Chapter 9 - Production Planning

8/16/2019 Chapter 9 - Production Planning

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PRODUCTIONPLANNING AND

CONTROL(MEFB 433)

Dr. Weria Khaksar

Email: [email protected]

Room No.: BN-03-08


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9- PRODUCTIONPLANNING


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9.1. AGGREGATE PLANNING


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9- Producto! P"#!!!$

9.1. A$$r%$#t% P"#!!!$&

A$$r%$#t% '"#!!!$ is essentially a big-picture aroa!h to lannin".

Does not #o!us on ea!h indi$idual rodu!t. %heya""re"ate all models to"ether unless there wereonly a sin"le rodu!t.

E#'"%*&

&!Donald's( Bur"er Kin" or %ele$ision )rodu!tion.

*t +e"ins with a forecast o# a""re"ate demand#or the intermediate ran"e and #ollowed +y ageneral plan to meet demand re,uirements +ysettin" outut( emloyment and nal rodu!t

in$entory le$els or ser$i!e !aa!ities.


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9.1. A$$r%$#t% P"#!!!$&


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9.1. A$$r%$#t% P"#!!!$&

B#*c A$$r%$#t% P"#!!!$ *tr#t%$%*

1. Pro#ct+% (D%#!d O'to!*)

)ri!in" )romotion

Ba!k orders

New demand

,. R%#ct+% (C#'#ct O'to!*)

irin" and rin" /$ertimesla!k time

)art time workers

*n$entories

1u+!ontra!tin"

3. M%d (D%#!d #!d C#'#ct)


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9.1. A$$r%$#t% P"#!!!$&

B#*c tr#t%$%* /or M%%t!$ U!%+%!D%#!d

1. M#!t#! # "%+%" 0or/orc%.

,. M#!t#! # *t%#d out'ut r#t%.

3. M#tc2 d%#!d '%rod '%rod.

4. U*% # co!#to! o/ d%c*o!

+#r#"%*.


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9.1. A$$r%$#t% P"#!!!$&

T%c2!u%* /or A$$r%$#t% P"#!!!$B#*c t%'* ! #$$r%$#t% '"#!!!$&

2. Determine demand #or ea!h eriod

. Determine !aa!ities #or ea!h eriod

3. *denti#y !omany or deartmental oli!ies that arerele$ant.

4. Determine unit !osts #or re"ular time( o$ertime(su+!ontra!tin"( holdin" in$entories( +a!k orders(

layo5s and other !osts.6. De$elo alternati$e lans and !omute the !ost

#or ea!h.

7. *# satis#a!tory lans emer"e( sele!t the +est one.

/therwise return to ste 6.


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9.1. A$$r%$#t% P"#!!!$&

T%c2!u%* /or A$$r%$#t% P"#!!!$

- Tr#"-#!d-Error T%c2!u%* U*!$

Gr#'2* #!d 'r%#d*2%%t*

- M#t2%#tc#" T%c2!u%*


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9.1. A$$r%$#t% P"#!!!$&

T%c2!u%* /or A$$r%$#t% P"#!!!$&Tr#"-#!d-Error T%c2!u%* U*!$ Gr#'2*#!d 'r%#d*2%%t*Num+ero#workersin aeriod

Num+er o#workers atend o#re$iouseriod

9Num+er o#new workersat start o# theeriod

Num+er o# laid-o5 workers atstart o# theeriod

Num+ero#workersin aeriod

Num+er o#workers atend o#re$iouseriod

9Num+er o#new workersat start o# theeriod

Num+er o# laid-o5 workers atstart o# theeriod

*n$entoryat the

end o# a

eriod

*n$entory

at end o#the re$ious

eriod

9)rodu!tion

in the!urrent

eriod

mount used tosatis#y demand inthe !urrent eriod

*n$entoryat the

end o# a

eriod

*n$entory

at end o#the re$ious

eriod

9)rodu!tion

in the!urrent

eriod

mount used tosatis#y demand inthe !urrent eriod

;ost#ora

/utut !ost


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9.1. A$$r%$#t% P"#!!!$&

T%c2!u%* /or A$$r%$#t% P"#!!!$&Tr#"-#!d-Error T%c2!u%* U*!$ Gr#'2*#!d 'r%#d*2%%t*T'% o/ co*t 5o0 to c#"cu"#t%

/utut Re"ular????.... /$ertime????. 1u+!ontra!t???..ire>ay-o5 ire??????..

>ay o5?????.

Re"ular !ost er unit uantity o# re"ularoutut/$ertime !ost er unit /$ertime ,uantity1u+!ontra!t !ost er unit 1u+!ontra!t,uantity

;ost er hire Num+er hired;ost er lay o5 Num+er laid o5 ;arryin" !ost er unit $era"e in$entory

Ba!k-order !ost er unit Num+er o# +a!k-order units

T'% o/ co*t 5o0 to c#"cu"#t%

/utut Re"ular????.... /$ertime????. 1u+!ontra!t???..ire>ay-o5 ire??????..

