aggregate implies that the planning is done !or asingle overall measure o! output or( at the most( a !e-single overall measure o! output or( at the most( a !e-aggregated product categories.aggregated product categories.
+he aim o! aggregate planning is to set overall output levels in+he aim o! aggregate planning is to set overall output levels in
the near to medium !uture in the !ace o! !luctuating or uncertainthe near to medium !uture in the !ace o! !luctuating or uncertaindemands.demands.
Aggregate planning might see, to in!luence demand as -ell as Aggregate planning might see, to in!luence demand as -ell assupply.supply.
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Aggregate Planning Aggregate Planning
Objective is to minimi)e cost over theObjective is to minimi)e cost over the planning period by adjusting planning period by adjusting
Production ratesProduction rates
Labor levelsLabor levels
#nventory levels#nventory levels
Overtime -or, Overtime -or,
%ubcontracting rates%ubcontracting rates
Other controllable variablesOther controllable variables
etermine the uantity and timing o!etermine the uantity and timing o! production !or the immediate !uture production !or the immediate !uture
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Aggregate Planning Aggregate Planning
A logical overall unit !or measuring sales A logical overall unit !or measuring sales
and output and output A !orecast o! demand !or an intermediate A !orecast o! demand !or an intermediate
planning period in these aggregate terms planning period in these aggregate terms
A method !or determining costs A method !or determining costs
A model that combines !orecasts and A model that combines !orecasts andcosts so that scheduling decisions cancosts so that scheduling decisions canbe made !or the planning period be made !or the planning period
/euired !or aggregate planning /euired !or aggregate planning
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+he Planning Process+he Planning Process
Figure 13.1Figure 13.1
Long0range plansover one year2/esearch and evelopment e- product plansCapital investments4acility location5e*pansion
#ntermediate0range plans3 to 16 months2%ales planning Production planning and budgeting %etting employment( inventory(
subcontracting levels Analy)ing operating plans
%hort0range plans
up to 3 months27ob assignmentsOrdering 7ob scheduling ispatching OvertimePart0time help
+ope*ecutives
Operationsmanagers
Operationsmanagers(supervisors(!oremen
/esponsibility /esponsibility Planning tas,s and hori)onPlanning tas,s and hori)on
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Aggregate Planning Aggregate Planning
8uarter 18uarter 1
7an7an 4eb4eb 9ar 9ar
1&( 1&( 1"( 1"( 11( 11(
8uarter " 8uarter "
Apr Apr 9ay 9ay 7un7un
1( 1( 13( 13( 1&( 1&(
8uarter 38uarter 3
7ul 7ul Aug Aug %ep%ep
16( 16( 1&( 1&( 1$( 1$(
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Aggregate AggregatePlanning Planning
Figure 13.2Figure 13.2
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Aggregate Planning Aggregate Planning
Combines appropriate resourcesCombines appropriate resourcesinto general termsinto general terms
Part o! a larger production planningPart o! a larger production planningsystemsystem
isaggregation brea,s the planisaggregation brea,s the plan
do-n into greater detail do-n into greater detail isaggregation results in a masterisaggregation results in a master
production schedule production schedule
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Aggregate Planning Aggregate Planning
%trategies%trategies1.1. 'se inventories to absorb changes in'se inventories to absorb changes in
demand demand
".". Accommodate changes by varying Accommodate changes by varying-or,!orce si)e-or,!orce si)e
3.3. 'se part0timers( overtime( or idle time to'se part0timers( overtime( or idle time toabsorb changesabsorb changes
$.$. 'se subcontractors and maintain a stable'se subcontractors and maintain a stable-or,!orce-or,!orce
&.&. Change prices or other !actors toChange prices or other !actors to
in!luence demand in!luence demand
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emand Optionsemand Options
#n!luencing demand #n!luencing demand
'se advertising or promotion to'se advertising or promotion toincrease demand in lo- periodsincrease demand in lo- periods
Attempt to shi!t Attempt to shi!tdemand to slo-demand to slo-
periods periods
9ay not be9ay not besu!!icient tosu!!icient tobalance demandbalance demandand capacity and capacity
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emand Optionsemand Options
;ac, ordering during high0;ac, ordering during high0demand periodsdemand periods
/euires customers to -ait !or an/euires customers to -ait !or anorder -ithout loss o! good-ill ororder -ithout loss o! good-ill orthe order the order
9ost e!!ective -hen there are !e-9ost e!!ective -hen there are !e-
i! any substitutes !or the producti! any substitutes !or the productor serviceor service
O!ten results in lost salesO!ten results in lost sales
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emand Optionsemand Options
Counterseasonal product andCounterseasonal product andservice mi*ing service mi*ing
evelop a product mi* o!evelop a product mi* o!counterseasonal itemscounterseasonal items
9ay lead to products or services9ay lead to products or servicesoutside the company
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Aggregate Planning Options Aggregate Planning Options
Table 13.1Table 13.1
OptionOption Advantages Advantages isadvantagesisadvantages %ome Comments%ome Comments
ChangingChanginginventoryinventorylevelslevels
Changes inChanges inhumanhumanresources areresources aregradual orgradual or
none= no abruptnone= no abrupt production productionchanges.changes.
