Templates to accompany Operations Mangement, Seventh Edition

created by Lee Tangedahl, The University of Montana

Copyright 2001 by The McGraw Hill Companies, Inc.
All rights Reserved.

Chapter Fourteen - Aggregate Planning

Templates:

Aggregate Planning
Transportation Model
Master Scheduling

Examples
Solved Problems

See Instructions template for complete instructions.

Aggregate Planning

Aggregate Planning
Number of periods:
Period
Forecast
Output
Regular
Part Time
Overtime
Subcontract
Output - Forecast
Inventory
Beginning
Ending
Average
Backlog
Costs:
Regular
Part Time
Overtime
Subcontract
Hire/Layoff
Inventory
Back orders
Total

Clear

1,600

1
100

2
150

3
300

4
300

5
500

6
150

Total
1,500

250

250

250

300

300

150

1,500
0
0
0
0

1,400
1,200
1,000

150

100

-50

-200

0
150
75.0
0

150
250
200.0
0

250
200
225.0
0

200
200
200.0
0

200
0
100.0
0

0
0
0.0
0

800
600
400
200
0

@
@
@
@

5
5
8
12

1,250
0
0
0

1,250
0
0
0

1,250
0
0
0

1,500
0
0
0

1,500
0
0
0

750
0
0
0

@
@

3
10

225.0
0

600.0
0
1,850.0

675.0
0
1,925.0

600.0
0
2,100.0

300.0
0
1,800.0

0.0
0
750.0

800
0
7,500
0
0
0
0
2,400.0
0
9,900.0

Cum Forecast

Cum Production

Aggregate Planning - Costs

2,500
2,000
1,500
1,000
500

Cumulative Forecast
Cumulative Production
Ending Inventory
Backlog

1
100
250
150

2
250
500
250

3
550
750
200

4
850
1,050
200

5
1,350
1,350

6
1,500
1,500

0
1

Regular

Part Time

Overtime

Inventory

Hire/Layoff

Inventory

Back orders

Page 2

Aggregate Planning

Page 3

Transportation Model
Input Matrix:
Demand for
Beginning Inventory
Regular Time
Overtime
1
Subcontract
Regular Time
Overtime
2
Subcontract
Regular Time
Overtime
3
Subcontract
Demand

Clear

Period 1
0
60
80
90
63
83
93
66
86
96
550

Period 2
1
61
81
91
60
80
90
63
83
93
700

Period 3
2
62
82
92
61
81
91
60
80
90
750

Solve

Solution Matrix:

Demand for
Beginning Inventory
Regular Time
Overtime
Subcontract
Regular Time
Overtime
Subcontract
Regular Time
Overtime
Subcontract
Demand

Unused
0
0
0
0
0
0
0
0
0
0
90

Period 1
100
400
50
0
0
0
0
0
0
0
550

Period 2
0
0
0
30
500
50
120
0
0
0
700

Period 3
0
100
0
0
0
0
0
500
50
100
750

Unused
0
0
0
90
0
0
0
0
0
0
90

Supply
100
500
50
120
500
50
120
500
50
100
Total Supply =
Total Demand =
Supply
100
500
50
120
500
50
120
500
50
100
Total Cost =

2090
2090

124730

Master Scheduling

Master Scheduling
Clear

Week
Forecast
Customer Orders
(committed)
Projected on-hand
inventory
MPS
ATP

50

1
20

2
20

25

15

25

10

3
20

4
40

5
40

20
60
75
55

Page 5

20

6
40

7
20

8
20

69
75
75

49

41
55
75
34

14

Chapter 14 - Examples
Aggregate Planning
Number of periods:
1. Period
Forecast
Output
Regular
Part Time
Overtime
Subcontract
Output - Forecast
Inventory
Beginning
Ending
Average
Backlog
Costs:
Regular
Part Time
Overtime
Subcontract
Hire/Layoff
Inventory
Back orders
Total

1
200

2
200

3
300

4
400

5
500

6
200

300

300

300

300

300

300

100

100

-100

-200

100

100
50.0
0

100
200
150.0
0

200
200
200.0
0

200
100
150.0
0

100
0
50.0
100

0
0
0.0
0

600
0
0
0

600
0
0
0

600
0
0
0

600
0
0
0

600
0
0
0

150.0
0
750.0

200.0
0
800.0

150.0
0
750.0

50.0
500
1,150.0

0.0
0
600.0

@
@
@
@

2
3
6

600
0
0
0

@
@

1
5

50.0
0

2. Aggregate Planning
Number of periods:
Period
Forecast
Output
Regular
Part Time
Overtime
Subcontract
Output - Forecast
Inventory
Beginning
Ending
Average
Backlog
Costs:
Regular
Part Time
Overtime
Subcontract
Hire/Layoff

