Production Planning .
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ภภภภภภภภภภภภ! " #ภ" ภภ(aggregate planning) ภภ(aggregate scheduling) ภภ(aggregate scheduling) "$ ภ" ภภ(aggregate planning) % ภ" & ภ' ภ( %! ภ)ภ*)ภ+, ภ$ *- -+ภ' $ +, .+ " + ( / 0 &()
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Planning Relationships
Business or annual plan
Figure 1 4
Planning Relationships Business or annual plan Production or staffing plan
Figure 1 5
Planning Relationships Business or annual plan Production or staffing plan MPS or workforce schedule Figure 1 6
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. ก =" 1 >)! ( 12-24 "0 ! %ก ) (/ # )A )B!! ( )A "0 0 > 7
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ก %1 D $ / #( ! ") & E(# / ก ( # ก & Eก # =" "$ ก ก " ( 0 $ / # # ก , ( # / & %1 ก " ( / # , &# % D%
. APICS >"#/ # $ !$ ก " & ก ก > # , )A # %1& ก ก$ " " ( ก =" 01 ( , " (& ก & %1>"# > #/ )B!! ( & %1 " # ก ( D ) 1 >)& ก !/ "# ก ( ก D/ ก $ ก$ > ก 1 " %1>"# " > #/ ก ! 8
Managerial Inputs Distribution and marketing
Operations Current machine capacities Plans for future capacities Workforce capacities Current staffing level
Materials Supplier capabilities Storage capacity Materials availability
Customer needs Demand forecasts Competition behavior Products and Sales Plan
Production plan
Engineering New products Product design changes Machine standards
Figure 2
Accounting and finance Cost data Financial condition of firm
Human resources Labor-market conditions Training capacity 9
Production 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
10
ภภ1. (Straight - Time Labor) 2. , (Overtime Labor)
Maximize Capacity
3. & (Inventory) 4. E# ( , (Subcontracting) 5. 1 ภ1 5. 1 ภภ$ 11
, / #!, / ภ(Production Planning Costs) â&#x20AC;˘ , )ภ( Regular-time Costs) â&#x20AC;˘ , , (Overtime Costs) â&#x20AC;˘ , ภ%1 (Add Shift Costs) â&#x20AC;˘ , !# E# ( , (Subconstract Costs) â&#x20AC;˘ , !# 1 , ) " ภ(Hiring and Layoff Costs) â&#x20AC;˘ , / #!, & , ภ(Inventory Holding Costs) â&#x20AC;˘ , / #!, ภ% , # 0 & " ^ ภ(Backorder and Stockout Costs) â&#x20AC;˘ , / #!, ภ%) ( ภ(Change in Production Rate Costs) 12
ก ก $ ( , %1ก$ D; & (( 01 - " & , ก, # W0,P0,I0
ก ( ก " /!