#nventory#nventoryholding costholding costmay increase.may increase.%hortages may%hortages may
result in lostresult in lostsales.sales.
Applies mainly to Applies mainly to production( not production( notservice(service(operations.operations.
>arying>arying-or,!orce-or,!orce
si)e bysi)e byhiring orhiring orlayo!!slayo!!s
Avoids the costs Avoids the costso! othero! other
alternatives.alternatives.
?iring( layo!!(?iring( layo!!(and trainingand training
costs may becosts may besigni!icant.signi!icant.
'sed -here si)e'sed -here si)eo! labor pool iso! labor pool is
large.large.
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Aggregate Planning Options Aggregate Planning Options
Table 13.1Table 13.1
OptionOption Advantages Advantages isadvantagesisadvantages %ome Comments%ome Comments
>arying>arying production productionratesratesthroughthrough
overtime orovertime oridle timeidle time
9atches9atchesseasonalseasonal!luctuations!luctuations-ithout hiring5-ithout hiring5
training costs.training costs.
OvertimeOvertime premiums= tired premiums= tired-or,ers= may-or,ers= maynot meetnot meet
demand.demand.
Allo-s !le*ibility Allo-s !le*ibility-ithin the-ithin theaggregate plan.aggregate plan.
%ub0 %ub0 contracting contracting
PermitsPermits!le*ibility and!le*ibility andsmoothing o!smoothing o!
the !irm
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Aggregate Planning Options Aggregate Planning Options
Table 13.1Table 13.1
OptionOption Advantages Advantages isadvantagesisadvantages %ome Comments%ome Comments
'sing part0 'sing part0 timetime-or,ers-or,ers
#s less costly#s less costlyand moreand more!le*ible than!le*ible than!ull0time!ull0time
-or,ers.-or,ers.
?igh turnover5?igh turnover5training costs=training costs=uality su!!ers=uality su!!ers=schedulingscheduling
di!!icult.di!!icult.
@ood !or@ood !oruns,illed jobs inuns,illed jobs inareas -ith largeareas -ith largetemporary labortemporary labor
pools. pools.
#n!luencing#n!luencingdemand demand
+ries to use+ries to usee*cesse*cesscapacity.capacity.iscounts dra-iscounts dra-
ne- customers.ne- customers.
'ncertainty in'ncertainty indemand. ?arddemand. ?ardto matchto matchdemand todemand to
supply e*actly.supply e*actly.
CreatesCreatesmar,etingmar,etingideas.ideas.Overboo,ingOverboo,ing
used in someused in somebusinesses.businesses.
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Aggregate Planning Options Aggregate Planning Options
Table 13.1Table 13.1
OptionOption Advantages Advantages isadvantagesisadvantages %ome Comments%ome Comments
;ac,;ac,orderingorderingduringduringhigh0 high0
demanddemand periods periods
9ay avoid9ay avoidovertime.overtime.eeps capacityeeps capacityconstant.constant.
Customer mustCustomer mustbe -illing tobe -illing to-ait( but-ait( butgood-ill is lost.good-ill is lost.
9any companies9any companiesbac, order.bac, order.
Counter0 Counter0 seasonalseasonal product product
and serviceand servicemi*ing mi*ing
4ully utili)es4ully utili)esresources=resources=allo-s stableallo-s stable
-or,!orce.-or,!orce.
