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© 2008 Prentice Hall, Inc. 13 – 1
Course: MBACourse: MBA
Subject: Production &Subject: Production &
Operation ManagementOperation Management
Unit:2.4Unit:2.4
AGGREGATE PLANNING
© 2008 Prentice Hall, Inc. 13 – 2
Anheuser-BuschAnheuser-Busch
 Product-focused facility with high fixedProduct-focused facility with high fixed
costscosts
 High utilization requires effectiveHigh utilization requires effective
aggregate planning of the four basicaggregate planning of the four basic
stages of productionstages of production
 Selection and delivery of raw materialsSelection and delivery of raw materials
 Brewing process from milling to agingBrewing process from milling to aging
 PackagingPackaging
 DistributionDistribution
© 2008 Prentice Hall, Inc. 13 – 3
Anheuser-BuschAnheuser-Busch
 Anheuser-Busch produces nearly 40%Anheuser-Busch produces nearly 40%
of the beer consumed in the U.S.of the beer consumed in the U.S.
 Matches fluctuating demand by brandMatches fluctuating demand by brand
to plant, labor, and inventory capacityto plant, labor, and inventory capacity
to achieve high facility utilizationto achieve high facility utilization
 High facility utilization requiresHigh facility utilization requires
 Meticulous cleaning between batchesMeticulous cleaning between batches
 Effective maintenanceEffective maintenance
 Efficient employee and facility schedulingEfficient employee and facility scheduling
© 2008 Prentice Hall, Inc. 13 – 4
Aggregate PlanningAggregate Planning
 Objective is to minimize cost over theObjective is to minimize cost over the
planning period by adjustingplanning period by adjusting
 Production ratesProduction rates
 Labor levelsLabor levels
 Inventory levelsInventory levels
 Overtime workOvertime work
 Subcontracting ratesSubcontracting rates
 Other controllable variablesOther controllable variables
Determine the quantity and timing ofDetermine the quantity and timing of
production for the immediate futureproduction for the immediate future
© 2008 Prentice Hall, Inc. 13 – 5
Aggregate PlanningAggregate Planning
 A logical overall unit for measuring salesA logical overall unit for measuring sales
and outputand output
 A forecast of demand for an intermediateA forecast of demand for an intermediate
planning period in these aggregate termsplanning period in these aggregate terms
 A method for determining costsA method for determining costs
 A model that combines forecasts andA model that combines forecasts and
costs so that scheduling decisions cancosts so that scheduling decisions can
be made for the planning periodbe made for the planning period
Required for aggregate planningRequired for aggregate planning
© 2008 Prentice Hall, Inc. 13 – 6
The Planning ProcessThe Planning Process
Figure 13.1Figure 13.1
Long-range plans
(over one year)
Research and Development
New product plans
Capital investments
Facility location/expansion
Intermediate-range plans
(3 to 18 months)
Sales planning
Production planning and budgeting
Setting employment, inventory,
subcontracting levels
Analyzing operating plans
Short-range plans
(up to 3 months)
Job assignments
Ordering
Job scheduling
Dispatching
Overtime
Part-time help
Top
executives
Operations
managers
Operations
managers,
supervisors,
foremen
ResponsibilityResponsibility Planning tasks and horizonPlanning tasks and horizon
© 2008 Prentice Hall, Inc. 13 – 7
Aggregate PlanningAggregate Planning
Quarter 1Quarter 1
JanJan FebFeb MarMar
150,000150,000 120,000120,000 110,000110,000
Quarter 2Quarter 2
AprApr MayMay JunJun
100,000100,000 130,000130,000 150,000150,000
Quarter 3Quarter 3
JulJul AugAug SepSep
180,000180,000 150,000150,000 140,000140,000
© 2008 Prentice Hall, Inc. 13 – 8
AggregateAggregate
PlanningPlanning
Figure 13.2Figure 13.2
© 2008 Prentice Hall, Inc. 13 – 9
Aggregate PlanningAggregate Planning
 Combines appropriate resourcesCombines appropriate resources
into general termsinto general terms
 Part of a larger production planningPart of a larger production planning
systemsystem
 Disaggregation breaks the planDisaggregation breaks the plan
down into greater detaildown into greater detail
 Disaggregation results in a masterDisaggregation results in a master
production scheduleproduction schedule
© 2008 Prentice Hall, Inc. 13 – 10
Aggregate PlanningAggregate Planning
StrategiesStrategies
1.1. Use inventories to absorb changes inUse inventories to absorb changes in
demanddemand
2.2. Accommodate changes by varyingAccommodate changes by varying
workforce sizeworkforce size
3.3. Use part-timers, overtime, or idle time toUse part-timers, overtime, or idle time to
absorb changesabsorb changes
4.4. Use subcontractors and maintain a stableUse subcontractors and maintain a stable
workforceworkforce
5.5. Change prices or other factors toChange prices or other factors to
influence demandinfluence demand
© 2008 Prentice Hall, Inc. 13 – 11
Capacity OptionsCapacity Options
 Changing inventory levelsChanging inventory levels
 Increase inventory in low demandIncrease inventory in low demand
periods to meet high demand inperiods to meet high demand in
the futurethe future
 Increases costs associated withIncreases costs associated with
storage, insurance, handling,storage, insurance, handling,
obsolescence, and capitalobsolescence, and capital
investment 15% to 40%investment 15% to 40%
 Shortages can mean lost sales dueShortages can mean lost sales due
to long lead times and poorto long lead times and poor
customer servicecustomer service
© 2008 Prentice Hall, Inc. 13 – 12
Capacity OptionsCapacity Options
 Varying workforce size by hiringVarying workforce size by hiring
or layoffsor layoffs
 Match production rate to demandMatch production rate to demand
 Training and separation costs forTraining and separation costs for
hiring and laying off workershiring and laying off workers
 New workers may have lowerNew workers may have lower
productivityproductivity
 Laying off workers may lowerLaying off workers may lower
morale and productivitymorale and productivity
© 2008 Prentice Hall, Inc. 13 – 13
Capacity OptionsCapacity Options
 Varying production rate throughVarying production rate through
overtime or idle timeovertime or idle time
 Allows constant workforceAllows constant workforce
 May be difficult to meet largeMay be difficult to meet large
increases in demandincreases in demand
 Overtime can be costly and mayOvertime can be costly and may
drive down productivitydrive down productivity
 Absorbing idle time may beAbsorbing idle time may be
difficultdifficult
© 2008 Prentice Hall, Inc. 13 – 14
Capacity OptionsCapacity Options
 SubcontractingSubcontracting
 Temporary measure duringTemporary measure during
periods of peak demandperiods of peak demand
 May be costlyMay be costly
 Assuring quality and timelyAssuring quality and timely
delivery may be difficultdelivery may be difficult
 Exposes your customers to aExposes your customers to a
possible competitorpossible competitor
© 2008 Prentice Hall, Inc. 13 – 15
Capacity OptionsCapacity Options
 Using part-time workersUsing part-time workers
 Useful for filling unskilled or lowUseful for filling unskilled or low
skilled positions, especially inskilled positions, especially in
servicesservices
© 2008 Prentice Hall, Inc. 13 – 16
Demand OptionsDemand Options
 Influencing demandInfluencing demand
 Use advertising or promotion toUse advertising or promotion to
increase demand in low periodsincrease demand in low periods
 Attempt to shiftAttempt to shift
demand to slowdemand to slow
periodsperiods
 May not beMay not be
sufficient tosufficient to
balance demandbalance demand
and capacityand capacity
© 2008 Prentice Hall, Inc. 13 – 17
Demand OptionsDemand Options
 Back ordering during high-Back ordering during high-
demand periodsdemand periods
 Requires customers to wait for anRequires customers to wait for an
order without loss of goodwill ororder without loss of goodwill or
the orderthe order
 Most effective when there are fewMost effective when there are few
if any substitutes for the productif any substitutes for the product
or serviceor service
 Often results in lost salesOften results in lost sales
© 2008 Prentice Hall, Inc. 13 – 18
Demand OptionsDemand Options
 Counterseasonal product andCounterseasonal product and
service mixingservice mixing
 Develop a product mix ofDevelop a product mix of
counterseasonal itemscounterseasonal items
 May lead to products or servicesMay lead to products or services
outside the company’s areas ofoutside the company’s areas of
expertiseexpertise
© 2008 Prentice Hall, Inc. 13 – 19
Aggregate Planning OptionsAggregate Planning Options
Table 13.1Table 13.1
OptionOption AdvantagesAdvantages DisadvantagesDisadvantages Some CommentsSome Comments
ChangingChanging
inventoryinventory
levelslevels
Changes inChanges in
humanhuman
resources areresources are
gradual orgradual or
none; no abruptnone; no abrupt
productionproduction
changes.changes.
InventoryInventory
holding costholding cost
may increase.may increase.
Shortages mayShortages may
result in lostresult in lost
sales.sales.
Applies mainly toApplies mainly to
production, notproduction, not
service,service,
operations.operations.
VaryingVarying
workforceworkforce
size bysize by
hiring orhiring or
layoffslayoffs
Avoids the costsAvoids the costs
of otherof other
alternatives.alternatives.
Hiring, layoff,Hiring, layoff,
and trainingand training
costs may becosts may be
significant.significant.
Used where sizeUsed where size
of labor pool isof labor pool is
large.large.