>ay o5?????.


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9- Producto! P"#!!!$9.1. A$$r%$#t% P"#!!!$&

T%c2!u%* /or A$$r%$#t% P"#!!!$&Tr#"-#!d-Error T%c2!u%* U*!$ Gr#'2*#!d 'r%#d*2%%t*EAamle:)lanners o# a !omany that makes se$eral models o#skate+oard are a+out to reare the a""re"ate lan that will!o$er siA eriods. %hey ha$e assem+led the #ollowin"in#ormations:P%ro

d1 , 3 4 6 7 Tot#

"

ore!ast

00 00 300 400 600 00 2(800

Co*t* /utut Re"ulartime

/$ertime

1u+!ontra!t *n$entory

C er skate+oard C3 er skate+oard C7 er skate+oard C2 er skate+oard er eriod on a$era"e

in$entory C6 er skate+oard er eriod


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9- Producto! P"#!!!$9.1. A$$r%$#t% P"#!!!$&T%c2!u%* /or A$$r%$#t% P"#!!!$& Tr#"-#!d-

Error T%c2!u%* U*!$ Gr#'2* #!d'r%#d*2%%t*

EAamle:

%hey now want to e$aluate a lan that !alls #or a steady rate o#

re"ular-time outut( mainly usin" in$entory to a+sor+ theune$en demand +ut allowin" some +a!klo". /$ertime andsu+!ontra!tin" are not used +e!ause they want steady outut. %hey intend to start with ero in$entory on hand in the rsteriod.)reare an a""re"ate lan and determine its !ost usin" there!edin" in#ormation.ssume a le$el outut rate o# 300 units


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9- Producto! P"#!!!$9.1. A$$r%$#t% P"#!!!$&

T%c2!u%* /or A$$r%$#t% P"#!!!$&Tr#"-#!d-Error T%c2!u%* U*!$ Gr#'2*#!d 'r%#d*2%%t*EAamle:

P%rod 1 , 3 4 6 7 Tot#"

ore!ast/utut Re"ular /$ertime 1u+!ontra!t/utut ore!ast*n$entory Be"innin" Endin" $era"eBa!klo"

;osts/utut Re"ular /$ertime 1u+!ontra!t ire>ay o5 *n$entoryBa!k orders

00

300----------200

0200600

C700

---------------

C 60C 0

00

300----------200

20000260

0

700---------------260

0

300

300----------

0

000000

0

700---------------00

0

400

300----------


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9- Producto! P"#!!!$9.1. A$$r%$#t% P"#!!!$&T%c2!u%* /or A$$r%$#t% P"#!!!$& Tr#"-#!d-Error T%c2!u%* U*!$ Gr#'2* #!d'r%#d*2%%t*

EAamle:

#ter re$iewin" the lan de$eloed +e#ore( lanners ha$ede!ided to de$elo an alternati$e lan. %hey understandthat one erson is a+out to retire #rom the !omany.Rather than rela!e the erson( they would like to staywith the smaller work#or!e and use o$ertime to make u#or the lost outut. %he redu!ed re"ular-time outut is80 units er eriod. %he maAimum mount o# o$ertimeoutut er eriod is 40 units.De$elo a lan and !omare it to the re$ious one.


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9- Producto! P"#!!!$9.1. A$$r%$#t% P"#!!!$&

T%c2!u%* /or A$$r%$#t% P"#!!!$&Tr#"-#!d-Error T%c2!u%* U*!$ Gr#'2*#!d 'r%#d*2%%t*EAamle:

P%rod 1 , 3 4 6 7 Tot#"

ore!ast/utut Re"ular /$ertime 1u+!ontra!t/utut ore!ast*n$entory Be"innin" Endin" $era"eBa!klo"

;osts /utut Re"ular /$ertime 1u+!ontra!t ire>ay o5 *n$entoryBa!k orders

00

80----------80

080400

C6700

----------

C 40C 0

00

80----------80

8027020

0

6700

----------20

0

300

8040

-----0

2702802F0

0

67020----------2F0

0

400

8040

-----


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9- Producto! P"#!!!$9.1. A$$r%$#t% P"#!!!$&

A$$r%$#t% '"#!!!$ ! *%r+c%*& %akes into a!!ount roGe!ted !ustomerdemands( e,uiment !aa!ities and la+or!aa!ities.

%he resultin" lan is a time-hasedroGe!tion o# ser$i!e sta5 re,uirements.