9ay reuire9ay reuires,ills ors,ills oreuipmenteuipment
outside theoutside the!irm
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9ethods !or Aggregate9ethods !or Aggregate
Planning Planning A mi*ed strategy may be the best A mi*ed strategy may be the best
-ay to achieve minimum costs-ay to achieve minimum costs
+here are many possible mi*ed+here are many possible mi*edstrategiesstrategies
4inding the optimal plan is not4inding the optimal plan is notal-ays possibleal-ays possible
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9i*ing Options to9i*ing Options to
evelop a Planevelop a Plan Chase strategy Chase strategy
9atch output rates to demand9atch output rates to demand
!orecast !or each period !orecast !or each period
>ary -or,!orce levels or vary>ary -or,!orce levels or vary production rate production rate
4avored by many service4avored by many serviceorgani)ationsorgani)ations
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9i*ing Options to9i*ing Options to
evelop a Planevelop a Plan Level strategy Level strategy
aily production is uni!ormaily production is uni!orm
'se inventory or idle time as bu!!er 'se inventory or idle time as bu!!er
%table production leads to better%table production leads to betteruality and productivity uality and productivity
%ome combination o! capacity%ome combination o! capacityoptions( a mi*ed strategy( might beoptions( a mi*ed strategy( might bethe best solutionthe best solution
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@raphical 9ethods@raphical 9ethods
Popular techniuesPopular techniues
Basy to understand and useBasy to understand and use
+rial0and0error approaches that do+rial0and0error approaches that donot guarantee an optimal solutionnot guarantee an optimal solution
/euire only limited computations/euire only limited computations
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@raphical 9ethods@raphical 9ethods
1.1. etermine the demand !or each period etermine the demand !or each period
".". etermine the capacity !or regular time(etermine the capacity !or regular time(
overtime( and subcontracting each period overtime( and subcontracting each period
3.3. 4ind labor costs( hiring and layo!! costs(4ind labor costs( hiring and layo!! costs(and inventory holding costsand inventory holding costs
$.$. Consider company policy on -or,ers andConsider company policy on -or,ers andstoc, levelsstoc, levels
&.&. evelop alternative plans and e*amineevelop alternative plans and e*aminetheir total coststheir total costs
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/oo!ing %upplier B*ample 1/oo!ing %upplier B*ample 1
Table 13.2Table 13.2
9onth9onth B*pected emand B*pected emand ProductionProduction
aysaysemand Per ayemand Per ay
computed2computed2
7an7an 900900 2222 4141
4eb4eb 700700 1818 3939
9ar 9ar 800800 2121 3838 Apr Apr 1,2001,200 2121 5757
9ay 9ay 1,5001,500 2222 6868
7une7une 1,1001,100 2020 5555
6,2006,200 124124
= = 50= = 50 units per day units per day 6,2006,200
124124
Average Averagereuirement reuirement
+otal e*pected demand +otal e*pected demand
umber o! production daysumber o! production days
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/oo!ing %upplier B*ample 1/oo!ing %upplier B*ample 1
Figure 13.3Figure 13.3
DD E
FF E
&& E
$$ E
33 E
E
7an7an 4eb4eb 9ar 9ar Apr Apr 9ay 9ay 7une7une 9onth9onth
"" "" 16 16 "1"1 "1"1 "" "" " " umber o! umber o! -or,ing days-or,ing days
P
r o d u c t i o n r a t e p
e r - o r , i n g d a y
P
r o d u c t i o n r a t e p
e r - o r , i n g d a y
Level production using averageLevel production using averagemonthly !orecast demand monthly !orecast demand
4orecast demand 4orecast demand
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/oo!ing %upplier B*ample " /oo!ing %upplier B*ample "
Table 13.3Table 13.3
Cost #n!ormationCost #n!ormation
#nventory carrying cost #nventory carrying cost $ 5$ 5 per unit per month per unit per month
%ubcontracting cost per unit %ubcontracting cost per unit $10$10 per unit per unit
Average pay rate Average pay rate $ 5$ 5 per hour per hour ($40($40 per day per day ))
Overtime pay rateOvertime pay rate $ 7$ 7 per hour per hour((aboveabove 88 hours per day hours per day ))
Labor0hours to produce a unit Labor0hours to produce a unit 1.61.6 hours per unit hours per unit
Cost o! increasing daily production rateCost o! increasing daily production ratehiring and training2hiring and training2
