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    Aggregate Planning

    Prof Indrajit Mukherjee

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    Dependent and Independent Demand

    Independent Demand

    100 tables

    Dependent Demand

    100 x 1 tabletops

    100 x 4 table legs

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    Demand (Priority) Resources(Capacity)

    Why Plan?

    To satisfy customer demand, ensure the availability of resources

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    How do you cope with fluctuations indemand?

    Absorb

    Demand Adjust output tomatch demand

    Change

    demand

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    Absorb demand

    Keep output level

    Make tostock

    Makecustomer

    wait

    Part finished,

    Finished Goods, or

    Customer Inventory

    Queues

    Backlogs

    Haveexcess

    capacity

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    6

    Adjust output tomatch demand

    Hire Fire

    TemporaryLabour

    Lay-off

    Overtime

    Subcontract

    Short time

    3rd party work

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    Change demand

    Change pattern of demand

    Develop alternative products and/orservices

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    Advertising, pricing & product promotion(shifting demand into other time periods)

    Counter cyclicbut similar type of products.Similar products with negatively correlated

    demands, e.g. Snow blowers and Lawn

    Mowers. AC pumps and Heater pumps

    Partnering with suppliers to reduce informationdistortion along the supply chain

    Prior Reservation systems

    Demand Influencing Tactics

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    Ways of reconci ling capacity and demand

    Capacity

    Demand Demand

    Capacity

    Demand

    Capacity

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    Masterproduction

    schedule andMRP

    systems

    Detailedwork

    schedules

    Processplanning and

    capacitydecisions

    Aggregateplan for

    production

    A Holistic View of Planning

    Productdecisions

    Demandforecasts,

    orders

    Marketplaceand

    demand

    Research

    and

    technology

    Rawmaterialsavailable

    Externalcapacity

    (subcontractors)

    Workforce

    Inventoryon

    hand

    Capacity

    Demand

    Lecture Slides by Indrajit SJMSOM

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    Pull and push philosophies of planning andcontrol

    CENTRAL OPS. PLANNING AND CONTROL SYSTEM

    Workcentre

    DEMANDWorkcentre

    Workcentre

    Workcentre

    Instruction onwhat to makeand where to

    send it

    FORECASTOR

    PULL CONTROL

    Workcentre

    Workcentre

    Workcentre

    Workcentre DEMAND

    Request Request Request Request

    Delivery Delivery Delivery Delivery

    PUSH CONTROL

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    MRPII

    Manufacturing Resource Planning

    An expanded system for determining manufacturing

    resource requirements and for scheduling production.

    Make sure you have enough parts when you needthem

    Take future demands, factor in lead times (time

    phase), compare to on-hand inventory, place

    order

    Determine order size and timing

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    Core MRP II (Manufacturing Resource Planning)

    Aggregate ForecastAggregate Production

    Plan

    Detailed Forecast Master ProductionSchedule

    Rough-Cut CapacityPlanning

    Material

    RequirementsPlanning

    Capacity

    RequirementsPlanning

    Production Activity

    Control

    PASSENGER CAR FAMILY

    (Independent Demand)

    PASSENGER CAR MODE

    PASSENGER CAR PARTS

    (Dependent Demand)

    Resource requirement

    Planning

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    THE BIG PICTURE

    A production and/or purchasing

    schedule for Dependent DemandItems

    (parts / components)

    Material Requirement Plan(MRP)

    Master Production Schedule(MPS)

    A production schedule for IndependentDemand Items(end items / parent items)

    The demand for this stuffis dependent on

    the independent demand for this.