@
@
@
@

2
3
6

1
200

2
200

3
300

4
400

5
500

6
200

280

280

280

280

280

280

40

40

40

80

80

20

-80

-180

80

80
40.0
0

80
160
120.0
0

160
180
170.0
0

180
100
140.0
0

100
0
50.0
80

0
0
0.0
0

560
0
0
0

560
0
0
0

560
0
120
0

560
0
120
0

560
0
120
0

560
0
0
0

Inventory
Back orders
Total

@
@

1
5

40.0
0

120.0
0
680.0

170.0
0
850.0

140.0
0
820.0

50.0
400
1,130.0

0.0
0
560.0

3. Aggregate Planning
Number of periods:
Period
Forecast
Output
Regular
Part Time
Overtime
Subcontract
Output - Forecast
Inventory
Beginning
Ending
Average
Backlog
Costs:
Regular
Part Time
Overtime
Subcontract
Hire/Layoff
Inventory
Back orders
Total

1
200

2
200

3
300

4
400

5
500

6
200

280

280

280

340

340

280

80

80

-20

-60

-160

80

80
40.0
0

80
160
120.0
0

160
140
150.0
0

140
80
110.0
0

80
0
40.0
80

0
0
0.0
0

560
0
0
0

560
0
0
0

680
0
0
0
400
40.0
400
1,520.0

560
0
0
0

Supply
100
500
50
120
500
50
120
500
50
100

@
@
@
@

2
3
6

560
0
0
0

@
@

1
5

40.0
0

120.0
0
680.0

150.0
0
710.0

680
0
0
0
400
110.0
0
1,190.0

Period 1
0
60
80
90
63
83
93
66
86
96
550

Period 2
1
61
81
91
60
80
90
63
83
93
700

Period 3
2
62
82
92
61
81
91
60
80
90
750

Unused
0
0
0
0
0
0
0
0
0
0
90

4. Transportation Model
Input Matrix:
Demand for
Beginning Inventory
Regular Time
Overtime
1
Subcontract
Regular Time
Overtime
2
Subcontract
Regular Time
Overtime
3
Subcontract
Demand
Solution Matrix:
Demand for
Beginning Inventory
Regular Time
1

Period 1
100
420

Period 2
0
80

Period 3
0
0

Unused
0
0

0.0
0
560.0

Total Supply =
Total Demand =
Supply
100
500

Overtime
Subcontract
Regular Time
Overtime
Subcontract
Regular Time
Overtime
Subcontract
Demand

0
30
0
0
0
0
0
0
550

50
0
500
50
20
0
0
0
700

0
0
0
0
100
500
50
100
750

0
90
0
0
0
0
0
0
90

50
120
500
50
120
500
50
100
Total Cost =

Total
1,800
1,800
0
0
0
0

600
100
3,600
0
0
0
0
600.0
500
4,700.0

Total
1,800
1,680
0
120
0
0

520
80
3,360
0
360
0
0

520.0
400
4,640.0

Total
1,800
1,800
0
0
0
0

460
80
3,600
0
0
0
800
460.0
400
5,260.0

2090
2090

124730

Chapter 14 - Solved Problems

1. Aggregate Planning
Number of periods:
Period
Forecast
Output
Regular
Part Time
Overtime
Subcontract
Output - Forecast
Inventory
Beginning
Ending
Average
Backlog
Costs:
Regular
Part Time
Overtime
Subcontract
Hire/Layoff
Inventory
Back orders
Total

1
190

2
230

3
260

4
280

5
210

6
170

220

220

220

220

220

210

30

-10

-40

-60

10

40

30
15.0
0

30
20
25.0
0

20
0
10.0
20

0
0
0.0
80

0
0
0.0
70

0
0
0.0
30

@
@
@
@

1,320
0
0
0

1,320
0
0
0

1,320
0
0
0

1,320
0
0
0

1,320
0
0
0

1,260
0
0
0

@
@

5
10

75.0
0

125.0
0
1,445.0

50.0
200
1,570.0

0.0
800
2,120.0

0.0
700
2,020.0

0.0
300
1,560.0

1
190
220
30

2
420
440
20

3
680
660

4
960
880

5
1,170
1,100

6
1,340
1,310

20

80

70

30

1
70

2
70

3
70

4
70

80

50

30

10

20
100
20

50
100
50

80
100
60

10

Cumulative Forecast
Cumulative Production
Ending Inventory
Backlog

2. Master Scheduling

Week
Forecast
Customer Orders
(committed)
Projected on-hand
inventory
MPS
ATP

7
160

8
260

9
180

Total
1,940

210

210

210

50

-50

30

1,940
0
0
0
0

0
20
10.0
0

20
0
10.0
30

0
0
0.0
0

70
230

1,260
0
0
0

1,260
0
0
0

1,260
0
0
0

50.0
0
1,310.0

50.0
300
1,610.0

0.0
0
1,260.0

7
1,500
1,520
20

8
1,760
1,730

9
1,940
1,940

30

11,640
0
0
0
0
350.0
2,300
14,290.0