$300$300 per unit per unit
Cost o! decreasing daily production rateCost o! decreasing daily production ratelayo!!s2layo!!s2
$600$600 per unit per unit
Plan 1 E con s
tant -or, ! orce
Plan 1 E con s
tant -or, ! orce
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/oo!ing %upplier B*ample " /oo!ing %upplier B*ample "
Table 13.3Table 13.3
Cost #n!ormationCost #n!ormation
#nventory carry cost #nventory carry cost $ 5$ 5 per unit per month per unit per month
%ubcontracting cost per unit %ubcontracting cost per unit $10$10 per unit per unit
Average pay rate Average pay rate $ 5$ 5 per hour per hour ($40($40 per day per day ))
Overtime pay rateOvertime pay rate $ 7$ 7 per hour per hour((aboveabove 88 hours per day hours per day ))
Labor0hours to produce a unit Labor0hours to produce a unit 1.61.6 hours per unit hours per unit
Cost o! increasing daily production rateCost o! increasing daily production ratehiring and training2hiring and training2
$300$300 per unit per unit
Cost o! decreasing daily production rateCost o! decreasing daily production ratelayo!!s2layo!!s2
$600$600 per unit per unit
Plan 1 E con s
tant -or, ! orce
Plan 1 E con s
tant -or, ! orce
9onthProduction at
50 'nits per ay emand4orecast
9onthly#nventoryChange
Bnding#nventory
7an 1,100 900 +200 200
4eb 900 700 +200 400
9ar 1,050 800 +250 650
Apr 1,050 1,200 -150 500
9ay 1,100 1,500 -400 100
7une 1,000 1,100 -100 0
1,850
+otal units o! inventory carried over !rom onemonth to the ne*t = 1,850 units
Wor,!orce reuired to produce 50 units per day = 10 -or,ers
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/oo!ing %upplier B*ample " /oo!ing %upplier B*ample "
Table 13.3Table 13.3
Cost #n!ormationCost #n!ormation
#nventory carry cost #nventory carry cost $ 5$ 5 per unit per month per unit per month
%ubcontracting cost per unit %ubcontracting cost per unit $10$10 per unit per unit
Average pay rate Average pay rate $ 5$ 5 per hour per hour ($40($40 per day per day ))
Overtime pay rateOvertime pay rate $ 7$ 7 per hour per hour((aboveabove 88 hours per day hours per day ))
Labor0hours to produce a unit Labor0hours to produce a unit 1.61.6 hours per unit hours per unit
Cost o! increasing daily production rateCost o! increasing daily production ratehiring and training2hiring and training2
$300$300 per unit per unit
Cost o! decreasing daily production rateCost o! decreasing daily production ratelayo!!s2layo!!s2
$600$600 per unit per unit
9onthProduction at
50 'nits per ay emand4orecast
9onthly#nventoryChange
Bnding#nventory
7an 1,100 900 +200 200
4eb 900 700 +200 400
9ar 1,050 800 +250 650
Apr 1,050 1,200 -150 500
9ay 1,100 1,500 -400 100
7une 1,000 1,100 -100 0
1,850
+otal units o! inventory carried over !rom onemonth to the ne*t = 1,850 units
Wor,!orce reuired to produce 50 units per day = 10 -or,ers
Costs Calculations
#nventory carrying $9,250 (= 1,850 units carried * $5 per unit )
/egular0time labor 49,600 (= 10 -or,ers * $40 per
day * 124 days)Other costs overtime(
hiring( layo!!s(subcontracting2 0
+otal cost $58,850
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/oo!ing %upplier B*ample " /oo!ing %upplier B*ample "
Figure 13.4Figure 13.4
C u m u l a t i v e d e m
a n d u n i t s
C u m u l a t i v e d e m
a n d u n i t s
D(D( E
F(F( E
&(&( E
$($( E
3(3( E
"( E
1( E
E
7an7an 4eb4eb 9ar 9ar Apr Apr 9ay 9ay 7une7une
Cumulative !orecastCumulative !orecast
reuirementsreuirements
Cumulative levelCumulative level production using production using
average monthlyaverage monthly!orecast!orecast
reuirementsreuirements
/eduction/eductiono! inventory o! inventory
B*cess inventory B*cess inventory
F(" unitsF(" units
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/oo!ing %upplier B*ample 3/oo!ing %upplier B*ample 3
Table 13.2Table 13.2
9onth9onth B*pected emand B*pected emand ProductionProduction
aysaysemand Per ayemand Per ay
computed2computed2
7an7an 900900 2222 4141
4eb4eb 700700 1818 3939
9ar 9ar
800800
2121
3838
Apr Apr 1,2001,200 2121 5757
9ay 9ay 1,5001,500 2222 6868
7une7une 1,1001,100 2020 5555
6,2006,200 124124
9inimum reuirement 9inimum reuirement = 38= 38 units per day units per day
Plan " E subc
ontracting
Plan " E subc
ontracting
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/oo!ing %upplier B*ample 3/oo!ing %upplier B*ample 3
DD E
FF E
&& E
$$ E
33 E
E
7an7an 4eb4eb 9ar 9ar Apr Apr 9ay 9ay 7une7une 9onth9onth
