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Aggregate Planning Final

The document contains production planning information for 6 products (A-F) over multiple periods. It includes details on setup times, batch sizes, production quantities, number of setups and calculated net production times for each product. It then checks the plan against constraints of maximum overtime, workforce capacity, inventory and confirms the plan is okay.

Uploaded by

Dewashish Rai
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as XLSX, PDF, TXT or read online on Scribd
44 views12 pages

Aggregate Planning Final

The document contains production planning information for 6 products (A-F) over multiple periods. It includes details on setup times, batch sizes, production quantities, number of setups and calculated net production times for each product. It then checks the plan against constraints of maximum overtime, workforce capacity, inventory and confirms the plan is okay.

Uploaded by

Dewashish Rai
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLSX, PDF, TXT or read online on Scribd
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Cost 300 500 640 6 2 5 30

Hired Laid Off Worker Over time Inv Stk out Sub Ctrct Productn
Period Ht Lt Wt Ot It St Ct Pt Demand

0 90 1000
1 0 26 64 0 1960 0 0 2560 1600
2 0 0 64 0 1520 0 0 2560 3000
3 0 0 64 0 880 0 0 2560 3200
4 0 0 64 0 0 220 140 2560 3800
5 0 0 64 0 140 0 0 2560 2200
6 0 0 64 0 500 0 0 2560 2200

Total Cost = 427660 Total Product Matl Cost Revenue

Revenue per unit $ per unit $


Wt Cost 245760 Hours per day 8 A 15 54
Ot Cost 0 No of working Days 20 B 7 30
Ht cost 0 Wage Rate ($ per hour) 4 C 9 39
Lt Cost 13000 Wages per month 640 D 12 49
It cost 10000 E 9 36
St Cost 1100 For Aggregate Product F 13 48
Ct Cost 4200 Hours Required 4
Pt 153600 Material Cost 10 Start Inventory 1000
Capacity per worker 40 End Inventory 500
No of workers at start 80

Disaggregating the Aggregate Plan


Product Setup Avg Batch Prod Time Productio No of Setup % share of Nett
Time per
per unit Productio Production
batch
(hour) size (hour) n Qty Setups Time unit sold n Time
A 8 50 5.6 256 5 40 0.1 1433.6
B 6 150 3 640 4 24 0.25 1920
C 8 100 3.8 512 5 40 0.2 1945.6
D 10 50 4.8 256 5 50 0.1 1228.8
E 6 100 3.6 512 5 30 0.2 1843.2
F 5 75 4.3 384 5 25 0.15 1651.2
209 10022.4
Total 10231.4
Is Plan OK? Yes

Product Setup Avg Batch Prod Time Productio No of Setup % share of Nett
Time per
per unit Productio Production
batch
(hour) size (hour) n Qty Setups Time unit sold n Time
A 8 50 5.6 256 5 40 0.1 1433.6
B 6 150 3 640 4 24 0.25 1920
C 8 100 3.8 512 5 40 0.2 1945.6
D 10 50 4.8 256 5 50 0.1 1228.8
E 6 100 3.6 512 5 30 0.2 1843.2
F 5 75 4.3 384 5 25 0.15 1651.2
209 10022.4
Total 10231.4
Is Plan OK? Yes

Product Setup Avg Batch Prod Time Productio No of Setup % share of Nett
Time per
per unit Productio Production
batch
(hour) size (hour) n Qty Setups Time unit sold n Time
A 8 50 5.6 256 5 40 0.1 1433.6
B 6 150 3 640 4 24 0.25 1920
C 8 100 3.8 512 5 40 0.2 1945.6
D 10 50 4.8 256 5 50 0.1 1228.8
E 6 100 3.6 512 5 30 0.2 1843.2
F 5 75 4.3 384 5 25 0.15 1651.2
209 10022.4
Total 10231.4
Is Plan OK? Yes

Product Setup Avg Batch Prod Time Productio No of Setup % share of Nett
Time per
per unit Productio Production
batch
(hour) size (hour) n Qty Setups Time unit sold n Time
A 8 50 5.6 256 5 40 0.1 1433.6
B 6 150 3 640 4 24 0.25 1920
C 8 100 3.8 512 5 40 0.2 1945.6
D 10 50 4.8 256 5 50 0.1 1228.8
E 6 100 3.6 512 5 30 0.2 1843.2
F 5 75 4.3 384 5 25 0.15 1651.2
209 10022.4
Total 10231.4
Is Plan OK? Yes

