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Chapter 4: 1AE (page 511)

Prepare an aggregate plan for the coming year, assuming that the sales forecast is perfect. Use the spreadsheet 鈥淏radford Manufacturing.鈥� In the spreadsheet, an area has been designated for your aggregate plan solution. Supply the number of packaging lines to run and the number of overtime hours for each quarter. You will need to set up the cost calculations in the spreadsheet. You may want to try using the Excel Solver to find a solution. Remember that your final solution needs an integer number of lines and an integer number of overtime hours for each quarter. (Solutions that require 8.9134 lines and 1.256 hours of overtime are not feasible.)

Short Answer

Expert verified

Aggregate planning is the method of defining, managing and assessing a company's estimated scope of activities

Step by step solution

01

Overall cost plan

First, we create the template including all the calculations for estimating the overall expenses of this problem using just 10 lines each period and therefore no overtime.

We computed the entire cost with a 13-week margin of error. We computed the finishing inventory as well as the departure from the stock objective, and then we began with the cost, which ended in the total balance.

As a result, the overall cost of the program is $5,258,957.

The excel sheet is shown below:

02

Solver approach explanation

The solver approachis used in the second stage to determine the best fit (the cheaper price of solution shifting open lines as well as overtime). There are no more than ten lines or no more than two extra hours each day. The overall cost of the scheme is $3,296,668 (10- 0, 10-0, 10-2, 10-1).

The excel sheet is shown below:

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Most popular questions from this chapter

Following are the process flow sequences for three products: A, B, and C. There are two bottleneck operations鈥攐n the first leg, and the fourth leg鈥攎arked with an X. Boxes represent processes, which may be either machine or manual. Suggest the location of the drum, buffer, and ropes.

Plan production for the next year. The demand forecast is spring, 20,000; summer, 10,000; fall, 15,000; winter, 18,000. At the beginning of spring, you have 70 workers and 1,000 units in inventory. The union contract specifies that you may lay off workers only once a year, at the beginning of summer. Also, you may hire new workers only at the end of summer to begin regular work in the fall. The number of workers laid off at the beginning of summer and the number hired at the end of summer should result in planned production levels for summer and fall that equal the demand forecasts for summer and fall, respectively. If demand exceeds supply, use overtime in spring only, which means that backorders could occur in winter. You are given these costs: hiring, \(100 per new worker; layoff, \)200 per worker laid off; holding, \(20 per unit-quarter; backorder cost, \)8 per unit; straight-time labor, \(10 per hour; over time, \)15 per hour. Productivity is 0.5 units per worker hour, eight hours per day, and 50 days per quarter. Find the total cost.

The MRP gross requirements for Item A are shown here for the next 10 weeks. Lead time for A is three weeks and setup cost is \(10. There is a carrying cost of \)0.01 per unit per week. The beginning inventory is 90 units.

Use the least total cost or the least unit cost lot-sizing method to determine when and for what quantity the first order should be released.

DAT, Inc. needs to develop an aggregate plan for its product line. Relevant data are

The forecast for next year is

Management prefers to keep a constant workforce and production level, absorbing variations in demand through inventory excesses and shortages. Demand not met is carried over to the following month. Develop an aggregate plan that will meet the demand and other conditions of the problem. Do not try to find the optimum; just find a good solution and state the procedure you might use to test for a better solution. Make any necessary assumptions.

What are the three primary data sources used by the MRP sources?
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