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    Production Plan

    Months January February

    Aggregate Production Plan 1,500 1,200(Shows the totalquantity of amplifiers)

    Weeks 1 2 3 4 5 6 7 8Master Production Schedule(Shows the specific type andquantity of amplifier to beproduced

    240-watt amplifier 100 100 100 100

    150-watt amplifier 500 500 450 45075-watt amplifier 300 100

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    Demand Patterns

    A pattern plus random influences Lumpy because of production lots

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    Dickson Chiu 2006

    Why demand becomes lumpy

    Time

    Time

    Orderpoint

    Orderpoint

    Le

    vel

    Level

    0

    0

    Production orderrelease

    Orderplacement

    (a) Field inventory (Finished product in warehouse)

    (b) Factory inventory (Finished product at plant)

    Time

    Order

    point

    Level

    0

    Purchase orderrelease

    (c) Component inventory (Supply stocks at plant)

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    Dependent vs Independent Demand

    Time

    Time Time

    Time

    Demand

    Demand

    Stable demand Lumpy demand

    Amountonhand

    Amounto

    nhand

    Safety stock

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    Historical Perspective

    mrp material

    requirements

    planning

    MRP II Manufacturing

    Resource Planning

    ERP- Enterprise

    Resource Planning

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    ERP

    Sales and

    distribution

    Financial

    accounting

    Financial

    controlling

    Fixed assets

    management

    Human resources Work flow Industry solutions Materials

    management

    Production

    planning (including

    MRP and CRP)

    Quality

    management Plant maintenance Project systems

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    Aggregate Plan

    *Aggregate Plan: A statement of a companys production rates,

    workforce levels, and inventory holding based on estimates

    of customer requirements and capacity limitations

    Service Industry Staffing Plan

    Manufacturing Industry Production Plan

    *Decisions made at a product family (not SKU) level

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    Product Classification Hierarchy

    Product typePump

    Family ASmall pumps

    Family BMedium pumps

    Family CLarge pumps

    S1 S2 S3 M1 M2 M3 L1 L2 L3

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    Aggregate

    Farm tools:

    Shovels

    Spades

    Forks

    Aggregate by similar characteristics

    Generic tool, call itShovel

    Same characteristics?

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    13-5

    Aggregate Planning: Objectives and

    Approaches

    Objectives:

    Match aggregate Capacity with aggregate Demand(Effectiveness)

    Minimize Costs (Efficiency)

    Demand(Priority)

    Supply (Capacity:(Machine, Manpower;Material and Products in

    Inventory)

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    Objectives of capacity planning and control

    Step 1 - Measure aggregatecapacity and demand.

    Step 2 - Identify the alternativecapacity plans.

    Step 3 - Choose the most

    appropr iate capacityplan.

    Time

    Estimate of current capacity

    Forecast demand

    Aggregatedoutput

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    Strategies for Adjusting Capacity

    Level production Producing at a constant rate and

    using inventory to absorb

    fluctuations in demand Chase demand

    Hiring and firing workers tomatch demand

    Subcontracting demand

    Maintaining resources forlowest-demand levels and subcontact in case of higherdemand

    Overtime and under-time Increasing or decreasing

    working hours

    Part-time workers Hiring part time workers to

    complete the work

    Backordering Providing the service or product

    at a later time period

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    Ways of reconci ling capacity and demand

    Level capacity

    Capacity

    Demand

    Chase demand

    Demand

    Capacity

    Demandmanagement

    Demand

    Capacity

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    Pure Aggregate Strategies

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    Example

    Youve started a newcompany. Youve developed 2

    production plans:

    Month Forecast Plan 1 Plan 2

    Jan 900 900 800Feb 700 700 800

    Mar 800 800 800

    You estimate 1 worker can make 100 units per month.

    Which plan do you use? How many workers do you hire?How do you meet demand?

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    Level Planning

    Month Expected Demand Production DaysDemand Per Day

    (computed)

    Jan 900 22 41

    Feb 700 18 39

    Mar 800 21 38

    Apr 1,200 21 57

    May 1,500 22 68

    June 1,100 20 55

    6,200 124

    = = 50 units per day6,200

    124

    Averagerequirement =

    Total expected demand

    Number of production days

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    Level Production Planning Strategy

    70

    60

    50

    40

    30

    0 Jan Feb Mar Apr May June = Month

    22 18 21 21 22 20 = Number of working days

    Productionratep

    erworkingday

    Level product ion using averagemonthly forecast demand

    Forecast demand

    Lecture Slides by Indrajit SJMSOM

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    Aggregate Production Planning

    Production rate: quantity of product produced perunit of time (autos/day).

