Sit-Yuen Foo has produced monthly forecasts of demand for a family of products as shown below. At the end of each month he reviews performance, and assigns a notional holding cost of $30 for every unit held in stock. If there are shortages, 20 per cent of orders are lost with a cost of $300 a unit, and the rest are met by back-orders, with a cost of $75 a unit. Each time the production rate changes there is a cost of $22,500. Designed capacity is 600 units a month, but utilization seldom reaches 80 per cent. How can Sit-Yuen Foo design an aggregate plan for the products? Month 1 2 3 4 6. 7 8 9. 10 Aggregate demand 460 420 390 450 540 375 240 150 100 210
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- Ajax Manufacturing produces a single product, which takes 8.0 pounds of direct materials per unitproduced. Assume that it is currently at the end of the first quarter of the year, and there are 50,000pounds of material on hand. The company’s policy is to maintain an end-of-quarter inventoryof materials equal to 25 percent of the following quarter’s material requirements for production.How many units of product were produced in the first quarter of the year? Under the assumptionthat production will increase by 10 percent in the second quarter, what are the direct materialsrequirements (in pounds) for planned production in the second quarter?14.5. Mama’s Stuffin’ is a popular food item during the fall and winter months, but it is marginal in the spring and summer. Use the following demand forecasts and costs to determine which of the following production planning strategies is best for Mama’s Stuffin’: a. Level production over the 12 months. b. Produce to meet demand each month. Absorb variations in demand by changing the size of the workforce. c. Keep the workforce at its current level. Supplement with overtime and subcontracting as necessary.1. The Kintampo Tourist Resort (KTR) is one of Ghana’s best holiday centers and sells a special type of souvenir called Expensive. As you might expect, the demand for Expensive is highly seasonal as tourist centers exhibit a highly seasonal attraction pattern, with peaks during the summer months. The following forecasts are available for Expensive.Inventory carrying cost = GH¢3 per piece per quarter Production per employee = 1000 piece per quarter Regular workforce = 50 workersCost of regular production = GH¢50 per piece Hiring cost per employee = GH¢75Firing cost per employee = GH¢100 The management of KTR does not wish to use Level production nor Chase Demand but wants to adopt one of the following strategies:Strategy I: Produce 71,000 pieces in Quarter 1, Produce 151,000pieces in Quarter 2, Produce 200,000 pieces in Quarter 3,and Produce 30,000 pieces in Quarter 4.Strategy II: Produce 51,000 pieces in Quarter 1, Produce 161,000pieces in Quarter 2, Produce 210,000 pieces in Quarter…
- Southeast Soda Pop, Inc., has a new fruit drink for which it has high hopes. John Mittenthal, the production planner, has assembled the following cost data and demand forecast: demand forecast. Quarter Forecast 1 1,900 2 1,200 3 1,600 4 800 Costs/Other Data Previous quarter's output=1,200 cases Beginning inventory=0 cases Stockout cost of backorders=$160 per case Inventory holding cost=$40 per case at end of quarter Hiring employees=$35 per case Terminating employees=$80 per case Subcontracting cost=$65 per case Unit cost on regular time=$30 per case Overtime cost=$20 extra per case Capacity on regular time=1,900 cases per quarter John's job is to develop an aggregate plan. The three initial options he wants to evaluate are: • Plan A: a strategy that hires and fires personnel as necessary to meet the forecast. • Plan B: a level strategy. • Plan C: a level strategy that…Over the past 12 months, Super Toy Mart hasexperienced a demand variance of 10,000 units and has produced an order variance of 12,000 units.a) What is the bullwhip measure for Super Toy Mart?b) If Super Toy Mart had made a perfect forecast of demandover the past 12 months and had decided to order 1/12 ofthat annual demand each month, what would its bullwhipmeasure have been?Dwayne Cole, owner of a F lorida firm that ma nufacturesdisplay cabinets, develops an 8-month aggregate plan.Demand and capacity (in units) a re fo recast as follows: The cost of producing each unit is $1,000 on regular time, $ 1,300 onovertime, and $1,800 on a subcontract. Inventory carrying cost is$200 per unit per month. There is no beginning or ending inventory )in stock, and no backorders are permitted from period to period. ~Let the production (workforce) vary by using regular timefirst, then overtime, and then subcontracting.a) Set up a production plan that minimizes cost by producingexactly what the demand is each month. This plan allows nobackorders or inventory. What is this plan's cost?b) Through better p lanning, regular-time production can be setat exactly the same amount, 275 units, per month. If demandcannot be met there is no cost assigned to shortages and theywill not be filled. Does this a lter…