ก " /! $ ( ,
%1ก$ ! D; W1,P1,I1
& , / #!, %1 ก "&;- ! กก " /! 1. , )ก 2. , / #!, ! กก !# 1 3. , " / ก / # ก 4. , / #!, / ก ) ( " (ก 5. , / #!, / ก 1 ก $ 6. , %1 $ ,
7. , / #!, / ก กC( ก # 8. , / #!, 01 # # 9. 01 a E) %1 3 : ((ก " /!& ก ก ((& - "% c;1 % & % , "% ; W = & "& , P= ก I= " (& # 0
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ภภภ( $ & #ภ+2 -ภ# ! * ภ: single state * ภ: multi state
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4 / # D ภ& E) (( # ภ%1 )A i"Eภ% 3 0 ภ%1! ! "ภ" %1. ) ( 0 ! "ภภ( # ภ(Manage Demand) 2. ! "ภภ(ภ( # ภ(Manage Supply) 0 ภภ3. $ - 2 , &# # 15
Production Planning Strategies 1. ภ" # ภ(Chase Strategy) ) ( " ( ภ# ภ=" ภ) (ภ!# 1 ) " ภ# ภ(matching production rate to the order rate - hire - layoff people as order rate varies) ! " %1 ) ( ) %1 1 = ภ$ (Stable work force - variable work hours) )A ภ) ( ภ=" ภ) ( 1 = ภ$ c;1 ! $
/ #ภ" # ภ( # ภ=" > ,/ #ภ1 - " 2. ภ" (ภ1$ (Level strategy) "$ ภ1$ (Maintain constant output rate) % " ( # &;- a a / ( , ! % # , %ภEq % ภ& / ( , (fluctuating inventory levels, order backlogs and lost sales) 3. ภ, ภ(Intermediate Strategy) 16
Production Planning Strategies Possible Alternatives during Slack Season
Possible Alternatives during Peak Season
Layoffs
Hiring
2. Chase #2: vary output rate to match demand
Layoffs, undertime, vacations
Hiring, overtime, subcontracting
3. Level #1: constant workforce level
No layoffs, building anticipation inventory, undertime, vacations
No hiring, depleting anticipation inventory, overtime, subcontracting, backorders, stockouts
4. Level #2: constant output rate
Layoffs, building anticipation inventory, undertime, vacations
Hiring, depleting anticipation inventory, overtime, subcontracting, backorders, stockouts
Strategy 1. Chase #1: vary workforce level to match demand
17
Production Planning Process ! # ภ$ ( ŕ¸
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%-(, 0 ภ, &# !$ ภ", , / #!,
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4. )A %1
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Move ahead to next planning session
Implement and update the plan
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& - ภภ"# % " DEภ, ((ภภ"# % " DEภ) ภ("# & - " %1. ! " % ภ& - # ( 0- s & # ภ%1>"#! ภภภ&# $ %1>"#! " $ &;- 1.1. ภ"& (forecasting Demand) , ภ/ ภ, 1.2. # ภ( Aggregate Demand)& ภ, 1.3. ) %1 # ภ)A # ภภ$ ŕ¸
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& - ก ก "# % " DEก( , ) 2. %-( , 0 ก &# !$ ก " , / #!, 3. r ก 4. ! , / #!, & ! , E , / #&# !$ ก " 0 > ,> D# > , / #) (! ก , ! E, 5. ! 0 ก 01 a& 01 # & % 1 1$ ก , # # ก (>)& - %1 2 3 ! ก - ) % ( % ( , / #!, & - 2 20
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, ก ก
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ก ก ก / . . ก. . . . . . . . . . ก. . . . ก. . . . . . %. .
22 20 23 19 22 22 20 23 11 22 22 18 244
5,000 4,000 4,000 5,000 7,000 9,000 11,000 9,000 6,500 6,000 5,000 5,000 76,500
227 200 174 263 318 409 550 392 591 273 227 278
2,800 2,500 2,500 2,800 3,000 3,500 4,100 3,500 3,000 3,000 2,800 2,800
4 # # "2,800 ,
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&# E ก% 1 ก ( , / #!, 4 # , , / , )ก = 30 ( 4 # , , / , , = 40 ( ( 1 &;- 10 ( / , ) 4 , / #!, / ก กC( ก # = 50 ( , , , )u 4 , / #!, / ก !# 1 = 200 ( / 4 , / #!, / ก ) " ก = 200 ( / 4 , !# E# ( , , , 45 ( / , ( 1 &;- 15 ( / , ) , / #!, ก %& " ^ ก> # = 25 ( / , / "0
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&# E = 4 ก ; 1 D $ ก >"# 1 , , 4 = D!# ก >"# E " 350 01 ! ก %&# !$ ก ""# %1 ! ก 01 0 )ก
4 ก$ ก )ก 350 , , 4 ก$ ก E " 410 , / =" ก $ ,
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ก ก Pi Pi Di Ii Ii
= = = = =
Di + Ii - Ii-1 ) # %1 # ก $ ( , i ) # ก # & , i ) & $ ) , i ) # # " i
. . P1 = 5000 + 2800 - 2800 = ก. . P2 = 4000 + 2500 - 2800 = %. . P3 = 4000 + 2500 - 2500 =
5000 3700 4000 26
ก ! ก "#$
ก
. . ก. . . . . . . . . . ก. . . . ก. . . . . . %. .