    Workforce level: number of workers required to

    meet a specific level of output.

    Ending Inventory Position: unsold units carried

    over from one period to the next.

    Ending inventory for any period = opening inventory + product ion demand= _____ + _____ ____= _____ units

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    Aggregate Planning

    Aggregate Plans(1) Production Planning

    (2) Resource Requirement planning [e.g., Labor, material] Plan

    (Typically these two are generated simultaneously)

    Purpose is to specify the optimal combination of production rate,

    the workforce level, and inventory-on-hand

    Given the demand forecast Ft for each period t in the planninghorizon over T periods, determine the production rate Pt,

    Inventory level It, and workforce level Wt for periods t = 1, 2, , T,

    that minimizes the relevant costs over the planning horizon (T).

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    Aggregate Planning Approach

    1. Trial and Error Approach

    2. Mathematical Approaches

    a) Linear Programming

    b) Search Heuristics

    Lecture Slides by Indrajit SJMSOM

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    The Aggregate Production Plan

    Consider the following aggregate demand forecast:

    The plan is stated in the common unit of capacity direct labor

    hours

    Period Q1 Q2 Q3 Q4

    Forecasted Demand (D) 5,000 0 20,000 5,000

    Aggregate Production (AP)

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    Suppose we want to try to match demand:

    Period Q1 Q2 Q3 Q4Forecasted Demand (D) 5,000 0 20,000 5,000

    Aggregate Production (AP) 5,000 0 20,000 5,000

    The Aggregate Chase ProductionPlan

    Lecture Slides by Indrajit SJMSOM

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    Costs of Maintaining and Changing Production

    Levels

    Costs of keeping production steady:

    Cc -- Inventory Holding cost ($ / unit / quarter)

    Cb -- Backorder cost ($ / unit / quarter)

    Costs of changing production

    CH -- Hiring cost ($ / Worker) CF -- Firing cost ($ / Worker)

    Also need to worry about:

    Cw -- Wage rate ($/unit)

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    Projected Available Balance is simply the estimated ending

    inventory for each period

    Period Q1 Q2 Q3 Q4Forecasted Demand (D) 5,000 0 20,000 5,000

    Aggregate Production (AP) 5,000 0 20,000 5,000

    Projected Available Balance (EI) 0 0 0 0 0

    Workers 10

    The Aggregate Production Plan

    Lecture Slides by Indrajit SJMSOM

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    The # workers needed is based on the planned production and

    average worker productivity here, say 500 Item

    Produced/Worker/Quarter

    Period Q1 Q2 Q3 Q4Forecasted Demand (D) 5,000 0 20,000 5,000

    Aggregate Production (AP) 5,000 0 20,000 5,000

    Projected Available Balance (EI) 0 0 0 0 0

    Workers 10 10 0 40 10

    The Aggregate Production Plan

    Lecture Slides by Indrajit SJMSOM

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    The Aggregate Production Plan

    For our example, the wage rate is $ 10/Item

    Period Q1 Q2 Q3 Q4

    Forecasted Demand (D) 5,000 0 20,000 5,000

    Aggregate Production (AP) 5,000 0 20,000 5,000

    Projected Available Balance (EI) 0 0 0 0 0

    Workers 10 10 0 40 10

    Wages Cost 50,000 0 200,000 50,000

    Hiring Cost

    Firing CostHolding Cost

    Backorder Cost

    Total Cost

    Lecture Slides by Indrajit SJMSOM

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    The hiring and firing costs are $ 2000 and $ 500, respectively

