Question
ABC Manufacturers produces different models of product P. The Operations Manager of ABC has to develop aggregate production plan for the next 6 months, April
ABC Manufacturers produces different models of product P. The Operations Manager of ABC has to develop aggregate production plan for the next 6 months, April to September. Below given are the data for the aggregate unit of product P.
Month | Working Days | Demand |
April | 20 | 15000 |
May | 24 | 7000 |
June | 18 | 9000 |
July | 26 | 12000 |
August | 22 | 20000 |
September | 15 | 14000 |
The Operations Manager found that there will be 130 workers working in March and 900 units in the inventory at the end of March. He wants to have 1400 units in the inventory at the end of September. A worker requires 2 hours to make one unit. It works 8 hours a day. Cannot hold more than 200 workers.
Hiring cost/worker $500
Firing cost/worker $1,000
Inventory holding cost $8/unit/month
Shortage (stockout) cost $15/unit/month
Regular labor cost $20/hour
Overtime labor cost $30/hour
Material cost $75/unit
Subcontract cost $140/unit
ABCs labor policy restricts the overtime production not to exceed 15% of regular production. Workers are paid full time payment. Develop aggregate production plan and find cost of the plan for ABC for the month April to September using the following methods: a. Pure Level (constant workforce with no overtime, subcontract, hire, or fire during the planning horizon) b. Pure Chase ((production = net demand) with no overtime, subcontract, shortage or inventory during the planning horizon. But inventory at the end of the planning horizon is accepted) c. Constant workforce of 125 and any excess requirement will be met by subcontracting (no overtime during the planning horizon) d. Optimal plan using excel i. Write down the mathematical model (Decision Variables, Objective Function, and Constraints). ii. Develop the excel model iii. Use excel solver to get the optimal plan.
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