© 2008 Prentice Hall, Inc. 13 – 20
Aggregate Planning OptionsAggregate Planning Options
Table 13.1Table 13.1
OptionOption AdvantagesAdvantages DisadvantagesDisadvantages Some CommentsSome Comments
VaryingVarying
productionproduction
ratesrates
throughthrough
overtime orovertime or
idle timeidle time
MatchesMatches
seasonalseasonal
fluctuationsfluctuations
without hiring/without hiring/
training costs.training costs.
OvertimeOvertime
premiums; tiredpremiums; tired
workers; mayworkers; may
not meetnot meet
demand.demand.
Allows flexibilityAllows flexibility
within thewithin the
aggregate plan.aggregate plan.
Sub-Sub-
contractingcontracting
PermitsPermits
flexibility andflexibility and
smoothing ofsmoothing of
the firm’sthe firm’s
output.output.
Loss of qualityLoss of quality
control;control;
reduced profits;reduced profits;
loss of futureloss of future
business.business.
Applies mainly inApplies mainly in
productionproduction
settings.settings.
© 2008 Prentice Hall, Inc. 13 – 21
Aggregate Planning OptionsAggregate Planning Options
Table 13.1Table 13.1
OptionOption AdvantagesAdvantages DisadvantagesDisadvantages Some CommentsSome Comments
Using part-Using part-
timetime
workersworkers
Is less costlyIs less costly
and moreand more
flexible thanflexible than
full-timefull-time
workers.workers.
High turnover/High turnover/
training costs;training costs;
quality suffers;quality suffers;
schedulingscheduling
difficult.difficult.
Good forGood for
unskilled jobs inunskilled jobs in
areas with largeareas with large
temporary labortemporary labor
pools.pools.
InfluencingInfluencing
demanddemand
Tries to useTries to use
excessexcess
capacity.capacity.
Discounts drawDiscounts draw
new customers.new customers.
Uncertainty inUncertainty in
demand. Harddemand. Hard
to matchto match
demand todemand to
supply exactly.supply exactly.
CreatesCreates
marketingmarketing
ideas.ideas.
OverbookingOverbooking
used in someused in some
businesses.businesses.
© 2008 Prentice Hall, Inc. 13 – 22
Aggregate Planning OptionsAggregate Planning Options
Table 13.1Table 13.1
OptionOption AdvantagesAdvantages DisadvantagesDisadvantages Some CommentsSome Comments
BackBack
orderingordering
duringduring
high-high-
demanddemand
periodsperiods
May avoidMay avoid
overtime.overtime.
Keeps capacityKeeps capacity
constant.constant.
Customer mustCustomer must
be willing tobe willing to
wait, butwait, but
goodwill is lost.goodwill is lost.
Many companiesMany companies
back order.back order.
Counter-Counter-
seasonalseasonal
productproduct
and serviceand service
mixingmixing
Fully utilizesFully utilizes
resources;resources;
allows stableallows stable
workforce.workforce.
May requireMay require
skills orskills or
equipmentequipment
outside theoutside the
firm’s areas offirm’s areas of
expertise.expertise.
Risky findingRisky finding
products orproducts or
services withservices with
oppositeopposite
demanddemand
patterns.patterns.
© 2008 Prentice Hall, Inc. 13 – 23
Methods for AggregateMethods for Aggregate
PlanningPlanning
 A mixed strategy may be the bestA mixed strategy may be the best
way to achieve minimum costsway to achieve minimum costs
 There are many possible mixedThere are many possible mixed
strategiesstrategies
 Finding the optimal plan is notFinding the optimal plan is not
always possiblealways possible
© 2008 Prentice Hall, Inc. 13 – 24
Mixing Options toMixing Options to
Develop a PlanDevelop a Plan
 Chase strategyChase strategy
 Match output rates to demandMatch output rates to demand
forecast for each periodforecast for each period
 Vary workforce levels or varyVary workforce levels or vary
production rateproduction rate
 Favored by many serviceFavored by many service
organizationsorganizations
© 2008 Prentice Hall, Inc. 13 – 25
Mixing Options toMixing Options to
Develop a PlanDevelop a Plan
 Level strategyLevel strategy
 Daily production is uniformDaily production is uniform
 Use inventory or idle time as bufferUse inventory or idle time as buffer
 Stable production leads to betterStable production leads to better
quality and productivityquality and productivity
 Some combination of capacitySome combination of capacity
options, a mixed strategy, might beoptions, a mixed strategy, might be
the best solutionthe best solution
© 2008 Prentice Hall, Inc. 13 – 26
Graphical MethodsGraphical Methods
 Popular techniquesPopular techniques
 Easy to understand and useEasy to understand and use
 Trial-and-error approaches that doTrial-and-error approaches that do
not guarantee an optimal solutionnot guarantee an optimal solution
 Require only limited computationsRequire only limited computations
© 2008 Prentice Hall, Inc. 13 – 27
Graphical MethodsGraphical Methods
1.1. Determine the demand for each periodDetermine the demand for each period
2.2. Determine the capacity for regular time,Determine the capacity for regular time,
overtime, and subcontracting each periodovertime, and subcontracting each period
3.3. Find labor costs, hiring and layoff costs,Find labor costs, hiring and layoff costs,
and inventory holding costsand inventory holding costs
4.4. Consider company policy on workers andConsider company policy on workers and
stock levelsstock levels
5.5. Develop alternative plans and examineDevelop alternative plans and examine
their total coststheir total costs
© 2008 Prentice Hall, Inc. 13 – 28
Roofing Supplier Example 1Roofing Supplier Example 1
Table 13.2Table 13.2
MonthMonth Expected DemandExpected Demand
ProductionProduction
DaysDays
Demand Per DayDemand Per Day
(computed)(computed)
JanJan 900900 2222 4141
FebFeb 700700 1818 3939
MarMar 800800 2121 3838
AprApr 1,2001,200 2121 5757
MayMay 1,5001,500 2222 6868
JuneJune 1,1001,100 2020 5555
6,2006,200 124124
= = 50= = 50 units per dayunits per day
6,2006,200
124124
AverageAverage
requirementrequirement ==
Total expected demandTotal expected demand
Number of production daysNumber of production days
© 2008 Prentice Hall, Inc. 13 – 29
Roofing Supplier Example 1Roofing Supplier Example 1
Figure 13.3Figure 13.3
7070 –
6060 –
5050 –
4040 –
3030 –
00 –
JanJan FebFeb MarMar AprApr MayMay JuneJune == MonthMonth
     
2222 1818 2121 2121 2222 2020 == Number ofNumber of
working daysworking days
ProductionrateperworkingdayProductionrateperworkingday
Level production using averageLevel production using average
monthly forecast demandmonthly forecast demand
Forecast demandForecast demand
© 2008 Prentice Hall, Inc. 13 – 30
Roofing Supplier Example 2Roofing Supplier Example 2
Table 13.3Table 13.3
Cost InformationCost Information
Inventory carrying costInventory carrying cost $ 5$ 5 per unit per monthper unit per month
Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit
Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day))
Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour
((aboveabove 88 hours per dayhours per day))
Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit
Cost of increasing daily production rateCost of increasing daily production rate
(hiring and training)(hiring and training)
$300$300 per unitper unit
Cost of decreasing daily production rateCost of decreasing daily production rate
(layoffs)(layoffs)
$600$600 per unitper unit
Plan 1 – constant workforce
Plan 1 – constant workforce
© 2008 Prentice Hall, Inc. 13 – 31
Roofing Supplier Example 2Roofing Supplier Example 2
Table 13.3Table 13.3
Cost InformationCost Information
Inventory carry costInventory carry cost $ 5$ 5 per unit per monthper unit per month
Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit
Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day))
Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour
((aboveabove 88 hours per dayhours per day))
Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit
Cost of increasing daily production rateCost of increasing daily production rate
(hiring and training)(hiring and training)
$300$300 per unitper unit
Cost of decreasing daily production rateCost of decreasing daily production rate
(layoffs)(layoffs)
$600$600 per unitper unit
Plan 1 – constant workforce
Plan 1 – constant workforce
Month
Production at
50 Units per Day
Demand
Forecast
Monthly
Inventory
Change
Ending
Inventory
Jan 1,100 900 +200 200
Feb 900 700 +200 400
Mar 1,050 800 +250 650
Apr 1,050 1,200 -150 500
May 1,100 1,500 -400 100
June 1,000 1,100 -100 0
1,850
Total units of inventory carried over from one
month to the next = 1,850 units
Workforce required to produce 50 units per day = 10 workers
© 2008 Prentice Hall, Inc. 13 – 32
Roofing Supplier Example 2Roofing Supplier Example 2
Table 13.3Table 13.3
Cost InformationCost Information
Inventory carry costInventory carry cost $ 5$ 5 per unit per monthper unit per month
Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit
Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day))
Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour
((aboveabove 88 hours per dayhours per day))
Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit
Cost of increasing daily production rateCost of increasing daily production rate
(hiring and training)(hiring and training)
$300$300 per unitper unit
Cost of decreasing daily production rateCost of decreasing daily production rate
(layoffs)(layoffs)
$600$600 per unitper unit
Month
Production at
50 Units per Day
Demand
Forecast
Monthly
Inventory
Change
Ending
Inventory
Jan 1,100 900 +200 200
Feb 900 700 +200 400
Mar 1,050 800 +250 650
Apr 1,050 1,200 -150 500
May 1,100 1,500 -400 100
June 1,000 1,100 -100 0
1,850
Total units of inventory carried over from one
