Develop a production schedule to produce the exact production requirements by va

Question

Develop a production schedule to produce the exact production requirements by varying the workforce size for the following problem.

     The monthly forecasts for Product X for January, February, and March are 950, 1,540, and 1,110, respectively. Safety stock policy recommends that half of the forecast for that month be defined as safety stock. There are 22 working days in January, 19 in February, and 21 in March. Beginning inventory is 610 units.

Develop a production schedule to produce the exact production requirements by varying the workforce size for the following problem The monthly forecasts for Product X for January, February, and March are 950, 1,540, and 1,110, respectively. Safety stock policy recommends that half of the forecast for that month be defined as safety stock. There are 22 working days in January, 19 in February, and 21 in March. Beginning inventory is 610 units. Manufacturing cost is $130 per unit, storage cost is $3 per unit per month, standard pay rate is $4 per hour, overtime rate is $6 per hour, cost of stockout is $8 per unit per month, hiring and training cost is $190 per worker, layoff cost is $290 per worker, and worker productivity is 0.1 unit per hour. Assume that you start off with 43 workers and that they work 8 hours per day. (Leave no cells blank be certain to enter "o" wherever required. Input all values as positive values. Round Workers Required up to next higher whole number. Round all other variables to nearest whole number.) January February March 1,540 770 Forecast Safety stock Beginning inventory Net production required Workers required Hired Laid off Actual production Ending inventory 1,110 475 610 47 827 January February Hiring Layoff Total Total

Explanation / Answer

Working Notes:

Productivity 0.1 units per hour

Hours Required for 1 Unit = 1/0.1 = 10

Units To be Produced in Jan = 815

Hours Required = 815*10 = 8150

Hours Available = 43*8*22 = 7568

Shorfall = 582

Workers hired in Jan = 3.3 = 4

Ending Inventory = Beg+Production - Forecast

=610+827-950 = 487

Feb

Productivity 0.1 units per hour

Hours Required for 1 Unit = 1/0.1 = 10

Units To be Produced in Feb = 1823

Hours Required = 1823*10 = 18230

Hours Available = 47*8*19 = 7144

Shorfall = 11086

Workers hired in Feb = 73

Mar

Productivity 0.1 units per hour

Hours Required for 1 Unit = 1/0.1 = 10

Units To be Produced = 894

Hours Required = 894*10 = 8940

Hours Available = 120*8*21 = 20160

Surplus = 11220

Workers laid off in Mar = 66

Note: Storage Cost has been taking on Average Inventory i.e. (Opening Inventory+Closing Inventory)/2

Jan Feb Mar Forecast 950 1540 1110 Safety Stock 475 770 555 Beginning Inventory 610 487 771 Net Production Required 815 1823 894 Workers Required 47 120 54 Hired 4 73 0 Laid Off 0 0 66 Actual Production 827 1824 907 Ending Inventory 487 771 568

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