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Aggregate Planning (Chapter 8-9)

Demand Forecast

Month Demand Forecast

January 1,800
February 1,500
March 1,100
April 900
May 1,100
June 1,600

Costs

Item Cost
Materials cost/unit $ 100
Inventory holding cost/unit/month $ 2
Marginal cost of stockout/unit/month $ 5
Hiring and training cost/worker $ 200
Layoff cost/worker $ 250
Labor hours required/unit 5
Regular time cost/hour $ 4
Over time cost/hour $ 6
Marginal subcontracting cost/unit $ 20

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Aggregate Plan Decision Variables

Ht Lt Wt Ot It St Ct Pt
Period # Hired # Laid off # Workforce Overtime Inventory Stockout Subcontract Production Demand Price
0 0 0 53 0 400 0 0 100
1 0 53 0 0 0 0 1,400 0 1,800 100
2 0 0 0 0 0 0 1,500 0 1,500 100
3 0 0 0 0 0 0 1,100 0 1,100 100
4 0 0 0 0 0 0 900 0 900 100
5 0 0 0 0 0 0 1,100 0 1,100 100
6 0 0 0 0 400 0 2,000 0 1,600 100
0 114 0 1143
Aggregate Plan Costs
Period Hiring Lay off Regular time Overtime Inventory Stockout Subcontract Material
1 0 13,250 0 0 0 0 28,000 0
2 0 0 0 0 0 0 30,000 0
3 0 0 0 0 0 0 22,000 0
4 0 0 0 0 0 0 18,000 0
5 0 0 0 0 0 0 22,000 0
6 0 0 0 0 600 0 40,000 0
Total Cost = $ 173,850
Total Revenue = $ 800,000
Profit = $ 626,150

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Aggregate Plan

Period # Hired # Laid off # Workforce over time Inventory Stockout Subcontract
0 0 0 80 1000 0 0
1 0 18 62 0 1880 0 0
2 0 0 62 0 1360 0 0
3 0 0 62 620 795 0 0
4 0 0 62 620 0 370 0
5 0 0 62 620 65 0 0
6 0 0 62 620 500 0 0

Aggregate Plan Costs

Period Hiring Lay off Regular time Over time Inventory Stockout Subcontract
1 0 4500 39680 0 2820 0 0
2 0 0 39680 0 2040 0 0
3 0 0 39680 0 1192.5 0 0
4 0 0 39680 0 0 1850 0
5 0 0 39680 0 97.5 0 0
6 0 0 39680 0 750 0 0

Total Cost = 251330

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Production Demand

2480 1,600
2480 3,000
2635 3,200
2635 3,800
2635 2,200
2635 2,200

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Aggregate Plan Decision Variables

Period # Hired # Laid off # Workforce Overtime Inventory Stockout Subcontract

0 0
1 0
2 0
3 16
4 0
5 0
6 0
0 80 0 1,000 0 0
29 51 0 1,450 0 0
0 51 0 500 0 0
0 68 0 0 0 0
0 68 0 0 500 600
0 68 0 0 0 0
0 68 0 500 0 0

Aggregate Plan Costs

Period Hiring Lay off Regular time Over time Inventory Stockout Subcontract
1 0 7,188 32,800 0 2,175 0 0
2 0 0 32,800 0 750 0 0
3 0 0 43,200 0 0 0 0
4 0 0 43,200 0 0 2,500 12,000
5 0 0 43,200 0 0 0 0
6 0 0 43,200 0 750 0 0

Total Cost = $ 1,753,763

Total Revenue = $ 496,000

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Constraints

Production Demand Workforce Production Inventory Over time

2,050 1,600 0 0 0 513

2,050 3,000 0 0 0 513
2,700 3,200 0 0 0 675
2,700 3,800 0 0 0 675
2,700 2,200 0 0 0 675
2,700 2,200 0 0 0 675

Material
205,000
205,000
270,000
270,000
270,000
270,000

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