Product Setup Avg Batch Prod Time Productio No of Setup % share of Nett
Time per
per unit Productio Production
batch
(hour) size (hour) n Qty Setups Time unit sold n Time
A 8 50 5.6 256 5 40 0.1 1433.6
B 6 150 3 640 4 24 0.25 1920
C 8 100 3.8 512 5 40 0.2 1945.6
D 10 50 4.8 256 5 50 0.1 1228.8
E 6 100 3.6 512 5 30 0.2 1843.2
F 5 75 4.3 384 5 25 0.15 1651.2
209 10022.4
Total 10231.4
Is Plan OK? Yes

Product Setup Avg Batch Prod Time Productio No of Setup % share of Nett
Time per
per unit Productio Production
batch
(hour) size (hour) n Qty Setups Time unit sold n Time
A 8 50 5.6 256 5 40 0.1 1433.6
B 6 150 3 640 4 24 0.25 1920
C 8 100 3.8 512 5 40 0.2 1945.6
D 10 50 4.8 256 5 50 0.1 1228.8
E 6 100 3.6 512 5 30 0.2 1843.2
F 5 75 4.3 384 5 25 0.15 1651.2
209 10022.4
Total 10231.4
Is Plan OK? Yes
Constraints
Max OT Workforce Capacity Inventory Max OT Is Plan OK
Available

640 0 0 0 640 Yes


640 0 0 0 640 Yes
640 0 0 0 640 Yes
640 0 0 0 640 Yes
640 0 0 0 640 Yes
640 0 0 0 640 Yes

Setup Avg Batch Prod Time Net % share of Revenue of


Time per Productio the
per unit
batch n Time per composite
(hour) size (hour) unit (hour) unit sold product
8 50 5.6 5.76 10.00% 0.8
6 150 3 3.04 25.00% 1.5
8 100 3.8 3.88 20.00% 1.6
10 50 4.8 5.00 10.00% 1
6 100 3.6 3.66 20.00% 1.2
5 75 4.3 4.37 15.00% 0.75
100.00% 6.85

Period 1 No of 64
2560
Workers

Available 10240

Period 2 No of 64

2560

Workers
Available 10240

Period 3 No of 64

2560

Workers

Available 10240

Period 4 No of 64

2560

Workers

Available 10240

Period 5 No of 64

2560

Workers
Available 10240

Period 6 No of 64

2560

Workers

Available 10240
Cost 300 500 640 6 2 5 30
Hired Laid Off Worker Over time Inv Stk out Sub Ctrct Productn
Period Ht Lt Wt Ot It St Ct Pt Demand

0 90 1000
1 0 25 65 0 2000 0 0 2600 1600
2 0 0 65 0 1600 0 0 2600 3000
3 0 0 65 0 1000 0 0 2600 3200
4 0 0 65 0 0 180 20 2600 3800
5 0 6 59 0 0 20 0 2360 2200
6 0 0 59 0 140 0 0 2360 2200
7 0 0 59 0 0 0 0 2360 2500
8 0 0 59 0 360 0 0 2360 2000
9 0 0 59 0 920 0 0 2360 1800
10 0 0 59 0 280 0 0 2360 3000
11 0 0 59 0 1440 0 0 2360 1200
12 0 0 59 0 500 0 5700 2360 9000

Total Cost = 965860 Total Product Matl Cost Revenue

Revenue per unit $ per unit $


Wt Cost 468480 Hours per day 8 A 15 54
Ot Cost 0 No of working Days 20 B 7 30
Ht cost 0 Wage Rate ($ per hour) 4 C 9 39
Lt Cost 15500 Wages per month 640 D 12 49
It cost 16480 E 9 36
St Cost 1000 For Aggregate Product F 13 48
Ct Cost 171600 Hours Required 4
Pt 292800 Material Cost 10 Start Inventory 1000
Capacity per worker 40 End Inventory 500
No of workers at start 80