month to the next = 1,850 units
Workforce required to produce 50 units per day = 10 workers
Costs Calculations
Inventory carrying $9,250 (= 1,850 units carried x $5
per unit)
Regular-time labor 49,600 (= 10 workers x $40 per
day x 124 days)
Other costs (overtime,
hiring, layoffs,
subcontracting) 0
Total cost $58,850
© 2008 Prentice Hall, Inc. 13 – 33
Roofing Supplier Example 2Roofing Supplier Example 2
Figure 13.4Figure 13.4
CumulativedemandunitsCumulativedemandunits
7,0007,000 –
6,0006,000 –
5,0005,000 –
4,0004,000 –
3,0003,000 –
2,000 –
1,000 –
–
JanJan FebFeb MarMar AprApr MayMay JuneJune
Cumulative forecastCumulative forecast
requirementsrequirements
Cumulative levelCumulative level
production usingproduction using
average monthlyaverage monthly
forecastforecast
requirementsrequirements
ReductionReduction
of inventoryof inventory
Excess inventoryExcess inventory
6,200 units6,200 units
© 2008 Prentice Hall, Inc. 13 – 34
Roofing Supplier Example 3Roofing Supplier Example 3
Table 13.2Table 13.2
MonthMonth Expected DemandExpected Demand
ProductionProduction
DaysDays
Demand Per DayDemand Per Day
(computed)(computed)
JanJan 900900 2222 4141
FebFeb 700700 1818 3939
MarMar 800800 2121 3838
AprApr 1,2001,200 2121 5757
MayMay 1,5001,500 2222 6868
JuneJune 1,1001,100 2020 5555
6,2006,200 124124
Minimum requirementMinimum requirement = 38= 38 units per dayunits per day
Plan 2 – subcontracting
Plan 2 – subcontracting
© 2008 Prentice Hall, Inc. 13 – 35
Roofing Supplier Example 3Roofing Supplier Example 3
7070 –
6060 –
5050 –
4040 –
3030 –
00 –
JanJan FebFeb MarMar AprApr MayMay JuneJune == MonthMonth
     
2222 1818 2121 2121 2222 2020 == Number ofNumber of
working daysworking days
ProductionrateperworkingdayProductionrateperworkingday
Level productionLevel production
using lowestusing lowest
monthly forecastmonthly forecast
demanddemand
Forecast demandForecast demand
© 2008 Prentice Hall, Inc. 13 – 36
Roofing Supplier Example 3Roofing Supplier Example 3
Table 13.3Table 13.3
Cost InformationCost Information
Inventory carrying costInventory carrying cost $ 5$ 5 per unit per monthper unit per month
Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit
Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day))
Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour
((aboveabove 88 hours per dayhours per day))
Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit
Cost of increasing daily production rateCost of increasing daily production rate
(hiring and training)(hiring and training)
$300$300 per unitper unit
Cost of decreasing daily production rateCost of decreasing daily production rate
(layoffs)(layoffs)
$600$600 per unitper unit
© 2008 Prentice Hall, Inc. 13 – 37
Roofing Supplier Example 3Roofing Supplier Example 3
Table 13.3Table 13.3
Cost InformationCost Information
Inventory carry costInventory carry cost $ 5$ 5 per unit per monthper unit per month
Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit
Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day))
Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour
((aboveabove 88 hours per dayhours per day))
Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit
Cost of increasing daily production rateCost of increasing daily production rate
(hiring and training)(hiring and training)
$300$300 per unitper unit
Cost of decreasing daily production rateCost of decreasing daily production rate
(layoffs)(layoffs)
$600$600 per unitper unit
In-house production = 38 units per day
x 124 days
= 4,712 units
Subcontract units = 6,200 - 4,712
= 1,488 units
© 2008 Prentice Hall, Inc. 13 – 38
Table 13.3Table 13.3
Cost InformationCost Information
Inventory carry costInventory carry cost $ 5$ 5 per unit per monthper unit per month
Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit
Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day))
Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour
((aboveabove 88 hours per dayhours per day))
Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit
Cost of increasing daily production rateCost of increasing daily production rate
(hiring and training)(hiring and training)
$300$300 per unitper unit
Cost of decreasing daily production rateCost of decreasing daily production rate
(layoffs)(layoffs)
$600$600 per unitper unit
Roofing Supplier Example 3Roofing Supplier Example 3
In-house production = 38 units per day
x 124 days
= 4,712 units
Subcontract units = 6,200 - 4,712
= 1,488 units
Costs Calculations
Regular-time labor $37,696 (= 7.6 workers x $40 per
day x 124 days)
Subcontracting 14,880 (= 1,488 units x $10 per
unit)
Total cost $52,576
© 2008 Prentice Hall, Inc. 13 – 39
Roofing Supplier Example 4Roofing Supplier Example 4
Table 13.2Table 13.2
MonthMonth Expected DemandExpected Demand
ProductionProduction
DaysDays
Demand Per DayDemand Per Day
(computed)(computed)
JanJan 900900 2222 4141
FebFeb 700700 1818 3939
MarMar 800800 2121 3838
AprApr 1,2001,200 2121 5757
MayMay 1,5001,500 2222 6868
JuneJune 1,1001,100 2020 5555
6,2006,200 124124
Production = Expected DemandProduction = Expected Demand
Plan 3 – hiring and firing
Plan 3 – hiring and firing
© 2008 Prentice Hall, Inc. 13 – 40
Roofing Supplier Example 4Roofing Supplier Example 4
7070 –
6060 –
5050 –
4040 –
3030 –
00 –
JanJan FebFeb MarMar AprApr MayMay JuneJune == MonthMonth
     
2222 1818 2121 2121 2222 2020 == Number ofNumber of
working daysworking days
ProductionrateperworkingdayProductionrateperworkingday
Forecast demand andForecast demand and
monthly productionmonthly production
© 2008 Prentice Hall, Inc. 13 – 41
Roofing Supplier Example 4Roofing Supplier Example 4
Table 13.3Table 13.3
Cost InformationCost Information
Inventory carrying costInventory carrying cost $ 5$ 5 per unit per monthper unit per month
Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit
Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day))
Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour
((aboveabove 88 hours per dayhours per day))
Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit
Cost of increasing daily production rateCost of increasing daily production rate
(hiring and training)(hiring and training)
$300$300 per unitper unit
Cost of decreasing daily production rateCost of decreasing daily production rate
(layoffs)(layoffs)
$600$600 per unitper unit
© 2008 Prentice Hall, Inc. 13 – 42
Roofing Supplier Example 4Roofing Supplier Example 4
Table 13.3Table 13.3
Cost InformationCost Information
Inventory carrying costInventory carrying cost $ 5$ 5 per unit per monthper unit per month
Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit
Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day))
Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour
((aboveabove 88 hours per dayhours per day))
Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit
Cost of increasing daily production rateCost of increasing daily production rate
(hiring and training)(hiring and training)
$300$300 per unitper unit
Cost of decreasing daily production rateCost of decreasing daily production rate
(layoffs)(layoffs)
$600$600 per unitper unit
Month
Forecast
(units)
Daily
Prod
Rate
Basic
Production
Cost
(demand x
1.6 hrs/unit x
$5/hr)
Extra Cost of
Increasing
Production
(hiring cost)
Extra Cost of
Decreasing
Production
(layoff cost) Total Cost
Jan 900 41 $ 7,200 — — $ 7,200
Feb 700 39 5,600 —
$1,200
(= 2 x $600)
6,800
Mar 800 38 6,400 —
$600
(= 1 x $600)
7,000
Apr 1,200 57 9,600
$5,700
(= 19 x $300)
— 15,300
May 1,500 68 12,000
$3,300
(= 11 x $300)
— 15,300
June 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
© 2008 Prentice Hall, Inc. 13 – 43
Comparison of Three PlansComparison of Three Plans
Table 13.5Table 13.5
CostCost Plan 1Plan 1 Plan 2Plan 2 Plan 3Plan 3
Inventory carryingInventory carrying $ 9,250$ 9,250 $ 0$ 0 $ 0$ 0
Regular laborRegular labor 49,60049,600 37,69637,696 49,60049,600
Overtime laborOvertime labor 00 00 00
HiringHiring 00 00 9,0009,000
LayoffsLayoffs 00 00 9,6009,600
SubcontractingSubcontracting 00 14,88014,880 00
Total costTotal cost $58,850$58,850 $52,576$52,576 $68,200$68,200
Plan 2 is the lowest cost optionPlan 2 is the lowest cost option
© 2008 Prentice Hall, Inc. 13 – 44
Mathematical ApproachesMathematical Approaches
 Useful for generating strategiesUseful for generating strategies
 Transportation Method of LinearTransportation Method of Linear
ProgrammingProgramming
 Produces an optimal planProduces an optimal plan
 Management Coefficients ModelManagement Coefficients Model
 Model built around manager’sModel built around manager’s
experience and performanceexperience and performance
 Other ModelsOther Models
 Linear Decision RuleLinear Decision Rule
 SimulationSimulation
© 2008 Prentice Hall, Inc. 13 – 45
Transportation MethodTransportation Method
Table 13.6Table 13.6
CostsCosts
Regular timeRegular time $40$40 per tireper tire
OvertimeOvertime $50$50 per tireper tire
SubcontractingSubcontracting $70$70 per tireper tire
CarryingCarrying $ 2$ 2 per tire per monthper tire per month
Sales PeriodSales Period
MarMar AprApr MayMay
DemandDemand 800800 1,0001,000 750750
Capacity:Capacity:
RegularRegular 700700 700700 700700
OvertimeOvertime 5050 5050 5050
SubcontractingSubcontracting 150150 150150 130130
Beginning inventoryBeginning inventory 100100 tirestires
© 2008 Prentice Hall, Inc. 13 – 46
Transportation ExampleTransportation Example
Important pointsImportant points
1.1. Carrying costs areCarrying costs are $2$2/tire/month. If/tire/month. If