    Period Q1 Q2 Q3 Q4

    Forecasted Demand (D) 5,000 0 20,000 5,000

    Aggregate Production (AP) 5,000 0 20,000 5,000

    Projected Available Balance (EI) 0 0 0 0 0

    Workers 10 10 0 40 10

    Wages Cost 50,000 0 200,000 50,000

    Hiring Cost 0 0 80,000 0

    Firing Cost 0 5,000 0 15,000

    Holding Cost

    Backorder Cost

    Total Cost

    The Aggregate Production Plan

    Lecture Slides by Indrajit SJMSOM

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    Holding and backorder costs are $ 1 and $ 3 /per unit/Quarter,

    respectively

    Period Q1 Q2 Q3 Q4Forecasted Demand (D) 5,000 0 20,000 5,000

    Aggregate Production (AP) 5,000 0 20,000 5,000

    Projected Available Balance (EI) 0 0 0 0 0

    Workers 10 10 0 40 10

    Wages Cost 50,000 0 200,000 50,000

    Hiring Cost 0 0 80,000 0

    Firing Cost 0 5,000 0 15,000

    Holding Cost 0 0 0 0

    Backorder Cost 0 0 0 0

    Total Cost

    The Aggregate Production Plan

    Lecture Slides by Indrajit SJMSOM

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    Which gives us a projected cost of $ 400,000 for the year

    Period Q1 Q2 Q3 Q4

    Forecasted Demand (D) 5,000 0 20,000 5,000

    Aggregate Production (AP) 5,000 0 20,000 5,000Projected Available Balance (EI) 0 0 0 0 0

    Workers 10 10 0 40 10

    Wages Cost 50,000 0 200,000 50,000

    Hiring Cost 0 0 80,000 0

    Firing Cost 0 5,000 0 15,000

    Holding Cost 0 0 0 0

    Backorder Cost 0 0 0 0

    Total Cost 50,000 5,000 280,000 65,000

    400,000

    The Aggregate Production Plan

    Lecture Slides by Indrajit SJMSOM

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    Chase, Level, & Mixed Strategies

    This example is the first of the two "pure" strategies

    Chase strategy: make only as much as you can sell

    The other pure strategy has a different cost structure Level strategy: maintain a steady production rate

    In reality, a firm's strategy will be a combination or mixed

    strategyof chase and level

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    A level strategy will absorb fluctuations in demand through

    fluctuations in inventory

    Period Q1 Q2 Q3 Q4

    Forecasted Demand (D) 5,000 0 20,000 5,000Aggregate Production (AP) 7,500 7,500 7,500 7,500

    Projected Available Balance (IP) 0

    Workers 10

    Wages Cost

    Hiring Cost

    Firing Cost

    Holding Cost

    Backorder Cost

    Total Cost

    The Aggregate Production Plan

    Lecture Slides by Indrajit SJMSOM

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    A level strategy will absorb fluctuations in demand through

    fluctuations in inventory

    Period Q1 Q2 Q3 Q4Forecasted Demand (D) 5,000 0 20,000 5,000

    Aggregate Production (AP) 7,500 7,500 7,500 7,500

    Projected Available Balance (IP) 0

    Workers 10 15 15 15 15

    Wages Cost

    Hiring CostFiring Cost

    Holding Cost

    Backorder Cost

    Total Cost

    The Aggregate Production Plan

    Lecture Slides by Indrajit SJMSOM

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    A level strategy will absorb fluctuations in demand through

    fluctuations in inventory

    Period Q1 Q2 Q3 Q4Forecasted Demand (D) 5,000 0 20,000 5,000

    Aggregate Production (AP) 7,500 7,500 7,500 7,500

    Projected Available Balance (EI) 0 2,500

    Workers 10 15 15 15 15

    Wages Cost

    Hiring CostFiring Cost

    Holding Cost

    Backorder Cost

    Total Cost

    The Aggregate Production Plan

    Lecture Slides by Indrajit SJMSOM

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    A level strategy will absorb fluctuations in demand through