E#'"%*&

- Hospitals- Airlines- Restaurants


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9.,. MATER PRODUCTIONC5EDULING (MP)


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9- Producto! P"#!!!$9.,. M#*t%r Producto! c2%du"% (MP)

D*#$$r%$#t!$ t2% #$$r%$#t% '"#!&Disa""re"ation means +reakin"down the a""re"ate lan intose!i! rodu!t re,uirements in

order to determine la+orre,uirements


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M#*t%r c2%du"!$&&)1 is the heart o# rodu!tion lannin" and !ontrol.it inter#a!es with marketin"( !aa!ity lannin"(rodu!tion lannin" and distri+ution lannin".

General duties o a master scheduler:2. E$aluatin" the ima!t o# new orders.. )ro$idin" deli$ery dates #or orders.3. Dealin" with ro+lems:

a. E$aluatin" the ima!t o# rodu!tion delays or late

deli$eries o# ur!hased "oods.+. Re$isin" the master s!hedule when ne!essary.!. Brin"in" instan!es o# insuH!ient !aa!ity to the

attention o# rodu!tion and marketin" ersonnel.


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MP&T% F%!c%* di$ide a s!hedulin" time horioninto three se!tions or hases( sometime re#erredto as Frozen( Slushy and Liquid .

Frozen is the near-term hase and deli$ery o#new "oods would +e imossi+le or $ery !ostly.Slushy is usually a #ew eriods +eyond the #roen

hase. /rder entry is less !ostly or disruti$e.Liquid is the #arthest out on the time horion.New orders and !an!ellations !an +e entered withease.


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9.,. M#*t%r Producto! c2%du"% (MP)

MP&

I!'ut* = %he master s!hedule has three inuts:- %he +e"innin" in$entory

-ore!asts #or ea!h eriod o# the s!hedule

- ;ustomer orders whi!h are already committed to !ustomers.

Out'ut* =- )roGe!ted in$entory- )rodu!tion re,uirements- Resultin" un!ommitted in$entory (A+#"#"%

to 'ro*% (ATP) !+%!tor)


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MP&E#'"%& !omany that makes industrial ums wants toreare a master rodu!tion s!hedule #or Iune and

Iuly. &arketin" has #ore!asted demand o# 20 ums#or Iune and 270 ums #or Iuly u!% >u"

1 , 3 4 1 , 3 4

ore!ast

30 30 30 30 40 40 40 40

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MP&E#'"%&Now suose that there are !urrently 74 ums inin$entory u"

1 , 3 4 1 , 3 4

ore!ast 30 30 30 30 40 40 40 40

;ustomer orders

33 0 20 4

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MP&

E#'"%&

Now we ha$e the three inuts o# the master s!hedulin" and

we should determine three oututs in!ludin": the roGe!tedon-hand in$entory( the &)1 and the un!ommitted

re,uirements

)roGe!ted on-hand

*n$entory

*n$entory#rom

re$iousweek

;urrentweek's

re,uirements


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MP&E#'"%&

Be"innin"*n$entory:

74

>u!% >u"

1 , 3 4 1 , 3 4

ore!ast 30 30 30 30 40 40 40 40

;ustomer orders

33 0 20 4

)roGe!ted on-handin$entory

31 1 -,9

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;ustomer orders are ore!ast is lar er than ore!ast is lar er than


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MP&E#'"%&When roGe!ted on-hand in$entory +e!omesne"ati$e( the rodu!tion is needed to rellin$entory.*# the lot size is F0( then the ne"ati$eroGe!ted on-hand in$entory re,uires

units and lea$es 42 ums #or #uturedemand: F2-42E$ery time roGe!ted on-hand in$entory+e!omes ne"ati$e( another rodu!tion lot o#

F0 ums is added to the s!hedule.

Week

*n$entory

rom

)re$iousWeek Re,uirements

Net*n$entor

y

Be#ore &)1


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MP&E#'"%&

Be"innin"

*n$entory:74

>u!% >u"

1 , 3 4 1 , 3 4

ore!ast 30 30 30 30 40 40 40 40

;ustomer orders

33 0 20 4


32 2 42 22 42 2 32 72

&)1 F0 F0 F0 F0

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MP&

E#'"%&

Now it is ossi+le to determine the amount o#in$entory that is un!ommitted and( a$aila+le toromise usin" a look-ahead ro!edure:1um +ooked !ustomer orders week +y week until


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MP&E#'"%&

Be"innin"

*n$entory:74

>u!% >u"

1 , 3 4 1 , 3 4

ore!ast 30 30 30 30 40 40 40 40

;ustomer orders

33 0 20 4


32 2 42 22 42 2 32 72

&)1 F0 F0 F0 F0

$aila+le-to-romise

in$entory 22 67 78 F0 F0

Documents

Chapter 9 - Production Planning