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Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Learning Objectives
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Role of Aggregate Planning
in a Supply Chain
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
The Aggregate Planning Problem
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Information Needed for
an Aggregate Plan
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Outputs of Aggregate Plan
• Inventory held
• Backlog/stockout quantity
• A poor aggregate plan can result in lost sales, lost profits, excess
inventory, or excess capacity
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Identifying Aggregate Units of Production
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Red Tomato Tools
D 12 49 10 50 4.80 5.00 10
F 13 48 5 75 4.30 4.37 15
Table 8-1
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Red Tomato Tools
• Similarly
Revenue per aggregate unit = $40
Net production time per aggregate unit = 4.00 hours
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Aggregate Planning Strategies
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Chase Strategy
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Time Flexibility Strategy
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Level Strategy
• Used when inventory holding and backlog costs are relatively low
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Aggregate Planning Using
Linear Programming
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Red Tomato Tools
Item Cost
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Red Tomato Tools Decision Variables
For t = 1, ..., 6
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Red Tomato Tools Objective Function
• Minimize
6 6 6 6
Minå 640Wt + å 6Ot + å 300H t + å 500Lt
t=1 t=1 t=1 t=1
6 6 6 6
+å 2I t + å 5St + å10Pt + å 30Ct
t=1 t=1 t=1 t=1
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Red Tomato Tools Constraints
(I 0 + IT ) / 2 + (å I ) T –1
Average time
é
ê (I 0 + IT ) / 2 +
=ê
(å ) T –1
t=1
ù
It ú
ú
é
ê
ê
( T –1ù
åt=1 Dt ú
ú
)
in inventory ê T ú ê T ú
ë û ë û
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Red Tomato Tools
Table 8-4
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Red Tomato Tools
inventory T 6
895
Average flow time = = 0.34 = 0.34 months
2,667
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Red Tomato Tools
Table 8-5
Average
seasonal =
(I 0 + IT ) / 2 + (å I ) = 6,450 = 1,075
T –1
t=1 t
inventory T 6
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Red Tomato Tools
Table 8-6
1,075
Average flow time = = 0.40 months
2,667
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Red Tomato Tools
Average
seasonal =
(I 0 + IT ) / 2 + (å I ) = 2,500 = 417
T –1
t=1 t
inventory T 6
417
Average flow time 0.16 months
2,667
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Red Tomato Tools
Table 8-7
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Forecast Error in Aggregate Plans
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Aggregate Planning In Excel
For t = 1, ..., 6
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Aggregate Planning in Excel
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Aggregate Planning in Excel
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Aggregate Planning in Excel
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Aggregate Planning in Excel
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Building a Rough Master Production
Schedule
Table 8-8
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
The Role of IT in Aggregate Planning
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Inventory Planning and Economic Theory-
Aberrations
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Implementing Aggregate Planning in
Practice
Supply Chain Management: Strategy, Planning, and Operation, 5/e Authors: Sunil Chopra, Peter Meindl and D. V. Kalra
Summary of Learning Objectives