    fluctuations in inventory

    Period Q1 Q2 Q3 Q4Forecasted Demand (D) 5,000 0 20,000 5,000

    Aggregate Production (AP) 7,500 7,500 7,500 7,500

    Projec ted Available Balance (IP) 0 2,500 10,000

    Workers 10 15 15 15 15

    Wages Cost

    Hiring CostFiring Cost

    Holding Cost

    Backorder Cost

    Total Cost

    The Aggregate Production Plan

    Lecture Slides by Indrajit SJMSOM

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    A level strategy will absorb fluctuations in demand through

    fluctuations in inventory

    Period Q1 Q2 Q3 Q4Forecasted Demand (D) 5,000 0 20,000 5,000

    Aggregate Production (AP) 7,500 7,500 7,500 7,500

    Projected Available Balance (IP) 0 2,500 10,000 -2,500 0

    Workers 10 15 15 15 15

    Wages Cost

    Hiring CostFiring Cost

    Holding Cost

    Backorder Cost

    Total Cost

    The Aggregate Production Plan

    Lecture Slides by Indrajit SJMSOM

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    A level strategy will absorb fluctuations in demand through

    fluctuations in inventory

    Period Q1 Q2 Q3 Q4Forecasted Demand (D) 5,000 0 20,000 5,000

    Aggregate Production (AP) 7,500 7,500 7,500 7,500

    Projected Av ailable Balance (IP) 0 2,500 10,000 -2,500 0

    Workers 10 15 15 15 15

    Wages Cost 75,000 75,000 75,000 75,000

    Hiring Cost 10,000 0 0 0

    Firing Cost 0 0 0 0

    Holding Cost 2,500 10,000 0 0

    Backorder Cost 0 0 7,500 0

    Total Cost 87,500 85,000 82,500 75,000

    330,000

    The Aggregate Production Plan

    Holding and backorder costs are Rs 1 and Rs 3/AP/Quarter, respectively

    Holding costs - charged on inventory at the end

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    Subcontracting

    Advantages:

    No excess capacity

    Level production

    Disadvantage:

    Costs of subcontracting

    Meet demand bysubcontracting

    Lecture Slides by Indrajit SJMSOM

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    Subcontracting Planning

    Month Expected DemandProduction

    DaysDemand Per Day

    (computed)

    Jan 900 22 41

    Feb 700 18 39

    Mar 800 21 38

    Apr 1,200 21 57May 1,500 22 68

    June 1,100 20 55

    6,200 124

    Minimum requirement = 38 units per day

    Lecture Slides by Indrajit SJMSOM

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    Subcontracting Planning

    70

    60

    50

    40

    30

    0 Jan Feb Mar Apr May June = Month

    22 18 21 21 22 20 = Number of working days

    Productionrateperworkingday

    Level productionusing lowest

    monthly forecast

    demand

    Forecast demand

    Combination or Mixed Strategy

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    Combination or Mixed Strategy

    Demand is matched to some extent , production is partially smoothenedIn peak period some subcontracting take place

    Mi d O i l S U i LPP

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    Mixed Optimal Strategy Using LPP

    Hiring cost = $100 per worker

    Firing cost = $500 per worker

    Inventory carrying cost = $0.50 pound per quarter/item

    Production per employee = 1,000 pounds per quarter

    Beginning work force = 100 workers

    QUARTER SALES FORECAST

    Spring 80,000

    Summer 50,000

    Fall 120,000

    Winter 150,000

    A candy company makes variety of candies in three factoriesworldwide. Its line of chocolate candies exhibit highly seasonal

    demand pattern with peak during winter, and valley during summer.Given the cost and quarterly sales forecast, determine a suitablecost effective production Plan.