goods are made in one period and heldgoods are made in one period and held
over to the next, holding costs areover to the next, holding costs are
incurredincurred
2.2. Supply must equal demand, so aSupply must equal demand, so a
dummy column called “unuseddummy column called “unused
capacity” is addedcapacity” is added
3.3. Because back ordering is not viable inBecause back ordering is not viable in
this example, cells that might be used tothis example, cells that might be used to
satisfy earlier demand are not availablesatisfy earlier demand are not available
© 2008 Prentice Hall, Inc. 13 – 47
Transportation ExampleTransportation Example
Important pointsImportant points
4.4. Quantities in each column designate theQuantities in each column designate the
levels of inventory needed to meetlevels of inventory needed to meet
demand requirementsdemand requirements
5.5. In general, production should beIn general, production should be
allocated to the lowest cost cellallocated to the lowest cost cell
available without exceeding unusedavailable without exceeding unused
capacity in the row or demand in thecapacity in the row or demand in the
columncolumn
© 2008 Prentice Hall, Inc. 13 – 48
TransportationTransportation
ExampleExample
Table 13.7Table 13.7
© 2008 Prentice Hall, Inc. 13 – 49
Management CoefficientsManagement Coefficients
ModelModel
 Builds a model based on manager’sBuilds a model based on manager’s
experience and performanceexperience and performance
 A regression model is constructedA regression model is constructed
to define the relationships betweento define the relationships between
decision variablesdecision variables
 Objective is to removeObjective is to remove
inconsistencies in decision makinginconsistencies in decision making
© 2008 Prentice Hall, Inc. 13 – 50
Other ModelsOther Models
Linear Decision RuleLinear Decision Rule
 Minimizes costs using quadratic cost curvesMinimizes costs using quadratic cost curves
 Operates over a particular time periodOperates over a particular time period
SimulationSimulation
 Uses a search procedure to try differentUses a search procedure to try different
combinations of variablescombinations of variables
 Develops feasible but not necessarily optimalDevelops feasible but not necessarily optimal
solutionssolutions
© 2008 Prentice Hall, Inc. 13 – 51
Summary of AggregateSummary of Aggregate
Planning MethodsPlanning Methods
TechniquesTechniques
SolutionSolution
ApproachesApproaches Important AspectsImportant Aspects
GraphicalGraphical
methodsmethods
Trial andTrial and
errorerror
Simple to understand andSimple to understand and
easy to use. Manyeasy to use. Many
solutions; one chosensolutions; one chosen
may not be optimal.may not be optimal.
TransportationTransportation
method of linearmethod of linear
programmingprogramming
OptimizationOptimization LP software available;LP software available;
permits sensitivitypermits sensitivity
analysis and newanalysis and new
constraints; linearconstraints; linear
functions may not befunctions may not be
realistic.realistic.
Table 13.8Table 13.8
© 2008 Prentice Hall, Inc. 13 – 52
Summary of AggregateSummary of Aggregate
Planning MethodsPlanning Methods
TechniquesTechniques
SolutionSolution
ApproachesApproaches Important AspectsImportant Aspects
ManagementManagement
coefficientscoefficients
modelmodel
HeuristicHeuristic Simple, easy to implement;Simple, easy to implement;
tries to mimic manager’stries to mimic manager’s
decision process; usesdecision process; uses
regression.regression.
SimulationSimulation ChangeChange
parametersparameters
Complex; may be difficultComplex; may be difficult
to build and for managersto build and for managers
to understand.to understand.
Table 13.8Table 13.8
© 2008 Prentice Hall, Inc. 13 – 53
Aggregate Planning inAggregate Planning in
ServicesServices
Controlling the cost of labor is criticalControlling the cost of labor is critical
1.1. Accurate scheduling of labor-hours toAccurate scheduling of labor-hours to
assure quick response to customerassure quick response to customer
demanddemand
2.2. An on-call labor resource to coverAn on-call labor resource to cover
unexpected demandunexpected demand
3.3. Flexibility of individual worker skillsFlexibility of individual worker skills
4.4. Flexibility in rate of output or hours ofFlexibility in rate of output or hours of
workwork
© 2008 Prentice Hall, Inc. 13 – 54
Five Service ScenariosFive Service Scenarios
 RestaurantsRestaurants
 Smoothing the productionSmoothing the production
processprocess
 Determining the optimalDetermining the optimal
workforce sizeworkforce size
 HospitalsHospitals
 Responding to patient demandResponding to patient demand
© 2008 Prentice Hall, Inc. 13 – 55
Five Service ScenariosFive Service Scenarios
 National Chains of Small ServiceNational Chains of Small Service
FirmsFirms
 Planning done at national levelPlanning done at national level
and at local leveland at local level
 Miscellaneous ServicesMiscellaneous Services
 Plan human resourcePlan human resource
requirementsrequirements
 Manage demandManage demand
© 2008 Prentice Hall, Inc. 13 – 56
Law Firm ExampleLaw Firm Example
Table 13.9Table 13.9
Labor-Hours RequiredLabor-Hours Required Capacity ConstraintsCapacity Constraints
(2)(2) (3)(3) (4)(4) (5)(5) (6)(6)
(1)(1) ForecastsForecasts MaximumMaximum Number ofNumber of
Category ofCategory of BestBest LikelyLikely WorstWorst Demand inDemand in QualifiedQualified
Legal BusinessLegal Business (hours)(hours) (hours)(hours) (hours)(hours) PeoplePeople PersonnelPersonnel
Trial workTrial work 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 lawCorporate law 8,0008,000 7,0007,000 6,5006,500 16.016.0 1515
Real estate lawReal estate law 1,7001,700 1,5001,500 1,3001,300 3.43.4 66
Criminal lawCriminal law 3,5003,500 3,0003,000 2,5002,500 7.07.0 1212
Total hoursTotal hours 19,50019,500 17,00017,000 15,00015,000
Lawyers neededLawyers needed 3939 3434 3030
© 2008 Prentice Hall, Inc. 13 – 57
Five Service ScenariosFive Service Scenarios
 Airline industryAirline industry
 Extremely complex planningExtremely complex planning
problemproblem
 Involves number of flights,Involves number of flights,
number of passengers, air andnumber of passengers, air and
ground personnel, allocation ofground personnel, allocation of
seats to fare classesseats to fare classes
 Resources spread through theResources spread through the
entire systementire system
© 2008 Prentice Hall, Inc. 13 – 58
Yield ManagementYield Management
Allocating resources to customers atAllocating resources to customers at
prices that will maximize yield orprices that will maximize yield or
revenuerevenue
1.1. Service or product can be sold inService or product can be sold in
advance of consumptionadvance of consumption
2.2. Demand fluctuatesDemand fluctuates
3.3. Capacity is relatively fixedCapacity is relatively fixed
4.4. Demand can be segmentedDemand can be segmented
5.5. Variable costs are low and fixed costsVariable costs are low and fixed costs
are highare high
© 2008 Prentice Hall, Inc. 13 – 59
DemandDemand
CurveCurve
Yield Management ExampleYield Management Example
Figure 13.5Figure 13.5
Passed-up
contribution
Money left
on the table
Potential customers exist whoPotential customers exist who
are willing to pay more than theare willing to pay more than the
$15$15 variable cost of the roomvariable cost of the room
Some customers who paidSome customers who paid
$150$150 were actually willingwere actually willing
to pay more for the roomto pay more for the roomTotalTotal
$$ contributioncontribution
== ((PricePrice)) xx
(50(50
roomsrooms))
== ($150 -($150 -
$15)$15)
xx (50)(50)
== $6,750$6,750 PricePrice
Room salesRoom sales
100100
5050
$150$150
Price chargedPrice charged
for roomfor room
$15$15
Variable costVariable cost
of roomof room
© 2008 Prentice Hall, Inc. 13 – 60
Total $ contribution =Total $ contribution =
(1(1st pricest price) x 30) x 30 roomsrooms + (2+ (2ndnd price) x 30 rooms =price) x 30 rooms =
($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
DemandDemand
CurveCurve
Yield Management ExampleYield Management Example
Figure 13.6Figure 13.6
PricePrice
Room salesRoom sales
100100
6060
3030
$100$100
Price 1Price 1
for roomfor room
$200$200
Price 2Price 2
for roomfor room
$15$15
Variable costVariable cost
of roomof room
© 2008 Prentice Hall, Inc. 13 – 61
Yield Management MatrixYield Management Matrix
Durationofuse
UnpredictablePredictable
Price
Tend to be fixed Tend to be variable
Quadrant 1: Quadrant 2:
Movies Hotels
Stadiums/arenas Airlines
Convention centers Rental cars
Hotel meeting space Cruise lines
Quadrant 3: Quadrant 4:
Restaurants Continuing care
Golf courses hospitals
Internet service
providers
Figure 13.7Figure 13.7
© 2008 Prentice Hall, Inc. 13 – 62
Making Yield ManagementMaking Yield Management
WorkWork
1.1. Multiple pricing structures mustMultiple pricing structures must
be feasible and appear logical tobe feasible and appear logical to
the customerthe customer
2.2. Forecasts of the use and durationForecasts of the use and duration
of useof use
3.3. Changes in demandChanges in demand
© 2008 Prentice Hall, Inc. 13 – 63
ReferenceReference
• www.csun.eduwww.csun.edu
• Principles of OperationsPrinciples of Operations
ManagementManagement
• www.aast.eduwww.aast.edu

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Mba ii pmom_unit-2.4 aggregate planning a

  • 1. © 2008 Prentice Hall, Inc. 13 – 1 Course: MBACourse: MBA Subject: Production &Subject: Production & Operation ManagementOperation Management Unit:2.4Unit:2.4 AGGREGATE PLANNING