"" "" 16 16 "1"1 "1"1 "" "" " " umber o! umber o! -or,ing days-or,ing days
P
r o d u c t i o n r a t e p
e r - o r , i n g d a y
P r o d u c t i o n r a t e p
e r - o r , i n g d a y
Level productionLevel productionusing lo-estusing lo-est
monthly !orecastmonthly !orecast
demand demand
4orecast demand 4orecast demand
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/oo!ing %upplier B*ample 3/oo!ing %upplier B*ample 3
Table 13.3Table 13.3
Cost #n!ormationCost #n!ormation
#nventory carrying cost #nventory carrying cost $ 5$ 5 per unit per month per unit per month
%ubcontracting cost per unit %ubcontracting cost per unit $10$10 per unit per unit
Average pay rate Average pay rate $ 5$ 5 per hour per hour ($40($40 per day per day ))
Overtime pay rateOvertime pay rate $ 7$ 7 per hour per hour((aboveabove 88 hours per day hours per day ))
Labor0hours to produce a unit Labor0hours to produce a unit 1.61.6 hours per unit hours per unit
Cost o! increasing daily production rateCost o! increasing daily production ratehiring and training2hiring and training2
$300$300 per unit per unit
Cost o! decreasing daily production rateCost o! decreasing daily production ratelayo!!s2layo!!s2
$600$600 per unit per unit
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/oo!ing %upplier B*ample 3/oo!ing %upplier B*ample 3
Table 13.3Table 13.3
Cost #n!ormationCost #n!ormation
#nventory carry cost #nventory carry cost $ 5$ 5 per unit per month per unit per month
%ubcontracting cost per unit %ubcontracting cost per unit $10$10 per unit per unit
Average pay rate Average pay rate $ 5$ 5 per hour per hour ($40($40 per day per day ))
Overtime pay rateOvertime pay rate $ 7$ 7 per hour per hour((aboveabove 88 hours per day hours per day ))
Labor0hours to produce a unit Labor0hours to produce a unit 1.61.6 hours per unit hours per unit
Cost o! increasing daily production rateCost o! increasing daily production ratehiring and training2hiring and training2
$300$300 per unit per unit
Cost o! decreasing daily production rateCost o! decreasing daily production ratelayo!!s2layo!!s2
$600$600 per unit per unit
#n0house production = 38 units per day * 124 days
= 4,712 units
%ubcontract units = 6,200 - 4,712= 1,488 units
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Table 13.3Table 13.3
Cost #n!ormationCost #n!ormation
#nventory carry cost #nventory carry cost $ 5$ 5 per unit per month per unit per month
%ubcontracting cost per unit %ubcontracting cost per unit $10$10 per unit per unit
Average pay rate Average pay rate $ 5$ 5 per hour per hour ($40($40 per day per day ))
Overtime pay rateOvertime pay rate $ 7$ 7 per hour per hour((aboveabove 88 hours per day hours per day ))
Labor0hours to produce a unit Labor0hours to produce a unit 1.61.6 hours per unit hours per unit
Cost o! increasing daily production rateCost o! increasing daily production ratehiring and training2hiring and training2
$300$300 per unit per unit
Cost o! decreasing daily production rateCost o! decreasing daily production ratelayo!!s2layo!!s2
$600$600 per unit per unit
/oo!ing %upplier B*ample 3/oo!ing %upplier B*ample 3
#n0house production = 38 units per day * 124 days
= 4,712 units
%ubcontract units = 6,200 - 4,712= 1,488 units
Costs Calculations
/egular0time labor $37,696 (= 7.6 -or,ers x $40 per day x 124 days)
%ubcontracting 14,880 (= 1,488 units x $10 perunit )
+otal cost $52,576
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/oo!ing %upplier B*ample $/oo!ing %upplier B*ample $
Table 13.2Table 13.2
9onth9onth B*pected emand B*pected emand ProductionProduction
aysaysemand Per ayemand Per ay
computed2computed2
7an7an 900900 2222 4141
4eb4eb 700700 1818 3939
9ar 9ar 800800 2121 3838
Apr Apr 1,2001,200 2121 5757
9ay 9ay 1,5001,500 2222 6868
7une7une 1,1001,100 2020 5555
6,2006,200 124124
Production B*pected emand Production B*pected emand
Plan 3 E hirin
g and ! iring
Plan 3 E hirin
g and ! iring
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/oo!ing %upplier B*ample $/oo!ing %upplier B*ample $
DD E
FF E
&& E
$$ E
33 E
E
7an7an 4eb4eb 9ar 9ar Apr Apr 9ay 9ay 7une7une 9onth9onth
"" "" 16 16 "1"1 "1"1 "" "" " " umber o! umber o! -or,ing days-or,ing days
P r o d u c t i o n r a t e p
e r - o r , i n g d a y
P r o d u c t i o n r a t e p
e r - o r , i n g d a y
4orecast demand and4orecast demand and
monthly productionmonthly production
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/oo!ing %upplier B*ample $/oo!ing %upplier B*ample $
