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Aggregate Planning

Aggregate Planning. Overview. Aggregate planning in the planning process Aggregate planning strategies Capacity options Chase strategy Level strategy Demand options Mixing options Graphical/charting methods Linear programming Simulation. Planning Relationships. Business . or annual .

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Aggregate Planning

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  1. Aggregate Planning

  2. Overview • Aggregate planning in the planning process • Aggregate planning strategies • Capacity options • Chase strategy • Level strategy • Demand options • Mixing options • Graphical/charting methods • Linear programming • Simulation

  3. Planning Relationships

  4. Business or annual plan Planning Relationships

  5. Business or annual plan Planning Relationships Aggregate plan – production and staffing plan

  6. Business or annual plan MPS or workforce schedule Planning Relationships Aggregate plan – production and staffing plan

  7. Business or annual plan MPS or workforce schedule Planning Relationships Aggregate plan – production and staffing plan

  8. Business or annual plan MPS or workforce schedule Planning Relationships Aggregate plan – production and staffing plan

  9. Planning Horizons Responsible: Operations managers Intermediate-range plans Sales planning Production planning and budgeting Setting employment, inventory, subcontracting levels Analyzing operating plans 1 year 5 years Today 3 Months Planning Horizon

  10. Planning Horizons Responsible: Top executives Long-range plans R&D New product plans Capital expenses Facility location, expansion 1 year 5 years Today 3 Months Planning Horizon

  11. Planning Horizons Short-range plans Job assignments Ordering Job scheduling Dispatching Responsible: Operations managers, supervisors, foremen 1 year 5 years Today 3 Months Planning Horizon

  12. Responsible: Operations managers Short-range plans Job assignments Ordering Job scheduling Dispatching Intermediate-range plans Sales planning Production planning and budgeting Setting employment, inventory, subcontracting levels Analyzing operating plans Responsible: Top executives Responsible: Operations managers, supervisors, foremen Long-range plans R&D New product plans Capital expenses Facility location, expansion 1 year 5 years Today 3 Months Planning Horizon Planning Horizons

  13. Planning hierarchy

  14. Planning hierarchy Planning horizon Long range: Years Itermediate range: 6 – 18 months Short range: Weeks

  15. Planning hierarchy Planning horizon Long range: Years Itermediate range: 6 – 18 months Short range: Weeks Scope Entire production line i.e. Ford trucks Product Family i.e. Ford F series Specific model i.e. Ford F-150

  16. What is an aggregate plan?

  17. What is an aggregate plan?

  18. What is an aggregate plan?

  19. Managerial Inputs

  20. Aggregate plan Managerial Inputs

  21. Distribution and marketing Customer needs Demand forecasts Competition behavior Aggregate plan Managerial Inputs

  22. Distribution and marketing Customer needs Demand forecasts Competition behavior Accounting and finance Aggregate Cost data plan Financial condition of firm Managerial Inputs

  23. Distribution and marketing Customer needs Demand forecasts Competition behavior Accounting and finance Aggregate Cost data plan Financial condition of firm Human resources Labor-market conditions Training capacity Managerial Inputs

  24. Distribution and marketing Customer needs Demand forecasts Competition behavior Accounting and finance Aggregate Cost data plan Financial condition of firm Engineering Human resources New products Labor-market conditions Product design changes Training capacity Machine standards Managerial Inputs

  25. Distribution and marketing Customer needs Demand forecasts Competition behavior Materials Accounting and finance Aggregate Supplier capabilities Cost data plan Storage capacity Financial condition Materials availability of firm Engineering Human resources New products Labor-market conditions Product design changes Training capacity Machine standards Managerial Inputs

  26. Operations Distribution and marketing Current machine capacities Customer needs Plans for future capacities Demand forecasts Workforce capacities Competition behavior Current staffing level Materials Accounting and finance Aggregate Supplier capabilities Cost data plan Storage capacity Financial condition Materials availability of firm Engineering Human resources New products Labor-market conditions Product design changes Training capacity Machine standards Managerial Inputs

  27. Aggregate Planning Objectives • Minimize Costs/Maximize Profits • Maximize Customer Service • Minimize Inventory Investment • Minimize Changes in Production Rates • Minimize Changes in Workforce Levels • Maximize Utilization of Plant and Equipment

  28. Aggregate Planning StrategiesPure Strategies • Capacity Options — change capacity: • changing inventory levels • varying work force size by hiring or layoffs • varying production capacity through overtime or idle time • subcontracting • using part-time workers

  29. Aggregate Planning StrategiesPure Strategies • Demand Options — change demand: • influencing demand • backordering during high demand periods • counterseasonal product mixing

  30. Advantage/Disadvantages of Aggregate Planning Options See Table 13.1

  31. Mixing the options:The Extremes Chase Strategy Level Strategy Production equals demand Production rate is constant

  32. Aggregate Planning Strategies • Level planning strategy • Produce same amount every month • Keep work force level constant • Find alternative work for employees when there is less demand • Vary non-work force capacity or demand options • Inventory levels allowed to fluctuate • Often results in lowest production costs • Toyota, Nissan employ this strategy

  33. Aggregate Planning Strategies • Chase planning strategy • Output rates match demand • Vary work force level • Hiring/laying off • Vary non-work force capacity or demand options • Overtime and outsource • Part time employees • Service industries often utilize this strategy • Hospitality, construction, education

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