  • 2. © 2008 Prentice Hall, Inc. 13 – 2 Anheuser-BuschAnheuser-Busch  Product-focused facility with high fixedProduct-focused facility with high fixed costscosts  High utilization requires effectiveHigh utilization requires effective aggregate planning of the four basicaggregate planning of the four basic stages of productionstages of production  Selection and delivery of raw materialsSelection and delivery of raw materials  Brewing process from milling to agingBrewing process from milling to aging  PackagingPackaging  DistributionDistribution
  • 3. © 2008 Prentice Hall, Inc. 13 – 3 Anheuser-BuschAnheuser-Busch  Anheuser-Busch produces nearly 40%Anheuser-Busch produces nearly 40% of the beer consumed in the U.S.of the beer consumed in the U.S.  Matches fluctuating demand by brandMatches fluctuating demand by brand to plant, labor, and inventory capacityto plant, labor, and inventory capacity to achieve high facility utilizationto achieve high facility utilization  High facility utilization requiresHigh facility utilization requires  Meticulous cleaning between batchesMeticulous cleaning between batches  Effective maintenanceEffective maintenance  Efficient employee and facility schedulingEfficient employee and facility scheduling
  • 4. © 2008 Prentice Hall, Inc. 13 – 4 Aggregate PlanningAggregate Planning  Objective is to minimize cost over theObjective is to minimize cost over the planning period by adjustingplanning period by adjusting  Production ratesProduction rates  Labor levelsLabor levels  Inventory levelsInventory levels  Overtime workOvertime work  Subcontracting ratesSubcontracting rates  Other controllable variablesOther controllable variables Determine the quantity and timing ofDetermine the quantity and timing of production for the immediate futureproduction for the immediate future
  • 5. © 2008 Prentice Hall, Inc. 13 – 5 Aggregate PlanningAggregate Planning  A logical overall unit for measuring salesA logical overall unit for measuring sales and outputand output  A forecast of demand for an intermediateA forecast of demand for an intermediate planning period in these aggregate termsplanning period in these aggregate terms  A method for determining costsA method for determining costs  A model that combines forecasts andA model that combines forecasts and costs so that scheduling decisions cancosts so that scheduling decisions can be made for the planning periodbe made for the planning period Required for aggregate planningRequired for aggregate planning
  • 6. © 2008 Prentice Hall, Inc. 13 – 6 The Planning ProcessThe Planning Process Figure 13.1Figure 13.1 Long-range plans (over one year) Research and Development New product plans Capital investments Facility location/expansion Intermediate-range plans (3 to 18 months) Sales planning Production planning and budgeting Setting employment, inventory, subcontracting levels Analyzing operating plans Short-range plans (up to 3 months) Job assignments Ordering Job scheduling Dispatching Overtime Part-time help Top executives Operations managers Operations managers, supervisors, foremen ResponsibilityResponsibility Planning tasks and horizonPlanning tasks and horizon
  • 7. © 2008 Prentice Hall, Inc. 13 – 7 Aggregate PlanningAggregate Planning Quarter 1Quarter 1 JanJan FebFeb MarMar 150,000150,000 120,000120,000 110,000110,000 Quarter 2Quarter 2 AprApr MayMay JunJun 100,000100,000 130,000130,000 150,000150,000 Quarter 3Quarter 3 JulJul AugAug SepSep 180,000180,000 150,000150,000 140,000140,000
  • 8. © 2008 Prentice Hall, Inc. 13 – 8 AggregateAggregate PlanningPlanning Figure 13.2Figure 13.2
  • 9. © 2008 Prentice Hall, Inc. 13 – 9 Aggregate PlanningAggregate Planning  Combines appropriate resourcesCombines appropriate resources into general termsinto general terms  Part of a larger production planningPart of a larger production planning systemsystem  Disaggregation breaks the planDisaggregation breaks the plan down into greater detaildown into greater detail  Disaggregation results in a masterDisaggregation results in a master production scheduleproduction schedule
  • 10. © 2008 Prentice Hall, Inc. 13 – 10 Aggregate PlanningAggregate Planning StrategiesStrategies 1.1. Use inventories to absorb changes inUse inventories to absorb changes in demanddemand 2.2. Accommodate changes by varyingAccommodate changes by varying workforce sizeworkforce size 3.3. Use part-timers, overtime, or idle time toUse part-timers, overtime, or idle time to absorb changesabsorb changes 4.4. Use subcontractors and maintain a stableUse subcontractors and maintain a stable workforceworkforce 5.5. Change prices or other factors toChange prices or other factors to influence demandinfluence demand
  • 11. © 2008 Prentice Hall, Inc. 13 – 11 Capacity OptionsCapacity Options  Changing inventory levelsChanging inventory levels  Increase inventory in low demandIncrease inventory in low demand periods to meet high demand inperiods to meet high demand in the futurethe future  Increases costs associated withIncreases costs associated with storage, insurance, handling,storage, insurance, handling, obsolescence, and capitalobsolescence, and capital investment 15% to 40%investment 15% to 40%  Shortages can mean lost sales dueShortages can mean lost sales due to long lead times and poorto long lead times and poor customer servicecustomer service
  • 12. © 2008 Prentice Hall, Inc. 13 – 12 Capacity OptionsCapacity Options  Varying workforce size by hiringVarying workforce size by hiring or layoffsor layoffs  Match production rate to demandMatch production rate to demand  Training and separation costs forTraining and separation costs for hiring and laying off workershiring and laying off workers  New workers may have lowerNew workers may have lower productivityproductivity  Laying off workers may lowerLaying off workers may lower morale and productivitymorale and productivity
  • 13. © 2008 Prentice Hall, Inc. 13 – 13 Capacity OptionsCapacity Options  Varying production rate throughVarying production rate through overtime or idle timeovertime or idle time  Allows constant workforceAllows constant workforce  May be difficult to meet largeMay be difficult to meet large increases in demandincreases in demand  Overtime can be costly and mayOvertime can be costly and may drive down productivitydrive down productivity  Absorbing idle time may beAbsorbing idle time may be difficultdifficult
  • 14. © 2008 Prentice Hall, Inc. 13 – 14 Capacity OptionsCapacity Options  SubcontractingSubcontracting  Temporary measure duringTemporary measure during periods of peak demandperiods of peak demand  May be costlyMay be costly  Assuring quality and timelyAssuring quality and timely delivery may be difficultdelivery may be difficult  Exposes your customers to aExposes your customers to a possible competitorpossible competitor
  • 15. © 2008 Prentice Hall, Inc. 13 – 15 Capacity OptionsCapacity Options  Using part-time workersUsing part-time workers  Useful for filling unskilled or lowUseful for filling unskilled or low skilled positions, especially inskilled positions, especially in servicesservices
  • 16. © 2008 Prentice Hall, Inc. 13 – 16 Demand OptionsDemand Options  Influencing demandInfluencing demand  Use advertising or promotion toUse advertising or promotion to increase demand in low periodsincrease demand in low periods  Attempt to shiftAttempt to shift demand to slowdemand to slow periodsperiods  May not beMay not be sufficient tosufficient to balance demandbalance demand and capacityand capacity
  • 17. © 2008 Prentice Hall, Inc. 13 – 17 Demand OptionsDemand Options  Back ordering during high-Back ordering during high- demand periodsdemand periods  Requires customers to wait for anRequires customers to wait for an order without loss of goodwill ororder without loss of goodwill or the orderthe order  Most effective when there are fewMost effective when there are few if any substitutes for the productif any substitutes for the product or serviceor service  Often results in lost salesOften results in lost sales
  • 18. © 2008 Prentice Hall, Inc. 13 – 18 Demand OptionsDemand Options  Counterseasonal product andCounterseasonal product and service mixingservice mixing  Develop a product mix ofDevelop a product mix of counterseasonal itemscounterseasonal items  May lead to products or servicesMay lead to products or services outside the company’s areas ofoutside the company’s areas of expertiseexpertise
  • 19. © 2008 Prentice Hall, Inc. 13 – 19 Aggregate Planning OptionsAggregate Planning Options Table 13.1Table 13.1 OptionOption AdvantagesAdvantages DisadvantagesDisadvantages Some CommentsSome Comments ChangingChanging inventoryinventory levelslevels Changes inChanges in humanhuman resources areresources are gradual orgradual or none; no abruptnone; no abrupt productionproduction changes.changes. InventoryInventory holding costholding cost may increase.may increase. Shortages mayShortages may result in lostresult in lost sales.sales. Applies mainly toApplies mainly to production, notproduction, not service,service, operations.operations. VaryingVarying workforceworkforce size bysize by hiring orhiring or layoffslayoffs Avoids the costsAvoids the costs of otherof other alternatives.alternatives. Hiring, layoff,Hiring, layoff, and trainingand training costs may becosts may be significant.significant. Used where sizeUsed where size of labor pool isof labor pool is large.large.