Table 13.3Table 13.3
Cost #n!ormationCost #n!ormation
#nventory carrying cost #nventory carrying cost $ 5$ 5 per unit per month per unit per month
%ubcontracting cost per unit %ubcontracting cost per unit $10$10 per unit per unit
Average pay rate Average pay rate $ 5$ 5 per hour per hour ($40($40 per day per day ))
Overtime pay rateOvertime pay rate $ 7$ 7 per hour per hour((aboveabove 88 hours per day hours per day ))
Labor0hours to produce a unit Labor0hours to produce a unit 1.61.6 hours per unit hours per unit
Cost o! increasing daily production rateCost o! increasing daily production ratehiring and training2hiring and training2
$300$300 per unit per unit
Cost o! decreasing daily production rateCost o! decreasing daily production ratelayo!!s2layo!!s2
$600$600 per unit per unit
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/oo!ing %upplier B*ample $/oo!ing %upplier B*ample $
Table 13.3Table 13.3
Cost #n!ormationCost #n!ormation
#nventory carrying cost #nventory carrying cost $ 5$ 5 per unit per month per unit per month
%ubcontracting cost per unit %ubcontracting cost per unit $10$10 per unit per unit
Average pay rate Average pay rate $ 5$ 5 per hour per hour ($40($40 per day per day ))
Overtime pay rateOvertime pay rate $ 7$ 7 per hour per hour((aboveabove 88 hours per day hours per day ))
Labor0hours to produce a unit Labor0hours to produce a unit 1.61.6 hours per unit hours per unit
Cost o! increasing daily production rateCost o! increasing daily production ratehiring and training2hiring and training2
$300$300 per unit per unit
Cost o! decreasing daily production rateCost o! decreasing daily production ratelayo!!s2layo!!s2
$600$600 per unit per unit
9onth4orecast(units)
ailyProd/ate
;asicProduction
Cost(demand *
1.6 hrs5unit *$5 5hr )
B*tra Cost o!#ncreasingProduction(hiring cost )
B*tra Cost o!ecreasingProduction(layo!! cost ) +otal Cost
7an 900 41 $ 7,200 $ 7,200
4eb 700 39 5,600 $1,200(= 2 x $600)
6,800
9ar 800 38 6,400 $600
(= 1 x $600)7,000
Apr 1,200 57 9,600$5,700
(= 19 x $300) 15,300
9ay 1,500 68 12,000 $3,300(= 11 x $300) 15,300
7une 1,100 55 8,800 $7,800
(= 13 x $600)16,600
$49,600 $9,000 $9,600 $68,200
Table 13.4Table 13.4
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Comparison o! +hree PlansComparison o! +hree Plans
Table 13.5Table 13.5
Cost Cost Plan 1Plan 1 Plan " Plan " Plan 3Plan 3
#nventory carrying #nventory carrying $ 9,250$ 9,250 $ 0$ 0 $ 0$ 0
/egular labor /egular labor 49,60049,600 37,69637,696 49,60049,600
Overtime labor Overtime labor 00 00 00
?iring ?iring 00 00 9,0009,000
Layo!!sLayo!!s 00 00 9,6009,600
%ubcontracting %ubcontracting 00 14,88014,880 00+otal cost +otal cost $58,850$58,850 $52,576$52,576 $68,200$68,200
Plan " is the lo-est cost optionPlan " is the lo-est cost option
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9athematical Approaches9athematical Approaches
'se!ul !or generating strategies'se!ul !or generating strategies
+ransportation 9ethod o! Linear+ransportation 9ethod o! LinearProgramming Programming
Produces an optimal planProduces an optimal plan
9anagement Coe!!icients 9odel 9anagement Coe!!icients 9odel
9odel built around manager
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+ransportation 9ethod +ransportation 9ethod
Table 13.6Table 13.6
CostsCosts/egular time/egular time $40$40 per tire per tire
OvertimeOvertime $50$50 per tire per tire
%ubcontracting %ubcontracting $70$70 per tire per tire
Carrying Carrying $ 2$ 2 per tire per month per tire per month
%ales Period %ales Period 9ar 9ar Apr Apr 9ay 9ay
emand emand 800800 1,0001,000 750750
Capacity:Capacity:
/egular /egular 700700 700700 700700 OvertimeOvertime 5050 5050 5050
%ubcontracting %ubcontracting 150150 150150 130130
;eginning inventory ;eginning inventory 100100 tirestires
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+ransportation B*ample+ransportation B*ample
#mportant points#mportant points
1.1. Carrying costs areCarrying costs are $2$2 5tire5month. #! 5tire5month. #!goods are made in one period and heldgoods are made in one period and held
over to the ne*t( holding costs areover to the ne*t( holding costs areincurred incurred
".". %upply must eual demand( so a%upply must eual demand( so adummy column called Gunuseddummy column called Gunused
capacityH is added capacityH is added