22 20 23 19 22 22 20 23 11 22 22 18 244
5,000 4,000 4,000 5,000 7,000 9,000 11,000 9,000 6,500 6,000 5,000 5,000 76,500
ก ' /
2,800 2,500 2,500 2,800 3,000 3,500 4,100 3,500 3,000 3,000 2,800 2,800
5,000 3,700 4,000 5,300 7,400 9,300 11,600 8,400 6,000 6,000 4,800 5,000 76,500
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ก ! ก D
ก / . . ก. . . . . . . . . . ก. . . . ก. . . . . . %. .
22 20 23 19 22 22 20 23 11 22 22 18 244
5,000 4,000 4,000 5,000 7,000 9,000 11,000 9,000 6,500 6,000 5,000 5,000 76,500
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ก / 227 200 174 263 318 409 550 392 591 273 227 278
ก ' / ก ' / 5,000 3,700 4,000 5,300 7,400 9,300 11,600 8,400 6,000 6,000 4,800 5,000 76,500
227 185 174 279 337 423 580 365 546 273 218 278 28
ก ! ! ก !
1
2
3
4
5
5 = 4
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ก ก ' ' ( ก ' ( / ( . . ก. . . . . . . . . . ก. . . . ก. . . . . . %. .
22 20 23 19 22 22 20 23 11 22 22 18 244
22 42 65 84 106 128 148 171 182 204 226 244
5,000 3,700 4,000 5,300 7,400 9,300 11,600 8,400 6,000 6,000 4,800 5,000 76,500
5,000 8,700 12,700 18,000 25,400 34,700 46,300 54,700 60,700 66,700 71,500 76,500
227 207 196 214 240 271 313 320 334 327 317 314 29
)
79300
75000
76500
70000 65000 60000 55000 50000 45000 50000 35000
# ก E " = Pt + It--1
30000 25000 20000 15000
" ( # # " = 2800
# ก
10000 5000
. ก&. . < & . . ก . ( . ก . . & . / .
30
,
# ก ,
750 700
ก /
650 600
591
550
550
500 450 400
409
350 300
318
150
278
273
250 200
392
263 227
200 174
227
100 50
. ก . % . . . ก . . ก . . . .
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,
# ก ,
750 700 650 600
580
550
546
500 450
423
400 350 300
279
250 200 150
227 185
174
365
337
278
273 218
100 50
. ก . % . . . ก . . ก . . . .
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ก %1 1 !# %1 314 "# %1 314 , , w "& ! กก$ " ก , 1$ / # ( # ก - )u = 76500/244 = 314 x
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# ก ,
750 700 650 600
580
550
%1 1 "# 1$ 314 , /
546
500 450
423
400 350 300
279
250 200 150
227 185
174
337
365
278
273 218
100 50
. ก . % . . . ก . . ก . . . .
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+ ' 75000
76500
" (ก & "
70000 65000 60000 55000
%1 1
50000 45000 50000 35000
# , ก
"# %1 314 , / ( 76500/244 = 314 )
30000 25000 20000 15000
# ก
10000 5000
. ก&. . < & . . ก . ( . ก . . & . / .
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ก %# !# &ก ( 314 / ) . . ก. . . . . . . . . . ก. . . . ก. . . . . . %. .
) ก *' ก ' *' ก ' / ก ' , ' + ' / - - ( 22 20 23 19 22 22 20 23 11 22 22 18 244
314 314 314 314 314 314 314 314 314 314 314 314
6,908 6,280 7,222 5,966 6,908 6,908 6,280 7,222 3,454 6,908 6,908 5,652 76,616
5,000 3,700 4,000 5,300 7,400 9,300 11,600 8,400 6,000 6,000 4,800 5,000 76,500
1,908 2,580 3,222 666 -492 -2,392 -5,320 -1,178 -2,546 908 2,108 652
1,908 4,488 7,710 8,376 7,884 5,492 172 -1,006 -3,552 -2,644 -536 116 36
ก %# !# &ก ( 314 / ) . . ก. . . . . . . . . . ก. . . . ก. . . . . . %. .