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    General Linear Programming (LP) Model

    LP gives an optimal solution, but demand andcosts must be linear

    Let

    Wt= workforce size for period t Pt =units produced in period t

    It =units in inventory at the end of period t

    Ft =number of workers fired for period t

    Ht= number of workers hired for period t

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    whereH

    t= # hired for period t

    Ft

    = # fired for period tIt

    = inventory at end

    of period tP

    t= units produced

    in period tW

    t= workforce size

    for period t

    Minimize Z = $100 (H1 + H2 + H3 + H4)

    + $500 (F1 + F2 + F3 + F4)+ $0.50 (I1 + I2 + I3 + I4)

    Subject to

    P1 - I1 = 80,000 (1)

    Demand I1 + P2 - I2 = 50,000 (2)

    constraints I2 + P3 - I3 = 120,000 (3)I3 + P4 - I4 = 150,000 (4)

    Production 1000 W1 = P1 (5)

    constraints 1000 W2 = P2 (6)

    1000 W3 = P3 (7)

    1000 W4 = P4 (8)100 + H1 - F1 = W1 (9)

    labour/Work force W1 + H2 - F2 = W2 (10)

    constraints W2 + H3 - F3 = W3 (11)

    W3 + H4 - F4 = W4 (12)

    APP Mixed Optimal Strategy Using LPP

    G li d f l ti f A t

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    Generalized formulation for Aggregate

    Planning Problems using Linear Programming

    Dt the forecasts of demand for aggregate units for period t, t = 1 T

    nt number of units that can be made by one worker in period t

    CtP cost to produce one unit in period t

    CtW cost of one worker in period t

    Ct

    H cost to hire one worker in period t

    CtL cost to layoff one worker in period t

    CtI cost to hold one unit in inventory in period t

    CtB cost to backorder one unit in period t

    Wt number of workers available in period tPt number of units produced in period t

    It number of units held in the inventory at the end of period t

    Ht number of workers hired in period t

    Ft number of workers fired in period t

    known info

    decision variables

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    Solver

    Example LP Model Cost$32,00

    0

    Beg Wkforce 100 Beg Inv. 0 Firing cost $500Units/wker 1000 Inv. Cost $0.50 Hiring cost $100

    Qtr Demand Production Inventory Wkers Needed Wkers Hired

    Wkers

    Fired

    Demand

    Constraint

    Production

    Constraint

    Wkforce

    Constrai

    nt

    1 80,000 80,000 0 80 0 20 80,000 80,000 802 50,000 80,000 30,000 80 0 0 50,000 80,000 803 120,000 90,000 0 90 10 0 120,000 90,000 904 150,000 150,000 0 150 60 0 150,000 150,000 150

    Total 400,000 400,000 30,000 70 20

    Note: LP approach ignores Economic Lot Sizing policy for production run

    Solve

    APP (Capacity Constraint) by the Transportation

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    APP (Capacity Constraint) by the TransportationMethod (A Special form of LPP)

    1 900 1000 100 500

    2 1500 1200 150 5003 1600 1300 200 500

    4 3000 1300 200 500

    Regular production cost per unit $20

    Overtime production cost per unit $25Subcontracting cost per unit $28

    Inventory holding cost per unit per period $3

    Beginning inventory 300 units

    Unused capacity cost $0

    No Backorder Allowed (in this example)

    EXPECTED REGULAR OVERTIME SUBCONTRACT

    QUARTER DEMAND CAPACITY CAPACITY CAPACITY

    (Assumed Cost & Constraint fuct ion are Linearand nobackorderor change in level of worker)

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    Network Diagram

    Source 1

    Source 2

    Source 3

    Source n

    .

    .

    .

    Destination 1

    Destination 2

    Destination 3

    Destination m

    .

    .

    .

    Supply

    S1

    S2

    S3

    Sn

    Demand

    D1

    D2

    D3

    Dm

    c11

    c12c13c1m

    c21c22

    c23c2mc31

    c32c33

    c3m

    cn1cn2

    cn3

    cnm

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    In general, a transportation problem is

    specified by the following information:

    A set of m supply points from which a good is

    shipped. Supply point ican supply at most si units.