Disaggregating the Aggregate Plan


Product Setup Avg Batch Prod Time Productio No of Setup % share of Nett
Time per
per unit Productio Production
batch
(hour) size (hour) n Qty Setups Time unit sold n Time
A 8 50 5.6 260 5 40 0.1 1456
B 6 150 3 650 4 24 0.25 1950
C 8 100 3.8 520 5 40 0.2 1976
D 10 50 4.8 260 5 50 0.1 1248
E 6 100 3.6 520 5 30 0.2 1872
F 5 75 4.3 390 5 25 0.15 1677
209 10179
Total 10388
Is Plan OK? Yes
Product Setup Avg Batch Prod Time Productio No of Setup % share of Nett
Time per
per unit Productio Production
batch
(hour) size (hour) n Qty Setups Time unit sold n Time
A 8 50 5.6 260 5 40 0.1 1456
B 6 150 3 650 4 24 0.25 1950
C 8 100 3.8 520 5 40 0.2 1976
D 10 50 4.8 260 5 50 0.1 1248
E 6 100 3.6 520 5 30 0.2 1872
F 5 75 4.3 390 5 25 0.15 1677
209 10179
Total 10388
Is Plan OK? Yes

Product Setup Avg Batch Prod Time Productio No of Setup % share of Nett
Time per
per unit Productio Production
batch
(hour) size (hour) n Qty Setups Time unit sold n Time
A 8 50 5.6 260 5 40 0.1 1456
B 6 150 3 650 4 24 0.25 1950
C 8 100 3.8 520 5 40 0.2 1976
D 10 50 4.8 260 5 50 0.1 1248
E 6 100 3.6 520 5 30 0.2 1872
F 5 75 4.3 390 5 25 0.15 1677
209 10179
Total 10388
Is Plan OK? Yes

Product Setup Avg Batch Prod Time Productio No of Setup % share of Nett
Time per
per unit Productio Production
batch
(hour) size (hour) n Qty Setups Time unit sold n Time
A 8 50 5.6 260 5 40 0.1 1456
B 6 150 3 650 4 24 0.25 1950
C 8 100 3.8 520 5 40 0.2 1976
D 10 50 4.8 260 5 50 0.1 1248
E 6 100 3.6 520 5 30 0.2 1872
F 5 75 4.3 390 5 25 0.15 1677
209 10179
Total 10388
Is Plan OK? Yes
Product Setup Avg Batch Prod Time Productio No of Setup % share of Nett
Time per
per unit Productio Production
batch
(hour) size (hour) n Qty Setups Time unit sold n Time
A 8 50 5.6 260 5 40 0.1 1456
B 6 150 3 650 4 24 0.25 1950
C 8 100 3.8 520 5 40 0.2 1976
D 10 50 4.8 260 5 50 0.1 1248
E 6 100 3.6 520 5 30 0.2 1872
F 5 75 4.3 390 5 25 0.15 1677
209 10179
Total 10388
Is Plan OK? Yes

Product Setup Avg Batch Prod Time Productio No of Setup % share of Nett
Time per
per unit Productio Production
batch
(hour) size (hour) n Qty Setups Time unit sold n Time
A 8 50 5.6 260 5 40 0.1 1456
B 6 150 3 650 4 24 0.25 1950
C 8 100 3.8 520 5 40 0.2 1976
D 10 50 4.8 260 5 50 0.1 1248
E 6 100 3.6 520 5 30 0.2 1872
F 5 75 4.3 390 5 25 0.15 1677
209 10179
Total 10388
Is Plan OK? Not OK
Constraints
Max OT Workforce Capacity Inventory Max OT Is Plan OK
Available

650 0 0 0 650 Yes


650 0 0 0 650 Yes
650 0 0 0 650 Yes
650 0 0 0 650 Yes
590 0 0 0 590 Yes
590 0 0 0 590 Not OK
590 0 0 0 590
590 0 0 0 590
590 0 0 0 590
590 0 0 0 590
590 0 0 0 590
590 0 0 0 590

Setup Avg Batch Prod Time Net % share of Revenue of


Time per Productio the
per unit
batch n Time per composite
(hour) size (hour) unit (hour) unit sold product
8 50 5.6 5.76 10.00% 0.8
6 150 3 3.04 25.00% 1.5
8 100 3.8 3.88 20.00% 1.6
10 50 4.8 5.00 10.00% 1
6 100 3.6 3.66 20.00% 1.2
5 75 4.3 4.37 15.00% 0.75
100.00% 6.85

Period 1 No of 65
2600
Workers

Available 10400
Period 2 No of 65

2600

Workers

Available 10400

Period 3 No of 65

2600

Workers

Available 10400

Period 4 No of 65

2600

Workers

Available 10400
Period 5 No of 65

2360

Workers

Available 10400

Period 6 No of 59

2360

Workers

Available 9440

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