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Network
Design
Demand
Forecast
Strategic
Job Routing
Release Data
Job
Dispatching
Operational
Hopp and Spearman, Factory Physics
7-2
Outline
Role of aggregate planning in a supply chain
The aggregate planning problem
Aggregate planning strategies
Implementing aggregate planning in practice
Trade-off
– Capacity (regular time, overtime, subcontract)
– Inventory
– Backlog / lost sales
Strategies
– Chase strategy
– Time flexibility from workforce or capacity
– Level strategy
6 6
Min∑ 640Wt + ∑ 300 H t
t =1 t =1
6 6 6
+ ∑ 500 Lt + ∑ 6Ot + ∑ 2 I t
t =1 t =1 t =1
6 6 6
+ ∑ 5S t + ∑ 10 Pt + ∑ 30Ct
t =1 t =1 t =1
Pt ≤ 40Wt + Ot / 4,
for t = 1,...,6.
S 0
= 0,and I 6
≥ 500.
What if stock-out is
not allowed?
Over time for each month
Assumptions
O ≤ 10W ,
t t 1. Employees are identical
2. No disruptions
for t = 1,...,6. 3. Hiring and firing each month
Avg Inventory?
Avg flow time?
Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 8-19
Scenarios
Increase in holding cost (from $2 to $6)
Overtime cost drops to $4.1 per hour
Increased demand fluctuation
Excel Sheet!
Jayaram, Srivastava, and Benton (1999), Supplier Selection and Order Quantity
Allocation: A Comprehensive Model, Journal of Supply Chain Management
8-30
Fixed cost of selecting a supplier
+ Variable cost
8-31
Sourcing Planning and Analysis
A firm should periodically analyze its procurement
spending and supplier performance and use this
analysis as an input for future sourcing decisions
Procurement spending should be analyzed by part and
supplier to ensure appropriate economies of scale
Supplier performance analysis should be used to build
a portfolio of suppliers with complementary strengths
– Cheaper but lower performing suppliers should be used to
supply base demand
– Higher performing but more expensive suppliers should be
used to buffer against variation in demand and supply from
the other source
Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 14-32
Summary
Aggregate planning
– Importance in supply chain
– Follows forecasting
– Mathematical model solved using Excel
Sourcing
– Mathematical model