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Aggregate Planning
McGraw-Hill/Irwin
Learning Objectives
Planning Horizon
Aggregate planning: Intermediate-range
capacity planning, usually covering 2 to 12
months.
Long range
Short
range
Now
Intermediate
range
2 months
1 Year
13-3
Long-range plans
Long term capacity
Location / layout
13-4
Planning Sequence
Figure 13.1
Corporate
strategies
and policies
Economic,
competitive,
and political
conditions
Aggregate
demand
forecasts
Business Plan
Establishes operations
and capacity strategies
Aggregate plan
Establishes
operations capacity
Master schedule
Establishes schedules
for specific products
13-5
Aggregate Planning
Begin with forecast of aggregate demand
Forecast intermediate range
General plan to meet demand by setting
Output levels
Employment
Finished goods inventory level
Demand forecast
Policies
Subcontracting
Overtime
Inventory levels
Back orders
Costs
Inventory carrying
Back orders
Hiring/firing
Overtime
Inventory changes
Subcontracting
13-7
Inventory
Output
Employment
Subcontracting
Backordering
13-8
Reactive
Alter capacity to match demand
Mixed
Some of each
13-9
Demand Options
Pricing
Promotion
Back orders
New demand
13-10
Capacity Options
13-11
13-12
Basic Strategies
Level capacity strategy:
Maintaining a steady rate of regular-time
output while meeting variations in
demand by a combination of options.
13-13
Chase Approach
Advantages
Investment in inventory is low
Labor utilization in high
Disadvantages
The cost of adjusting output rates and/or
workforce levels
13-14
Level Approach
Advantages
Stable output rates and workforce
Disadvantages
Greater inventory costs
Increased overtime and idle time
Resource utilizations vary over time
13-15
13-16
Cumulative Graph
Cumulative output/demand
Figure 13.3
Cumulative
production
Cumulative
demand
2
10
13-17
Average Inventory
13-18
Mathematical Techniques
Linear programming: Methods for
obtaining optimal solutions to problems
involving allocation of scarce resources
in terms of cost minimization.
Simulation models: Computerized models
that can be tested under different
scenarios to problems.
13-19
Table 13.7
Summary of Planning
Techniques
Technique
Solution
Characteristics
Graphical/charting
Heuristic (trial
and error)
Linear
programming
Optimizing
Simulation
Heuristic (trial
and error)
13-20
Disaggregation
Master
Schedule
13-22
13-23
Master Scheduling
Master schedule
Determines quantities needed to meet
demand
Interfaces with
Marketing
Capacity planning
Production planning
Distribution planning
13-24
Master Scheduler
Evaluates impact of new orders
Provides delivery dates for orders
Deals with problems
Production delays
Revising master schedule
Insufficient capacity
13-25
Inputs
Outputs
Beginning inventory
Forecast
Customer orders
Projected inventory
Master
Scheduling
13-26
Projected on-hand
=
inventory
Inventory from
previous week
Current weeks
requirements
13-27
64
Forecast
Customer Orders
(committed)
Projected on-hand
inventory
Customer orders are
larger than forecast in
week 1
1
30
JUNE
2
3
30 30
4
30
5
40
33
20
10
31
-29
JULY
6
7
40 40
8
40
13-28
Time Fences
13-29
frozen
(firm or
fixed)
slushy
somewhat
firm
liquid
(open)
13-30
13-31