Question: TABLE 1 : Forecasted demand and working days working days (jan to june)= 22,19,21,21,22,20 TABLE 2 : Costs Inventory holding cost Cost of stockout Cost
TABLE 1: Forecasted demand and working days
working days (jan to june)= 22,19,21,21,22,20
TABLE 2: Costs
| Inventory holding cost Cost of stockout Cost of subcontracting Hiring and training cost Layoff/firing cost Labor hours required Straight-line cost (first 8 hours each day) Overtime cost (time and half) | $1.50/unit/month $5/unit/month $20/unit $200/worker $250/worker 5 hours/unit $4/hour $6/hour |
TABLE 3: Initial inventory 400 and safety stock requirements 25% of month's demand.
| Table 4: Aggregate Production Planning Requirements | ||||||
| January | February | March | April | May | June | |
| Beginning inventory | 400 | 450 | 375 | 275 | 225 | 275 |
| Demand forecast | 1800 | 1,500 | 1,100 | 900 | 1,100 | 1,600 |
| Safety stock (.25 x Demand forecast) | 450 | 375 | 275 | 225 | 275 | 400 |
| Production requirement (Demand forecast + Safety stock - Beginning inventory) | 1850 | 1425 | 1000 | 850 | 1150 | 1725 |
| Ending inventory (Beginning inventory + Production requirement - Demand forecast) | 450 | 375 | 275 | 225 | 275 | 400 |
NOTE: Straight-line production cost = regular-time (8 hours each day) production cost.
PLAN 3: Produce to meet the minimum forecasted demand (Aprils demand) using a constant workforce on regular time. Subcontract to meet additional output requirements. The number of workers is calculated by locating the minimum monthly production requirement and determining how many workers would be needed for that month and subcontracting any monthly difference between requirements and production. What is the number of workers needed in this case? Again, for this plan, assume that the available workforce at the start of January is equal to the number of workers needed for this plan (to be determined). In other words, there will be no hiring and firing for this plan.
Use the information given in Tables 1, 2, 3, and 4 to fill in appropriate values for the quantities listed in the first column of the following table (Table 7) for each month (January to June) of the planning period. What is the total cost of production plan 3?
NOTE 4: In solving this aggregate plan, please be sure to give explicit equations/calculations you have used to obtain the number of workers required and the quantities in the first column of TABLE 7 below for the months of January, February and March.
| Production Plan 3 | |||||||
| No. of workers required | ? | ||||||
| (low constant workforce) | |||||||
| jan. | feb | mar | apr | may | jun | total | |
| Production Requirement | |||||||
| Working days per month | |||||||
| Production hours available | |||||||
| actual production | |||||||
| units subcontracted | |||||||
| subcontracting cost | ? | ||||||
| straight line cost | ? | ||||||
| total cost | ? | ||||||
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