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Aggregate
Planning
in the Supply
Chain
8-1
Outline
Role of aggregate planning in a supply chain
The aggregate planning problem
Aggregate planning strategies
Implementing aggregate planning in practice
8-2
8-3
production rate
workforce
overtime
machine capacity level
subcontracting
backlog
inventory on hand
8-4
8-5
8-6
8-7
8-8
Chase Strategy
Production rate is synchronized with demand by varying
machine capacity or hiring and laying off workers as the
demand rate varies
However, in practice, it is often difficult to vary capacity and
workforce on short notice
Expensive if cost of varying capacity is high
Negative effect on workforce morale
Results in low levels of inventory
Should be used when inventory holding costs are high and costs
of changing capacity are low
8-9
8-10
Level Strategy
Maintain stable machine capacity and workforce levels with a
constant output rate
Shortages and surpluses result in fluctuations in inventory levels
over time
Inventories that are built up in anticipation of future demand or
backlogs are carried over from high to low demand periods
Better for worker morale
Large inventories and backlogs may accumulate
Should be used when inventory holding and backlog costs are
relatively low
8-11
Fundamental Tradeoffs in
Aggregate Planning
Capacity (regular time, overtime, subcontract)
Inventory
Backlog / lost sales
Basic Strategies
Chase strategy
Time flexibility from workforce or capacity
Level strategy
8-12
Aggregate Planning at
Red Tomato Tools
Month
January
February
March
April
May
June
Demand Forecast
1,600
3,000
3,200
3,800
2,200
2,200
8-13
Cost
$10/unit
$2/unit/month
$5/unit/month
$300/worker
$500/worker
4/unit
$4/hour
$6/hour
$30/unit
8-14
8-15
t 1
t 1
t 1
t 1
t 1
500 Lt 6 Ot 2 I t
6
t 1
t 1
t 1
5 S t 10 Pt 30 C t
8-16
W t W t 1 H t Lt, or
W t W t 1 H t Lt 0
for t 1,...,6, where W 0 80.
8-17
Pt 40W t Ot 4 ,
40W t Ot 4 Pt 0,
for t 1,...,6.
8-18
I t 1 Pt C t Dt S t 1 I t S t ,
I t 1 Pt C t Dt S t 1 I t S t 0,
for t 1,...,6,where I 0 1,000,
S 0 0,and I 6 500.
8-19
Ot 10W t,
10W t Ot 0,
for t 1,...,6.
8-20
Scenarios
Increase in holding cost (from $2 to $6)
Overtime cost drops to $4.1 per hour
Increased demand fluctuation
8-21
Demand Forecast
1,000
3,000
3,800
4,800
2,000
1,400
8-22
8-23
8-24