  • 20. © 2008 Prentice Hall, Inc. 13 – 20 Aggregate Planning OptionsAggregate Planning Options Table 13.1Table 13.1 OptionOption AdvantagesAdvantages DisadvantagesDisadvantages Some CommentsSome Comments VaryingVarying productionproduction ratesrates throughthrough overtime orovertime or idle timeidle time MatchesMatches seasonalseasonal fluctuationsfluctuations without hiring/without hiring/ training costs.training costs. OvertimeOvertime premiums; tiredpremiums; tired workers; mayworkers; may not meetnot meet demand.demand. Allows flexibilityAllows flexibility within thewithin the aggregate plan.aggregate plan. Sub-Sub- contractingcontracting PermitsPermits flexibility andflexibility and smoothing ofsmoothing of the firm’sthe firm’s output.output. Loss of qualityLoss of quality control;control; reduced profits;reduced profits; loss of futureloss of future business.business. Applies mainly inApplies mainly in productionproduction settings.settings.
  • 21. © 2008 Prentice Hall, Inc. 13 – 21 Aggregate Planning OptionsAggregate Planning Options Table 13.1Table 13.1 OptionOption AdvantagesAdvantages DisadvantagesDisadvantages Some CommentsSome Comments Using part-Using part- timetime workersworkers Is less costlyIs less costly and moreand more flexible thanflexible than full-timefull-time workers.workers. High turnover/High turnover/ training costs;training costs; quality suffers;quality suffers; schedulingscheduling difficult.difficult. Good forGood for unskilled jobs inunskilled jobs in areas with largeareas with large temporary labortemporary labor pools.pools. InfluencingInfluencing demanddemand Tries to useTries to use excessexcess capacity.capacity. Discounts drawDiscounts draw new customers.new customers. Uncertainty inUncertainty in demand. Harddemand. Hard to matchto match demand todemand to supply exactly.supply exactly. CreatesCreates marketingmarketing ideas.ideas. OverbookingOverbooking used in someused in some businesses.businesses.
  • 22. © 2008 Prentice Hall, Inc. 13 – 22 Aggregate Planning OptionsAggregate Planning Options Table 13.1Table 13.1 OptionOption AdvantagesAdvantages DisadvantagesDisadvantages Some CommentsSome Comments BackBack orderingordering duringduring high-high- demanddemand periodsperiods May avoidMay avoid overtime.overtime. Keeps capacityKeeps capacity constant.constant. Customer mustCustomer must be willing tobe willing to wait, butwait, but goodwill is lost.goodwill is lost. Many companiesMany companies back order.back order. Counter-Counter- seasonalseasonal productproduct and serviceand service mixingmixing Fully utilizesFully utilizes resources;resources; allows stableallows stable workforce.workforce. May requireMay require skills orskills or equipmentequipment outside theoutside the firm’s areas offirm’s areas of expertise.expertise. Risky findingRisky finding products orproducts or services withservices with oppositeopposite demanddemand patterns.patterns.
  • 23. © 2008 Prentice Hall, Inc. 13 – 23 Methods for AggregateMethods for Aggregate PlanningPlanning  A mixed strategy may be the bestA mixed strategy may be the best way to achieve minimum costsway to achieve minimum costs  There are many possible mixedThere are many possible mixed strategiesstrategies  Finding the optimal plan is notFinding the optimal plan is not always possiblealways possible
  • 24. © 2008 Prentice Hall, Inc. 13 – 24 Mixing Options toMixing Options to Develop a PlanDevelop a Plan  Chase strategyChase strategy  Match output rates to demandMatch output rates to demand forecast for each periodforecast for each period  Vary workforce levels or varyVary workforce levels or vary production rateproduction rate  Favored by many serviceFavored by many service organizationsorganizations
  • 25. © 2008 Prentice Hall, Inc. 13 – 25 Mixing Options toMixing Options to Develop a PlanDevelop a Plan  Level strategyLevel strategy  Daily production is uniformDaily production is uniform  Use inventory or idle time as bufferUse inventory or idle time as buffer  Stable production leads to betterStable production leads to better quality and productivityquality and productivity  Some combination of capacitySome combination of capacity options, a mixed strategy, might beoptions, a mixed strategy, might be the best solutionthe best solution
  • 26. © 2008 Prentice Hall, Inc. 13 – 26 Graphical MethodsGraphical Methods  Popular techniquesPopular techniques  Easy to understand and useEasy to understand and use  Trial-and-error approaches that doTrial-and-error approaches that do not guarantee an optimal solutionnot guarantee an optimal solution  Require only limited computationsRequire only limited computations
  • 27. © 2008 Prentice Hall, Inc. 13 – 27 Graphical MethodsGraphical Methods 1.1. Determine the demand for each periodDetermine the demand for each period 2.2. Determine the capacity for regular time,Determine the capacity for regular time, overtime, and subcontracting each periodovertime, and subcontracting each period 3.3. Find labor costs, hiring and layoff costs,Find labor costs, hiring and layoff costs, and inventory holding costsand inventory holding costs 4.4. Consider company policy on workers andConsider company policy on workers and stock levelsstock levels 5.5. Develop alternative plans and examineDevelop alternative plans and examine their total coststheir total costs
  • 28. © 2008 Prentice Hall, Inc. 13 – 28 Roofing Supplier Example 1Roofing Supplier Example 1 Table 13.2Table 13.2 MonthMonth Expected DemandExpected Demand ProductionProduction DaysDays Demand Per DayDemand Per Day (computed)(computed) JanJan 900900 2222 4141 FebFeb 700700 1818 3939 MarMar 800800 2121 3838 AprApr 1,2001,200 2121 5757 MayMay 1,5001,500 2222 6868 JuneJune 1,1001,100 2020 5555 6,2006,200 124124 = = 50= = 50 units per dayunits per day 6,2006,200 124124 AverageAverage requirementrequirement == Total expected demandTotal expected demand Number of production daysNumber of production days
  • 29. © 2008 Prentice Hall, Inc. 13 – 29 Roofing Supplier Example 1Roofing Supplier Example 1 Figure 13.3Figure 13.3 7070 – 6060 – 5050 – 4040 – 3030 – 00 – JanJan FebFeb MarMar AprApr MayMay JuneJune == MonthMonth       2222 1818 2121 2121 2222 2020 == Number ofNumber of working daysworking days ProductionrateperworkingdayProductionrateperworkingday Level production using averageLevel production using average monthly forecast demandmonthly forecast demand Forecast demandForecast demand
  • 30. © 2008 Prentice Hall, Inc. 13 – 30 Roofing Supplier Example 2Roofing Supplier Example 2 Table 13.3Table 13.3 Cost InformationCost Information Inventory carrying costInventory carrying cost $ 5$ 5 per unit per monthper unit per month Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day)) Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour ((aboveabove 88 hours per dayhours per day)) Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit Cost of increasing daily production rateCost of increasing daily production rate (hiring and training)(hiring and training) $300$300 per unitper unit Cost of decreasing daily production rateCost of decreasing daily production rate (layoffs)(layoffs) $600$600 per unitper unit Plan 1 – constant workforce Plan 1 – constant workforce
  • 31. © 2008 Prentice Hall, Inc. 13 – 31 Roofing Supplier Example 2Roofing Supplier Example 2 Table 13.3Table 13.3 Cost InformationCost Information Inventory carry costInventory carry cost $ 5$ 5 per unit per monthper unit per month Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day)) Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour ((aboveabove 88 hours per dayhours per day)) Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit Cost of increasing daily production rateCost of increasing daily production rate (hiring and training)(hiring and training) $300$300 per unitper unit Cost of decreasing daily production rateCost of decreasing daily production rate (layoffs)(layoffs) $600$600 per unitper unit Plan 1 – constant workforce Plan 1 – constant workforce Month Production at 50 Units per Day Demand Forecast Monthly Inventory Change Ending Inventory Jan 1,100 900 +200 200 Feb 900 700 +200 400 Mar 1,050 800 +250 650 Apr 1,050 1,200 -150 500 May 1,100 1,500 -400 100 June 1,000 1,100 -100 0 1,850 Total units of inventory carried over from one month to the next = 1,850 units Workforce required to produce 50 units per day = 10 workers
  • 32. © 2008 Prentice Hall, Inc. 13 – 32 Roofing Supplier Example 2Roofing Supplier Example 2 Table 13.3Table 13.3 Cost InformationCost Information Inventory carry costInventory carry cost $ 5$ 5 per unit per monthper unit per month Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day)) Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour ((aboveabove 88 hours per dayhours per day)) Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit Cost of increasing daily production rateCost of increasing daily production rate (hiring and training)(hiring and training) $300$300 per unitper unit Cost of decreasing daily production rateCost of decreasing daily production rate (layoffs)(layoffs) $600$600 per unitper unit Month Production at 50 Units per Day Demand Forecast Monthly Inventory Change Ending Inventory Jan 1,100 900 +200 200 Feb 900 700 +200 400 Mar 1,050 800 +250 650 Apr 1,050 1,200 -150 500 May 1,100 1,500 -400 100 June 1,000 1,100 -100 0 1,850 Total units of inventory carried over from one month to the next = 1,850 units Workforce required to produce 50 units per day = 10 workers Costs Calculations Inventory carrying $9,250 (= 1,850 units carried x $5 per unit) Regular-time labor 49,600 (= 10 workers x $40 per day x 124 days) Other costs (overtime, hiring, layoffs, subcontracting) 0 Total cost $58,850