    A set of n demand points to which the good is

    shipped. Demand pointjmust receive at least di

    units of the shipped good.

    Each unit produced at supply point iand shipped

    to demand pointjincurs a variable cost of cij.

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    A transportation problem is specified by the

    supply, the demand, and the shipping costs.Relevant data can be summarized in a

    transportation table given below.

    Fr o m To

    Ci t y 1 Ci t y 2 Ci t y 3 Ci t y 4 Su p p l y ( M i l l i o n

    k w h )

    P la n t 1 $8 $6 $10 $9 35

    P la n t 2 $9 $12 $13 $7 50

    P la n t 3 $14 $9 $16 $5 40

    D em a n d ( M i l l io n

    k w h )

    45 20 30 30

    Solution

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    Solution

    Decision Variables

    Powerco must determine how much power is sntfrom each plant to each city soxij = Amount ofelectricity produced at plant iand sent to cityj

    x14 = Amount of electricity produced at plant 1 and sentto city 4

    Constraints A supply constraint ensures that the total quality

    produced does not exceed plant capacity. Each plantis a supply point.

    A demand constraint ensures that a locationreceives its demand. Each city is a demand point.

    Since a negative amount of electricity can not beshipped allxijs must be non negative

    Method for Handling Supply Not

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    Method for Handling Supply Not

    Equal to Demand

    When supply does not equal demand, you can use

    the idea of a slack variable to handle the excess.

    A slack variable is a variable that can be incorporated

    into the model to allow inequality constraints tobecome equality constraints.

    If supply is greater than demand, then you need a slack

    variable known as a dummy destination.

    If demand is greater than supply, then you need a slackvariable known as a dummy source.

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    Powerco Solution

    LP Formulation of the ProblemMinZ= 8x11+6x12+10x13+9x14+9x21+12x22+13x23+7x24

    +14x31+9x32+16x33+5x34

    S.T.: x11+x12+x13+x14 = 30

    x14+x24+x34 >= 30

    xij >= 0 (i= 1,2,3; j= 1,2,3,4)

    Farnsworth Tire Company

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    Farnsworth Tire Company developed data that relates to production,demand, capacity, and cost at its West Virginia plant. The data is providedbelow:

    Sales Period

    Mar. Apr. MayDemand 800 1000 750

    Capacity

    Regular 700 700 700

    Overtime 50 50 50

    Subcontract 150 150 130

    Beg. Inv 100 tires

    Cost

    Regular time $40/tire

    Overtime $50/tire

    Subcontract $ 70/tire

    Carrying cost $2/tire/month

    Backorder cost $ 4/tire/month (Solve the problem without thisfirst, and then with backorder)

    Backorder is not a viable alternative for this company. Give an initialsolution to the company and check if its optimal (use u-v method).

    Solution (Assumed Cost & Constraints Linearity and no

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    ( y

    backorder or change in level of worker)

    Supply From Period 1 Period 2 Period 3DummyCapacity

    TotalCapacity

    Avai lable

    Beg Inv 100

    Period 1

    Reg Time 700

    Overtime 50

    Subcontract 150

    Period 2

    Reg Time X 700

    Overtime X 50

    Subcontract X 150

    Period 3

    Reg Time X X 700

    Overtime X X 50

    Subcontract X X 130

    Total Demand 800 1000 750 230 2780

    Initial Solution= $105900 and optimal is $105700 (without backorder)

    PERIOD OF USEPERIOD OF Unused

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    PRODUCTION 1 2 3 4 Capac ity Capac ity