- A Pizza Company has a demand forecast for the next 12 months that is shown in Table 1 The current workforce of 100 staff can produce 1500 cases of pizzas per month. (a) Prepare a production plan that keeps the output level. How much warehouse space would the company need for this plan? (b) Prepare a demand chase plan. What implications would this have for staffing levels, assuming that the maximum amount of overtime would result in production levels of only 10 per cent greater than normal working hours? Table 1 demand forecast Month Demand (cases per month) January 600 February 800 March 1000 April 1500 May 2000 June 1700 July…1. David Villa Manufacturing has the following demand aggregate requirements And other data for the next four periods: Quarter Forecast 1 1400 2 1200 3 1600 4 1500 COSTS/OTHER DATA Previous quarter’s output = 1,300 cases Beginning inventory = 0 cases Stock out cost = $50 per case Inventory holding cost = $10 per case at end of quarter Hiring employees = $40 per case Terminating employees = $80 per case Subcontracting cost = $60 per case Unit cost on regular time = $30 per case Overtime cost = $15 extra per case Capacity on regular time = 1,800 cases per quarter The three initial options he wants to evaluate are: Plan A: a strategy that hires and fires personnel as necessary to meet the forecast. Plan B: a level strategy. Plan C: a level strategy that produces 1,350 cases per quarter and meets the forecast demand with inventory and subcontracting. Which strategy is the lowest-cost plan? If you are…Lot sizing A producer with one product faces the following forecasted demand for the next 10 weeks: week 1. 2. 3. 4. 5. 6. 7. 8. 9. 10 Requirement 30 12 72 11 24 42 35 30 75 68 Assume furthermore that the producer faces a Set-up cost (K) equal to 132 each time production takes place and storage costs (h) of 0.6 per unit per week. a) Find the cost of the two extreme strategies Lot - for - lot (produce exactly what is needed in each period) and Produce - once (produce everything needed in the first period).
- Arizona Instruments produces bar code scannersfor consumers and other manufacturers on aproduce to stock basis. The production planneris developing an MPS for scanners for the next12 weeks.The product is built in a fixedorder quantityof 125 units, and there are 110 units in beginninginventory. The demand forecasts for the next 12weeks, including customer orders promised tocustomers for delivery in that time period, isshown on the shown on the next slide. Customer Orders Forecast Demand Period 1 2 3 4 5 6 7 8 9 10 11 12 Forecast 50 50 50 50 75 75 75 75 50 50 50 50 Customer order 35 25 25 20 0 15 0 0 10 0 0 10 Determine the MPS and Available to Promise (ATP)Refer to the Par, Inc., problem. Suppose that Par’s management encounters the following situations. a. The accounting department revises its estimate of the profit contribution for the deluxe bag to $18 per bag. b. A new low-cost material is available for the standard bag, and the profit contribution per standard bag can be increased to $20 per bag. (Assume that the profit contribution of the deluxe bag is the original $9 value.) c. New sewing equipment is available that would increase the sewing operation capacity to 750 hours. (Assume that 10A+9B is the appropriate objective function.) If each of these situations is encountered separately, what is the optimal solution and the total profit contribution?Slopes & Sleds (S&S) makes skis, snowboards, and high- end sledding equipment. As shown below, the demand for its products is highly seasonal. The company employs 10 workers who can each produce 200 units of various equipment per month. The cost of regular production is $8 per unit, overtime $12, and subcontracting $16. Overtime is limited to regular production each period. Subcontracting is unlimited. Hiring and firing costs are $500 per worker. In- ventory holding costs are $2 per unit per month. Given the estimates of demand below, create an aggregate production plan for Slopes & Sleds using: a. the current workforce level (supplemented with overtime and subcontracting as needed), b. chase demand. Month DemandJanuary 6400February 7000March 1500April 500May 600June 1400July 1600August 2000September 1400October 1500November 5200December 6900