  • 33. © 2008 Prentice Hall, Inc. 13 – 33 Roofing Supplier Example 2Roofing Supplier Example 2 Figure 13.4Figure 13.4 CumulativedemandunitsCumulativedemandunits 7,0007,000 – 6,0006,000 – 5,0005,000 – 4,0004,000 – 3,0003,000 – 2,000 – 1,000 – – JanJan FebFeb MarMar AprApr MayMay JuneJune Cumulative forecastCumulative forecast requirementsrequirements Cumulative levelCumulative level production usingproduction using average monthlyaverage monthly forecastforecast requirementsrequirements ReductionReduction of inventoryof inventory Excess inventoryExcess inventory 6,200 units6,200 units
  • 34. © 2008 Prentice Hall, Inc. 13 – 34 Roofing Supplier Example 3Roofing Supplier Example 3 Table 13.2Table 13.2 MonthMonth Expected DemandExpected Demand ProductionProduction DaysDays Demand Per DayDemand Per Day (computed)(computed) JanJan 900900 2222 4141 FebFeb 700700 1818 3939 MarMar 800800 2121 3838 AprApr 1,2001,200 2121 5757 MayMay 1,5001,500 2222 6868 JuneJune 1,1001,100 2020 5555 6,2006,200 124124 Minimum requirementMinimum requirement = 38= 38 units per dayunits per day Plan 2 – subcontracting Plan 2 – subcontracting
  • 35. © 2008 Prentice Hall, Inc. 13 – 35 Roofing Supplier Example 3Roofing Supplier Example 3 7070 – 6060 – 5050 – 4040 – 3030 – 00 – JanJan FebFeb MarMar AprApr MayMay JuneJune == MonthMonth       2222 1818 2121 2121 2222 2020 == Number ofNumber of working daysworking days ProductionrateperworkingdayProductionrateperworkingday Level productionLevel production using lowestusing lowest monthly forecastmonthly forecast demanddemand Forecast demandForecast demand
  • 36. © 2008 Prentice Hall, Inc. 13 – 36 Roofing Supplier Example 3Roofing Supplier Example 3 Table 13.3Table 13.3 Cost InformationCost Information Inventory carrying costInventory carrying cost $ 5$ 5 per unit per monthper unit per month Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day)) Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour ((aboveabove 88 hours per dayhours per day)) Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit Cost of increasing daily production rateCost of increasing daily production rate (hiring and training)(hiring and training) $300$300 per unitper unit Cost of decreasing daily production rateCost of decreasing daily production rate (layoffs)(layoffs) $600$600 per unitper unit
  • 37. © 2008 Prentice Hall, Inc. 13 – 37 Roofing Supplier Example 3Roofing Supplier Example 3 Table 13.3Table 13.3 Cost InformationCost Information Inventory carry costInventory carry cost $ 5$ 5 per unit per monthper unit per month Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day)) Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour ((aboveabove 88 hours per dayhours per day)) Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit Cost of increasing daily production rateCost of increasing daily production rate (hiring and training)(hiring and training) $300$300 per unitper unit Cost of decreasing daily production rateCost of decreasing daily production rate (layoffs)(layoffs) $600$600 per unitper unit In-house production = 38 units per day x 124 days = 4,712 units Subcontract units = 6,200 - 4,712 = 1,488 units
  • 38. © 2008 Prentice Hall, Inc. 13 – 38 Table 13.3Table 13.3 Cost InformationCost Information Inventory carry costInventory carry cost $ 5$ 5 per unit per monthper unit per month Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day)) Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour ((aboveabove 88 hours per dayhours per day)) Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit Cost of increasing daily production rateCost of increasing daily production rate (hiring and training)(hiring and training) $300$300 per unitper unit Cost of decreasing daily production rateCost of decreasing daily production rate (layoffs)(layoffs) $600$600 per unitper unit Roofing Supplier Example 3Roofing Supplier Example 3 In-house production = 38 units per day x 124 days = 4,712 units Subcontract units = 6,200 - 4,712 = 1,488 units Costs Calculations Regular-time labor $37,696 (= 7.6 workers x $40 per day x 124 days) Subcontracting 14,880 (= 1,488 units x $10 per unit) Total cost $52,576
  • 39. © 2008 Prentice Hall, Inc. 13 – 39 Roofing Supplier Example 4Roofing Supplier Example 4 Table 13.2Table 13.2 MonthMonth Expected DemandExpected Demand ProductionProduction DaysDays Demand Per DayDemand Per Day (computed)(computed) JanJan 900900 2222 4141 FebFeb 700700 1818 3939 MarMar 800800 2121 3838 AprApr 1,2001,200 2121 5757 MayMay 1,5001,500 2222 6868 JuneJune 1,1001,100 2020 5555 6,2006,200 124124 Production = Expected DemandProduction = Expected Demand Plan 3 – hiring and firing Plan 3 – hiring and firing
  • 40. © 2008 Prentice Hall, Inc. 13 – 40 Roofing Supplier Example 4Roofing Supplier Example 4 7070 – 6060 – 5050 – 4040 – 3030 – 00 – JanJan FebFeb MarMar AprApr MayMay JuneJune == MonthMonth       2222 1818 2121 2121 2222 2020 == Number ofNumber of working daysworking days ProductionrateperworkingdayProductionrateperworkingday Forecast demand andForecast demand and monthly productionmonthly production
  • 41. © 2008 Prentice Hall, Inc. 13 – 41 Roofing Supplier Example 4Roofing Supplier Example 4 Table 13.3Table 13.3 Cost InformationCost Information Inventory carrying costInventory carrying cost $ 5$ 5 per unit per monthper unit per month Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day)) Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour ((aboveabove 88 hours per dayhours per day)) Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit Cost of increasing daily production rateCost of increasing daily production rate (hiring and training)(hiring and training) $300$300 per unitper unit Cost of decreasing daily production rateCost of decreasing daily production rate (layoffs)(layoffs) $600$600 per unitper unit
  • 42. © 2008 Prentice Hall, Inc. 13 – 42 Roofing Supplier Example 4Roofing Supplier Example 4 Table 13.3Table 13.3 Cost InformationCost Information Inventory carrying costInventory carrying cost $ 5$ 5 per unit per monthper unit per month Subcontracting cost per unitSubcontracting cost per unit $10$10 per unitper unit Average pay rateAverage pay rate $ 5$ 5 per hourper hour ($40($40 per dayper day)) Overtime pay rateOvertime pay rate $ 7$ 7 per hourper hour ((aboveabove 88 hours per dayhours per day)) Labor-hours to produce a unitLabor-hours to produce a unit 1.61.6 hours per unithours per unit Cost of increasing daily production rateCost of increasing daily production rate (hiring and training)(hiring and training) $300$300 per unitper unit Cost of decreasing daily production rateCost of decreasing daily production rate (layoffs)(layoffs) $600$600 per unitper unit Month Forecast (units) Daily Prod Rate Basic Production Cost (demand x 1.6 hrs/unit x $5/hr) Extra Cost of Increasing Production (hiring cost) Extra Cost of Decreasing Production (layoff cost) Total Cost Jan 900 41 $ 7,200 — — $ 7,200 Feb 700 39 5,600 — $1,200 (= 2 x $600) 6,800 Mar 800 38 6,400 — $600 (= 1 x $600) 7,000 Apr 1,200 57 9,600 $5,700 (= 19 x $300) — 15,300 May 1,500 68 12,000 $3,300 (= 11 x $300) — 15,300 June 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
  • 43. © 2008 Prentice Hall, Inc. 13 – 43 Comparison of Three PlansComparison of Three Plans Table 13.5Table 13.5 CostCost Plan 1Plan 1 Plan 2Plan 2 Plan 3Plan 3 Inventory carryingInventory carrying $ 9,250$ 9,250 $ 0$ 0 $ 0$ 0 Regular laborRegular labor 49,60049,600 37,69637,696 49,60049,600 Overtime laborOvertime labor 00 00 00 HiringHiring 00 00 9,0009,000 LayoffsLayoffs 00 00 9,6009,600 SubcontractingSubcontracting 00 14,88014,880 00 Total costTotal cost $58,850$58,850 $52,576$52,576 $68,200$68,200 Plan 2 is the lowest cost optionPlan 2 is the lowest cost option
  • 44. © 2008 Prentice Hall, Inc. 13 – 44 Mathematical ApproachesMathematical Approaches  Useful for generating strategiesUseful for generating strategies  Transportation Method of LinearTransportation Method of Linear ProgrammingProgramming  Produces an optimal planProduces an optimal plan  Management Coefficients ModelManagement Coefficients Model  Model built around manager’sModel built around manager’s experience and performanceexperience and performance  Other ModelsOther Models  Linear Decision RuleLinear Decision Rule  SimulationSimulation
  • 45. © 2008 Prentice Hall, Inc. 13 – 45 Transportation MethodTransportation Method Table 13.6Table 13.6 CostsCosts Regular timeRegular time $40$40 per tireper tire OvertimeOvertime $50$50 per tireper tire SubcontractingSubcontracting $70$70 per tireper tire CarryingCarrying $ 2$ 2 per tire per monthper tire per month Sales PeriodSales Period MarMar AprApr MayMay DemandDemand 800800 1,0001,000 750750 Capacity:Capacity: RegularRegular 700700 700700 700700 OvertimeOvertime 5050 5050 5050 SubcontractingSubcontracting 150150 150150 130130 Beginning inventoryBeginning inventory 100100 tirestires