    Beginning inventoryi i+h i+2h i+3h I

    1 Regularr r+h r+2h r+3h R1

    Overtime

    o o+h o+2h o+3h O1

    Subcontracts s+h s+2h s+3h S1

    2 Regularr+b r r+h r+2h R2

    Overtimeo+b o o+h o+2h O2

    Subcontracts+b s s+h s+2h S2

    3 Regularr+2b r+b r r+h R3

    Overtimeo+2b o+b o o+h O3

    Subcontracts+2b s+b s s+h S3

    4 Regularr+3b r+2b r+b r R4

    Overtimeo+3b o+2b o+b o O4

    Subcontracts+3b s+2b s+b s S4

    Unmet Demand

    D1 D2 D3 D4

    Demand of

    period 1 is

    produced/

    satisfied in

    period 2.Addition

    cost of

    back-

    ordering

    (loss of

    goodwill,

    cost ofexpediting

    etc is

    added.

    h i blDummy Demand

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    The Transportation Tableau

    Unused

    PERIOD OF PRODUCTION 1 2 3 4 Capacity Capacity

    Beginning 0 3 6 9 0

    Inventory 300 300

    Regular 600 300 100 0 1000

    Overtime 0 100 0 100

    Subcontract 500 0 500

    Regular 1200 1200

    Overtime 150 150

    Subcontract 350 150 0 500

    Regular 1300 1300

    Overtime 200 200

    Subcontract 500 500

    Regular 1300 1300

    Overtime 200 200

    Subcontract 500 500

    Demand 900 1500 1600 3000 750 7750

    1

    2

    3

    4

    PERIOD OF USE

    20 23 26 29

    25 28 31 34

    28 31 34 37

    20 23 26

    25 28 31

    28 31 34

    20 23

    25 28

    28 31

    20

    25

    28

    yBalanced Problem

    M

    High Costsay 9999if usingsolver or

    puttingextremelylargenumberinto thecost ofproducingthat willforce thevalue toequalzero

    No backorder allowed

    InitialBasic

    Feasible

    Solution(Vogels,LC, orNWC)andthen

    Simplex,Steep-ing

    Stone orU-V

    method

    Determine a BFS for the below Production Plan. Is the BFS also optimal?-Home

    Exercise

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    2007 Pearson Education

    Exercise

    Transportation Tableau for Tru-Rainbow Company

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    There are three basic methods to find the

    starting basic feasible solution (bfs) for a

    balanced TP problem

    Northwest Corner Method

    Minimum Cost Method

    Vogels Approximation Method

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    The minimum cost method uses shipping

    costs in order come up with a BFS that hasa lower cost.

    To find the BFS (basic feasible solution) by

    the Minimum Cost method:

    Find the decision variable with the smallest

    shipping cost (xij). Then assignxij its largest

    possible value, which is the minimum of si and

    dj

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    Next, cross out row iand columnjand reduce

    the supply or demand of the noncrossed-out

    row or column by the value ofxij.

    Choose the cell with the minimum cost of

    shipping from the cells that do not lie in a

    crossed-out row or column and repeat the

    procedure.

    Often the minimum cost method may yield a

    costly BFS.

    Vogels approximation method for finding a bfsusually avoids extremely high shipping costs.

    Simplex in Solver: Integer Solutions

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    Simplex in Solver: Integer Solutions

    Property

    If all the supplies and demands have integer

    values, then the transportation problem with

    feasible solutions is guaranteed to have an

    optimal solution with integer values for all itsdecision variables.

    This implies that there is no need to add restrictionson the model to force integer solutions.

    Home Exercise

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    Aggregate Planningfor Services

    1. Most services cant be inventoried

    2. Demand for services is difficult to predict

    3. Capacity is also difficult to predict

    4. Service capacity must be provided at theappropriate place and time

    5. Laboris usually the most constrainingresource for services

    Lecture Slides of Indrajit Mukherjee, SJMSOM

    Daily demand profile

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    6.00 8.00 10.00 12.00 14.00 16.00 18.00 20.00 22.00

    Number ofcustomers

    Daily demand profile

    Core shift team 1 Core shift team 2

    PartTime

    PartTime

    Part-

    time

    Staff scheduling

    Figure Chase capacity strategy for a fast-food restaurant

    Time