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10000 9000
What we want to do is 8000
8000
balance out the production
6000
rate, workforce levels, and 6000
4500 4000 4000
inventory to make these 4000
figures match up.
2000
0
Jan Feb Mar Apr May Jun
Key Strategies for Meeting
Demand
• Chase
• Level
Materials $5/unit
Holding costs $1/unit per mo.
Marginal cost of stock-out $1.25/unit per mo.
Hiring and training cost $200/worker
Layoff costs $250/worker
Labor hours required .15 hrs/unit
Straight time labor cost $8/hour
Beginning inventory 250 units
Productive hours/worker/day 7.25
Paid straight hrs/day 8
Determining Straight Labor
Costs and Output
Given the demand and cost information below, what are the
aggregate hours/worker/month, units/worker, and dollars/worker?
J an Fe b M ar Apr M ay Jun C o s ts
M ate r i al $ 2 1 ,2 5 0 .0 0$ 2 7 ,5 0 0 .0 0$ 3 5 ,0 0 0 .0 0$ 5 0 ,0 0 0 .0 0$ 4 0 ,0 0 0 .0 0$ 3 0 ,0 0 0 .0 0 2 0 3 ,7 5 0 .0 0
L ab o r 5 ,6 2 7 .5 9 7 ,2 8 2 .7 6 9 ,2 6 8 .9 7 1 3 ,2 4 1 .3 8 1 0 ,5 9 3 .1 0 7 ,9 4 4 .8 3 5 3 ,9 5 8 .6 2
H i r in g c o s t 4 0 0 .0 0 2 0 0 .0 0 6 0 0 .0 0 1 ,2 0 0 .0 0
F i r in g c o s t 7 5 0 .0 0 5 0 0 .0 0 2 5 0 .0 0 1 ,5 0 0 .0 0
$260,408.62
Level Workforce Strategy
(Surplus and Shortage
Allowed)
Lets take the same problem as
before but this time use the
Level Workforce strategy. Jan
Demand 4 ,500
This time we will seek to use a
workforce level of 6 workers. Beg. inv. 250
Net req. 4 ,250
W orkers 6
P ro duction 6 ,380
Ending invento ry 2 ,130
Surplus 2 ,130
Shortage
Below are the complete calculations for the remaining
months in the six month planning horizon.
Jan Feb Mar Apr M
Demand 4,500 5,500 7,000 10,000 8,
Beg. inv. 250 2,130 2,140 1,230 -2,
Net req. 4,250 3,370 4,860 8,770 10,
Workers 6 6 6 6
Production 6,380 5,510 6,090 6,090 6,
Ending inventory 2,130 2,140 1,230 -2,680 -1,
Surplus 2,130 2,140 1,230
Shortage 2,680
Note, if we recalculate this sheet with 7 workers 1,
we would have a surplus.
Below are the complete calculations for the remaining months
in the six month planning horizon with the other costs included.
Jan Feb Mar Apr May Jun
4,500 5,500 7,000 10,000 8,000 6,000
250 2,130 10 -910 -3,910 -1,620
4,250 3,370 4,860 8,770 10,680 7,300
6 6 6 6 6 6
6,380 5,510 6,090 6,090 6,380 5,800
2,130 2,140 1,230 -2,680 -1,300 -1,500
2,130 2,140 1,230
2,680 1,300 1,500
Labor
Material
Jan Feb Mar Apr May Jun Storage
$8,448 $7,296 $8,064 $8,064 $8,448 $7,680 Stock-out
$48,0
31,900 27,550 30,450 30,450 31,900 29,000 181,2
2,130 2,140 1,230 5,5
Note, the total costs under this strategy
3,350are less than under
1,625 Chase.
1,875 6,8
Graphical Methods
Month Expected Production Demand per
Demand Days Day
Jan 900 22 41
Feb 700 18 39
Mar 800 21 38
Apr 1200 21 58
May 1500 22 68
June 1100 20 55
6200 124
Level = 6200/124= 50 units/day
Month Estimated Level Difference
Demand/ Production Build vs.
Month Deplete Inv
Jan 900 1100 +200
6000
5000
4000
Level
Estimate
3000
Deplete Inv
2000
1000
0
Jan Feb Mar April May June
Build Inv.
Determining the Optimal Mix Strategy
• Try multiple attempts with different
scenarios
OR
• Use Linear Programming (LP)
– You will need to install Solver on your laptop
– In Excel:
• Click Tools
• Click Add-ins
• Click Solver Add-in
• We can use LP to address many
production planning & distribution
problems.
What is Linear Programming?
• A sequence of steps that will lead to
an optimal solution.
• Used to
– allocate scarce resources
– assign workers
– determine transportation schemes
– solve blending problems
– solve many other types of problems
Five essential conditions:
• Explicit Objective: What are we
maximizing or minimizing? Usually profit,
units, costs, labor hours, etc.
• Limiting resources create constraints:
workers, equipment, parts, budgets,etc.
• Linearity (2 is twice as good as 1, if it
takes 3 hours to make 1 part then it takes
6 hours to make 2 parts)
• Homogeneity (machines make identical
parts)
Farm Resource Allocation
• A farmer owns 45 acres of land. The
farmer is gong to plant each acre
with wheat (W) or corn (C). Each
acre planted with wheat yields $200
profit while corn yields $300 profit.
– An acre of wheat requires 3 workers
and 2 tons fertilizer
– An acre of corn requires 2 workers and
4 tons of fertilizer.
– 100 workers and 120 tons of fertilizer
are available
• How many acres of Wheat or Corn should
be planted?
Graphical Approach (2 variables)
• Formulate the problem in
mathematical equations
• Plot all the Equations
• Determine the area of feasibility
– Maximizing problem: feasible area is on
or below the lines
– Minimization: feasible area is on or
above the lines
– Plot a few Profit line (Iso-profit) by
setting profit equation = different
values.
– Answer point will be one of the corner
points (most extreme)
Equations
• Maximize Profit : $200 C + $300 W
• Constrained Resources
– 2 C + 3 W < 100 (Worker resource)
– 4 C + 2 W < 120 (Fertilizer resource)
– C + W < 45 (available land resource)
50
40
Land
10
0
0 50 100
Wheat
Solver Set-up on Excel
Adjustable Cells
Cell Name Original Value Final Value
$C$2 VARIABLES Wheat 0 20
$D$2 Corn 0 20
Constraints
Cell Name Cell Value Formula Status Slack
$E$5 Labor LSE 100 $E$5<=$F$5 Binding 0
$E$6 Fertilizer LSE 120 $E$6<=$F$6 Binding 0
$E$7 Land LSE 40 $E$7<=$F$7 Not Binding 5