  • 46. © 2008 Prentice Hall, Inc. 13 – 46 Transportation ExampleTransportation Example Important pointsImportant points 1.1. Carrying costs areCarrying costs are $2$2/tire/month. If/tire/month. If goods are made in one period and heldgoods are made in one period and held over to the next, holding costs areover to the next, holding costs are incurredincurred 2.2. Supply must equal demand, so aSupply must equal demand, so a dummy column called “unuseddummy column called “unused capacity” is addedcapacity” is added 3.3. Because back ordering is not viable inBecause back ordering is not viable in this example, cells that might be used tothis example, cells that might be used to satisfy earlier demand are not availablesatisfy earlier demand are not available
  • 47. © 2008 Prentice Hall, Inc. 13 – 47 Transportation ExampleTransportation Example Important pointsImportant points 4.4. Quantities in each column designate theQuantities in each column designate the levels of inventory needed to meetlevels of inventory needed to meet demand requirementsdemand requirements 5.5. In general, production should beIn general, production should be allocated to the lowest cost cellallocated to the lowest cost cell available without exceeding unusedavailable without exceeding unused capacity in the row or demand in thecapacity in the row or demand in the columncolumn
  • 48. © 2008 Prentice Hall, Inc. 13 – 48 TransportationTransportation ExampleExample Table 13.7Table 13.7
  • 49. © 2008 Prentice Hall, Inc. 13 – 49 Management CoefficientsManagement Coefficients ModelModel  Builds a model based on manager’sBuilds a model based on manager’s experience and performanceexperience and performance  A regression model is constructedA regression model is constructed to define the relationships betweento define the relationships between decision variablesdecision variables  Objective is to removeObjective is to remove inconsistencies in decision makinginconsistencies in decision making
  • 50. © 2008 Prentice Hall, Inc. 13 – 50 Other ModelsOther Models Linear Decision RuleLinear Decision Rule  Minimizes costs using quadratic cost curvesMinimizes costs using quadratic cost curves  Operates over a particular time periodOperates over a particular time period SimulationSimulation  Uses a search procedure to try differentUses a search procedure to try different combinations of variablescombinations of variables  Develops feasible but not necessarily optimalDevelops feasible but not necessarily optimal solutionssolutions
  • 51. © 2008 Prentice Hall, Inc. 13 – 51 Summary of AggregateSummary of Aggregate Planning MethodsPlanning Methods TechniquesTechniques SolutionSolution ApproachesApproaches Important AspectsImportant Aspects GraphicalGraphical methodsmethods Trial andTrial and errorerror Simple to understand andSimple to understand and easy to use. Manyeasy to use. Many solutions; one chosensolutions; one chosen may not be optimal.may not be optimal. TransportationTransportation method of linearmethod of linear programmingprogramming OptimizationOptimization LP software available;LP software available; permits sensitivitypermits sensitivity analysis and newanalysis and new constraints; linearconstraints; linear functions may not befunctions may not be realistic.realistic. Table 13.8Table 13.8
  • 52. © 2008 Prentice Hall, Inc. 13 – 52 Summary of AggregateSummary of Aggregate Planning MethodsPlanning Methods TechniquesTechniques SolutionSolution ApproachesApproaches Important AspectsImportant Aspects ManagementManagement coefficientscoefficients modelmodel HeuristicHeuristic Simple, easy to implement;Simple, easy to implement; tries to mimic manager’stries to mimic manager’s decision process; usesdecision process; uses regression.regression. SimulationSimulation ChangeChange parametersparameters Complex; may be difficultComplex; may be difficult to build and for managersto build and for managers to understand.to understand. Table 13.8Table 13.8
  • 53. © 2008 Prentice Hall, Inc. 13 – 53 Aggregate Planning inAggregate Planning in ServicesServices Controlling the cost of labor is criticalControlling the cost of labor is critical 1.1. Accurate scheduling of labor-hours toAccurate scheduling of labor-hours to assure quick response to customerassure quick response to customer demanddemand 2.2. An on-call labor resource to coverAn on-call labor resource to cover unexpected demandunexpected demand 3.3. Flexibility of individual worker skillsFlexibility of individual worker skills 4.4. Flexibility in rate of output or hours ofFlexibility in rate of output or hours of workwork
  • 54. © 2008 Prentice Hall, Inc. 13 – 54 Five Service ScenariosFive Service Scenarios  RestaurantsRestaurants  Smoothing the productionSmoothing the production processprocess  Determining the optimalDetermining the optimal workforce sizeworkforce size  HospitalsHospitals  Responding to patient demandResponding to patient demand
  • 55. © 2008 Prentice Hall, Inc. 13 – 55 Five Service ScenariosFive Service Scenarios  National Chains of Small ServiceNational Chains of Small Service FirmsFirms  Planning done at national levelPlanning done at national level and at local leveland at local level  Miscellaneous ServicesMiscellaneous Services  Plan human resourcePlan human resource requirementsrequirements  Manage demandManage demand
  • 56. © 2008 Prentice Hall, Inc. 13 – 56 Law Firm ExampleLaw Firm Example Table 13.9Table 13.9 Labor-Hours RequiredLabor-Hours Required Capacity ConstraintsCapacity Constraints (2)(2) (3)(3) (4)(4) (5)(5) (6)(6) (1)(1) ForecastsForecasts MaximumMaximum Number ofNumber of Category ofCategory of BestBest LikelyLikely WorstWorst Demand inDemand in QualifiedQualified Legal BusinessLegal Business (hours)(hours) (hours)(hours) (hours)(hours) PeoplePeople PersonnelPersonnel Trial workTrial work 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 lawCorporate law 8,0008,000 7,0007,000 6,5006,500 16.016.0 1515 Real estate lawReal estate law 1,7001,700 1,5001,500 1,3001,300 3.43.4 66 Criminal lawCriminal law 3,5003,500 3,0003,000 2,5002,500 7.07.0 1212 Total hoursTotal hours 19,50019,500 17,00017,000 15,00015,000 Lawyers neededLawyers needed 3939 3434 3030
  • 57. © 2008 Prentice Hall, Inc. 13 – 57 Five Service ScenariosFive Service Scenarios  Airline industryAirline industry  Extremely complex planningExtremely complex planning problemproblem  Involves number of flights,Involves number of flights, number of passengers, air andnumber of passengers, air and ground personnel, allocation ofground personnel, allocation of seats to fare classesseats to fare classes  Resources spread through theResources spread through the entire systementire system
  • 58. © 2008 Prentice Hall, Inc. 13 – 58 Yield ManagementYield Management Allocating resources to customers atAllocating resources to customers at prices that will maximize yield orprices that will maximize yield or revenuerevenue 1.1. Service or product can be sold inService or product can be sold in advance of consumptionadvance of consumption 2.2. Demand fluctuatesDemand fluctuates 3.3. Capacity is relatively fixedCapacity is relatively fixed 4.4. Demand can be segmentedDemand can be segmented 5.5. Variable costs are low and fixed costsVariable costs are low and fixed costs are highare high
  • 59. © 2008 Prentice Hall, Inc. 13 – 59 DemandDemand CurveCurve Yield Management ExampleYield Management Example Figure 13.5Figure 13.5 Passed-up contribution Money left on the table Potential customers exist whoPotential customers exist who are willing to pay more than theare willing to pay more than the $15$15 variable cost of the roomvariable cost of the room Some customers who paidSome customers who paid $150$150 were actually willingwere actually willing to pay more for the roomto pay more for the roomTotalTotal $$ contributioncontribution == ((PricePrice)) xx (50(50 roomsrooms)) == ($150 -($150 - $15)$15) xx (50)(50) == $6,750$6,750 PricePrice Room salesRoom sales 100100 5050 $150$150 Price chargedPrice charged for roomfor room $15$15 Variable costVariable cost of roomof room
  • 60. © 2008 Prentice Hall, Inc. 13 – 60 Total $ contribution =Total $ contribution = (1(1st pricest price) x 30) x 30 roomsrooms + (2+ (2ndnd price) x 30 rooms =price) x 30 rooms = ($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 DemandDemand CurveCurve Yield Management ExampleYield Management Example Figure 13.6Figure 13.6 PricePrice Room salesRoom sales 100100 6060 3030 $100$100 Price 1Price 1 for roomfor room $200$200 Price 2Price 2 for roomfor room $15$15 Variable costVariable cost of roomof room
  • 61. © 2008 Prentice Hall, Inc. 13 – 61 Yield Management MatrixYield Management Matrix Durationofuse UnpredictablePredictable Price Tend to be fixed Tend to be variable Quadrant 1: Quadrant 2: Movies Hotels Stadiums/arenas Airlines Convention centers Rental cars Hotel meeting space Cruise lines Quadrant 3: Quadrant 4: Restaurants Continuing care Golf courses hospitals Internet service providers Figure 13.7Figure 13.7
  • 62. © 2008 Prentice Hall, Inc. 13 – 62 Making Yield ManagementMaking Yield Management WorkWork 1.1. Multiple pricing structures mustMultiple pricing structures must be feasible and appear logical tobe feasible and appear logical to the customerthe customer 2.2. Forecasts of the use and durationForecasts of the use and duration of useof use 3.3. Changes in demandChanges in demand
  • 63. © 2008 Prentice Hall, Inc. 13 – 63 ReferenceReference • www.csun.eduwww.csun.edu • Principles of OperationsPrinciples of Operations ManagementManagement • www.aast.eduwww.aast.edu