Question: Kindly provide an answer to the following question using excel Skycell, a major European cell phone manufacturer is making production plans for the coming year.
Kindly provide an answer to the following question using excel
Skycell, a major European cell phone manufacturer is making production plans for the coming year. Skycell has worked with its customers (the service providers) to come up with forecasts of monthly requirements (in thousands of phones) as shown in (Table 8-10).
Table 1: monthly demand for cellphones, in thousands.
| Month | Demand |
| January | 1200 |
| February | 1300 |
| March | 1000 |
| April | 1150 |
| May | 1400 |
| June | 1300 |
| July | 1200 |
| August | 1100 |
| September | 1200 |
| October | 1200 |
| November | 1300 |
| December | 1600 |
Manufacturing is primarily an assembly operation, and capacity is governed by the number of people on the production line. The plant operates for 20 days a month, 8 hours each day. One person can assemble a phone every 10 minutes. Workers are paid 20 euros per hour and 50% premium for overtime. The plant currently employs 1250 workers. Component costs for each phone total 20 euros. Given the rapid decline in component and finished product prices, carrying inventory from month the next incurs a cost of 3 euros per phone per month. Skycell currently has a no-layoff policy in place. Overtime is limited to a maximum of 20 hours per month per employee. Assume that Skycell has a starting inventory of 50000 units and wants to end the year with the same level of inventory.
- Assuming no backlogs, no subcontracting, and no new hires, what is the optimum production schedule? What is the annual cost of this schedule (i.e.: total cost)?
- Is there any value for management to negotiate an increase of allowed overtime per employee per month from 20 hours to 40 hours?
- Reconsider parts a) and b) if Skycell starts with only 1200 employees. Reconsider parts a) and b) if Skycell starts with 1300 employees. What happens to the value of additional overtime as the workforce size decreases?
- Consider part a) for the case in which Skycell aims for a level of production schedule such that the quantity produced each month does not exceed the average demand over the next 12 months (average demand = 1241667 units) by 50000 units. Thus, the monthly production, including overtime, should be no more than 1291667 units per month. What would be the cost of this level production schedule? What is the value of overtime flexibility?
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