3.3. ;ecause bac, ordering is not viable in;ecause bac, ordering is not viable inthis e*ample( cells that might be used tothis e*ample( cells that might be used to
satis!y earlier demand are not availablesatis!y earlier demand are not available
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+ransportation B*ample+ransportation B*ample
#mportant points#mportant points
$.$. 8uantities in each column designate the8uantities in each column designate thelevels o! inventory needed to meetlevels o! inventory needed to meet
demand reuirementsdemand reuirements&.&. #n general( production should be#n general( production should be
allocated to the lo-est cost cellallocated to the lo-est cost cellavailable -ithout e*ceeding unusedavailable -ithout e*ceeding unused
capacity in the ro- or demand in thecapacity in the ro- or demand in thecolumncolumn
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+ransportation+ransportation
B*ampleB*ample
Table 13.7Table 13.7
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9anagement Coe!!icients9anagement Coe!!icients
9odel 9odel ;uilds a model based on manager
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Other 9odelsOther 9odels
Linear ecision /uleLinear ecision /ule
9inimi)es costs using uadratic cost curves9inimi)es costs using uadratic cost curves
Operates over a particular time period Operates over a particular time period
%imulation%imulation
'ses a search procedure to try di!!erent'ses a search procedure to try di!!erent
combinations o! variablescombinations o! variables evelops !easible but not necessarily optimalevelops !easible but not necessarily optimal
solutionssolutions
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%ummary o! Aggregate%ummary o! AggregatePlanning 9ethodsPlanning 9ethods
+echniues+echniues%olution%olution
Approaches Approaches #mportant Aspects#mportant Aspects
@raphical @raphical
methodsmethods
+rial and+rial and
error error
%imple to understand and%imple to understand and
easy to use. 9anyeasy to use. 9anysolutions= one chosensolutions= one chosenmay not be optimal.may not be optimal.
+ransportation+ransportationmethod o! linearmethod o! linear
programming programming
Optimi)ationOptimi)ation LP so!t-are available=LP so!t-are available= permits sensitivity permits sensitivity
analysis and ne-analysis and ne-constraints= linearconstraints= linear!unctions may not be!unctions may not berealistic.realistic.
Table 13.8Table 13.8
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%ummary o! Aggregate%ummary o! AggregatePlanning 9ethodsPlanning 9ethods
+echniues+echniues%olution%olution
Approaches Approaches #mportant Aspects#mportant Aspects
9anagement9anagement
coe!!icientscoe!!icientsmodel model
?euristic ?euristic %imple( easy to implement=%imple( easy to implement=
tries to mimic manager
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Aggregate Planning in Aggregate Planning in
%ervices%ervicesControlling the cost o! labor is critical Controlling the cost o! labor is critical
1.1. Accurate scheduling o! labor0hours to Accurate scheduling o! labor0hours toassure uic, response to customerassure uic, response to customerdemand demand
".". An on0call labor resource to cover An on0call labor resource to cover
une*pected demand une*pected demand 3.3. 4le*ibility o! individual -or,er s,ills4le*ibility o! individual -or,er s,ills
$.$. 4le*ibility in rate o! output or hours o!4le*ibility in rate o! output or hours o!-or, -or,
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4ive %ervice %cenarios4ive %ervice %cenarios
/estaurants/estaurants
%moothing the production%moothing the production process process
etermining the optimaletermining the optimal-or,!orce si)e-or,!orce si)e
?ospitals?ospitals/esponding to patient demand /esponding to patient demand
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4ive %ervice %cenarios4ive %ervice %cenarios
ational Chains o! %mall %erviceational Chains o! %mall %ervice4irms4irms
Planning done at national levelPlanning done at national leveland at local level and at local level
9iscellaneous %ervices9iscellaneous %ervices
Plan human resourcePlan human resourcereuirementsreuirements
9anage demand 9anage demand
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La- 4irm B*ampleLa- 4irm B*ample
Table 13.9Table 13.9
Labor0?ours /euired Labor0?ours /euired Capacity Constraints Capacity Constraints
"2"2 3232 $2$2 &2&2 F2F2
1212 4orecasts4orecasts 9a*imum9a*imum umber o! umber o!
