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SYNDICATE 8

Operations Management Syndicate Assignment Chapter 16

3.

Demand and Working Days

February

March

April

May

Demand forecast

80000

64000

100000

40000

Number of working days

20

20

20

20

 

Costs

Inventory holding cost

$10/unit/month

Marginal cost of backorder

$20/unit

Hiring cost

$50/worker

Layoff cost

$70/worker

Labor hours required

0.25/unit

Straight-time cost

$10/hour

Overtime cost

$15/hour

 

February

March

Total

Production requirement

80000

64000

Production hours required

20000

16000

Working days per month

20

20

Hours per month per worker

160

160

Workers required

125

100

New workers hired

25

0

Hiring cost

1250

0

1250

Workers laid off

0

25

Layoff cost

0

1750

1750

Straight-time cost

200000

160000

360000

 

Total cost

363000

 

April

May

Total

Beginning inventory

0

Beginning inventory

0

Working days per month

20

Working days per month

20

Production hours available

16000

Production hours available

16000

Regular shift production

64000

Regular shift production

64000

Demand forecast

100000

Demand forecast

40000

Units available before overtime

-36000

Units available before overtime

24000

Units overtime

36000

Units overtime

0

Overtime hours

9000

SYNDICATE 8

Overtime hours permitted

5000

Overtime cost

18750

Overtime cost

0

18750

Overtime production

20000

Units excess

24000

Units available after overtime

-16000

Inventory cost

240000

240000

Units backordered

16000

Backorder cost

320000

320000

Straight-time cost

160000

Straight-time cost

160000

320000

 

Total cost

898750

Total cost of this plan

1261750

4.

Demand and Working Days

Spring

Summer

Fall

Winter

Demand forecast

20000

10000

15000

18000

Number of working days

50

50

50

50

Costs

Inventory holding cost

$20/unit/quarter

 

Marginal cost of backorder

$8/unit

Hiring cost

$100/worker

 

Layoff cost

$200/worker

Labor hours required

2/unit

Straight-time cost

$10/hour

Overtime cost

$15/hour

Spring

Summer

Fall

Total

Beginning inventory

1000

Production requirement

10000

15000

Working days per quarter

50

Production hours required

20000

30000

Production hours available

28000

Working days per quarter

50

50

Regular shift production

14000

Hours per quarter per worker

400

400

Demand forecast

20000

Workers required

50

75

Units available before overtime

-5000

New workers hired

0

25

Units overtime

5000

Hiring cost

0

2500

2500

Overtime cost

150000

Workers laid off

20

0

Straight-time cost

280000

Layoff cost

4000

0

4000

Total cost

430000

Straight-time cost

200000

300000

500000

 

Total cost

506500

SYNDICATE 8

 

Winter

Production requirement

18000

Working days per quarter

50

Production hours available

30000

Actual production

15000

Units backordered

3000

Backorder cost

24000

Straight-time cost

300000

Total cost

324000

Total cost of this plan

1260500

5.

 

January

February

March

April

May

June

July

Demand forecast

2500

3000

4000

3500

3500

3000

3000

Number of working days

20

20

20

20

20

20

20

August

September

October

November

December

Totals

Number of working days

4000

4000

4000

3000

3000

40500

Demand forecast

20

20

20

20

20

240

Costs

Production time

1/unit

Average labor cost

$10/hour

Shortage cost

$20/unit/month

 

Carrying cost

$5/unit/month

Inventory

 

Beginning inventory

500 units

One-half month

Safety stock

 

Aggregate Production Planning Requirements

 

January

February

March

April

May

June

July

Beginning inventory

500

1250

1500

2000

1750

1750

1500

Demand forecast

2500

3000

4000

3500

3500

3000

3000

Safety stock

1250

1500

2000

1750

1750

1500

1500

Production requirements

3250

3250

4500

3250

3500

2750

3000

Ending inventory

1250

1500

2000

1750

1750

1500

1500

SYNDICATE 8

 

August

September

October

November

December

Beginning inventory

1500

2000

2000

2000

1500

Demand forecast

4000

4000

4000

3000

3000

Safety stock

2000

2000

2000

1500

1500

Production requirements

4500

4000

4000

2500

3000

Ending inventory

2000

2000

2000

1500

1500

Workers = (40500*1)/(240*8) = 22 people

 
 

January

February

March

April

May

June

July

Beginning inventory

500

1520

2040

1560

1580

1600

2120

Working days per month

20

20

20

20

20

20

20

Production hours available

3520

3520

3520

 

3520

3520

3520

3520

Actual production

3520

3520

3520

3520

3520

3520

3520

Demand forecast

2500

3000

4000

3500

3500

3000

3000

Ending inventory

1520

2040

1560

1580

1600

2120

2640

Safety stock

1250

1500

2000

1750

1750

1500

1500

Units excess

270

540

0

0

0

620

1140

Inventory cost

1350

2700

0

0

0

3100

5700

Straight-time cost

35200

35200

35200

35200

35200

35200

35200

August

September

October

 

November

December

Total

Beginning inventory

2640

2160

1680

1200

1720

Working days per month

20

20

20

20

20

Production hours available

3520

3520

3520

3520

3520

Actual production

3520

3520

3520

3520

3520

Demand forecast

4000

4000

4000

3000

3000

Ending inventory

2160

1680

1200

1720

2240

Safety stock

2000

2000

2000

1500

1500

Units excess

160

0

0

220

740

Inventory cost

800

0

0

1100

3700

18450

Straight-time cost

35200

35200

35200

35200

35200

422400

 

Total cost

440850

6.

 

Demand and Working Days

 

January February

March

April

May

June

Customers' hourly requirements

6240

5300

7040

6380

6240

4800

Number of working days

25

25

25

25

25

25

SYNDICATE 8

 

January

February

March

April

May

June

Total

Working days per month

25

25

25

25

25

25

Working hours available

4800

4800

4800

4800

4800

4800

Customers' hourly requirements

6240

5300

7040

6380

6240

4800

Overtime working hours needed

1440

500

2240

1580

1440

0

Maximum overtime work

1440

1440

1440

1440

1440

0

Overtime cost

59040

59040

59040

59040

59040

0

295200

Early work performed

0

940

140

0

0

0

Early work cost

0

3760

560

0

0

0

4320

Late work performed

0

0

0

0

0

0

Late work cost

0

0

0

0

0

0

Straight-time cost

168000

168000

168000

168000

168000

168000

1008000

 

Total cost

1307520

10.

 

May

June

July

August

Total

 

Beginning inventory

403

158

313

168

Demand for bathing suits

3200

2800

 

3100

3000

FT employees production available

2460

2460

2460

2460

Demand deficit

337

182

327

372

PT employees production needed (3)

495

495

495

495

Excess inventory

158

313

168

123

Production cost

134320

124520

130720

124920

514480

Carrying cost

126.4

250.4

134.4

98.4

609.6

 

Total cost

515089.6