Category o! Category o! ;est;est Li,ely Li,ely Worst Worst emand inemand in 8uali!ied 8uali!ied
Legal ;usinessLegal ;usiness hours2hours2 hours2hours2 hours2hours2 PeoplePeople Personnel Personnel
+rial -or, +rial -or, 1,8001,800 1,5001,500 1,2001,200 3.63.6 44
Legal researchLegal research 4,5004,500 4,0004,000 3,5003,500 9.09.0 3232
Corporate la- Corporate la- 8,0008,000 7,0007,000 6,5006,500 16.016.0 1515
/eal estate la- /eal estate la- 1,7001,700 1,5001,500 1,3001,300 3.43.4 66
Criminal la- Criminal la- 3,5003,500 3,0003,000 2,5002,500 7.07.0 1212
+otal hours+otal hours 19,50019,500 17,00017,000 15,00015,000La-yers needed La-yers needed 3939 3434 3030
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4ive %ervice %cenarios4ive %ervice %cenarios
Airline industry Airline industry
B*tremely comple* planningB*tremely comple* planning problem problem
#nvolves number o! !lights(#nvolves number o! !lights(number o! passengers( air andnumber o! passengers( air and
ground personnel( allocation o!ground personnel( allocation o!seats to !are classesseats to !are classes
/esources spread through the/esources spread through theentire systementire system
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Iield 9anagement Iield 9anagement
Allocating resources to customers at Allocating resources to customers at prices that -ill ma*imi)e yield or prices that -ill ma*imi)e yield orrevenuerevenue
1.1. %ervice or product can be sold in%ervice or product can be sold inadvance o! consumptionadvance o! consumption
".". emand !luctuatesemand !luctuates
3.3. Capacity is relatively !i*ed Capacity is relatively !i*ed $.$. emand can be segmented emand can be segmented
&.&. >ariable costs are lo- and !i*ed costs>ariable costs are lo- and !i*ed costs
are highare high
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emandemandCurveCurve
Iield 9anagement B*ampleIield 9anagement B*ample
Figure 13.5Figure 13.5
Passed0upcontribution
9oney le!ton the table
Potential customers e*ist -hoPotential customers e*ist -hoare -illing to pay more than theare -illing to pay more than the$15$15 variable cost o! the roomvariable cost o! the room
%ome customers -ho paid%ome customers -ho paid$150$150 -ere actually -illing-ere actually -illingto pay more !or the roomto pay more !or the room+otal +otal
$$ contributioncontribution == ((PricePrice)) * *
(50(50roomsrooms))== ($150 -($150 -$15)$15)
* * (50)(50)== $6,750$6,750 PricePrice
/oom sales/oom sales
1 1
& &
$150$150Price chargedPrice charged
!or room!or room
$15$15>ariable cost >ariable cost
o! roomo! room
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+otal J contribution +otal J contribution (1(1st pricest price) x 30) x 30 roomsrooms + (2+ (2nd nd !ri"e) x 30 r##% =!ri"e) x 30 r##% =
($100 - $15) x 30 + ($200 - $15) x 30 =($100 - $15) x 30 + ($200 - $15) x 30 =$2,550 + $5,550 = $8,100$2,550 + $5,550 = $8,100
emandemandCurveCurve
Iield 9anagement B*ampleIield 9anagement B*ample
Figure 13.6Figure 13.6
PricePrice
/oom sales/oom sales
1 1
F F
3 3
$100$100Price 1Price 1
!or room!or room
$200$200Price " Price "
!or room!or room
$15$15>ariable cost >ariable cost
o! roomo! room
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Iield 9anagement 9atri* Iield 9anagement 9atri*
u r a t i o n o ! u s e
' n p r e d i c t
a b l e
P r e d i c t a b l e
Price
+end to be !i*ed +end to be variable
8uadrant 1: 8uadrant ":
9ovies ?otels
%tadiums5arenas AirlinesConvention centers /ental cars?otel meeting space Cruise lines
8uadrant 3: 8uadrant $:
/estaurants Continuing care@ol! courses hospitals#nternet service
providers
Figure 13.7Figure 13.7
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9a,ing Iield 9anagement9a,ing Iield 9anagement
Wor, Wor, 1.1. 9ultiple pricing structures must9ultiple pricing structures must
be !easible and appear logical tobe !easible and appear logical tothe customer the customer
".". 4orecasts o! the use and duration4orecasts o! the use and durationo! useo! use
3.3. Changes in demand Changes in demand
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+han, Iou +han, Iou