*' ก ' / ก ' , ' / - - ( 6,908 6,280 7,222 5,966 6,908 6,908 6,280 7,222 3,454 6,908 6,908 5,652 76,616
5,000 3,700 4,000 5,300 7,400 9,300 11,600 8,400 6,000 6,000 4,800 5,000 76,500
1,908 2,580 3,222 666 -492 -2,392 -5,320 -1,178 -2,546 908 2,108 652
1,908 4,488 7,710 8,376 7,884 5,492 172 -1,006 -3,552 -2,644 -536 116
( ) / )+ 01 172.03 367.87 726.76 652.23 710.85 495.18 14.10 -----8.56 3147.6 37
%1 1
ก (314 ! " / " ) (ก % & '( )
, กC( ก # i"Eก
= 3147.6 X 50
= 157,380 (
, / #!, # & " 0 , / #!, & ก
= 7,738 X 25
= 193,450 ( = 350,830 (
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ก %1 1 ) ("# # !# %1 314 "# %1 314 , , , "# ก # # " 1 &;- 3552 , ! ก)uก, # $ / # # ก z& E, 0 # # ก " ก ,
w " ! ก " (ก & " E "/ %1 1x 39
+ '
76500
75000 70000 65000
%1 1
60000 55000 50000
%1 2
45000 50000 35000 30000 25000
# # "
"# %1 314 , /
3552 ,
, 1 # # " 3552 ,
20000 15000
# ก
10000 5000
. ก . % . . . ก . . ก . . . .
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กก %# !# &ก ( 314 / ) "- # ก 3552 . . ก. . . . . . . . . . ก. . . . ก. . . . . . %. .
) ก *' ก ' *' ก ' / ก ' , ' + ' / - - ( 22 20 23 19 22 22 20 23 11 22 22 18 244
314 314 314 314 314 314 314 314 314 314 314 314
6,908 6,280 7,222 5,966 6,908 6,908 6,280 7,222 3,454 6,908 6,908 5,652 76,616
5,000 3,700 4,000 5,300 7,400 9,300 11,600 8,400 6,000 6,000 4,800 5,000 76,500
1,908 2,580 3,222 666 -492 -2,392 -5,320 -1,178 -2,546 908 2,108 652
5,460 8,040 11,262 11,928 11,436 9,044 7,329 2,546 0 908 3,016 3,668 41
%1 1
) , / #!, ก =" %1 (314 , / ) "# # # "(ก %> , % # & " 0 =" 1 # # " %ก 3552 , ) , กC( ก # i"Eก
= =
6,699.6 x50 334,980 (
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2 ก # ก "# ก ) ( " ( )A , a "# ก $ , # 4 . - % . 230/ !# 230 4 .- . 406 , / !# 350 1 ! ก "0 %. . 120 / , )ก 350 , $ , 56 , 4 ก . 350 , / " ( 350 , " (> , % , ) 4 . | . "# 230 , , !# " ( 230 =" " 120 4 . "# 253 , , !# " ( 230 , " / , , 23 , ,
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,
# ก ,
750 700 650 600 550 500
%1 2
550
450
406
400 350 300 250
230
200
227 200
150
318 263
409
591
391 350
253 273
278
230 227
173
100 50
. ก . % . . . ก . . ก . . . .
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* & ก $ ! / +2ก" กก " 230 ! กก " " $ " $ ก + & ก * . " กกC$ " ก $ - ( ก . "( *+ & ก . " ก & $ " Part time
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2 . . ก. . . . . . . . . . ก. . . . ก. . . . . . %. .
) ก *' ก ' *' ก ' ' 0ก + 0ก + 22 20 23 19 22 22 20 23 11 22 22 18 244
230 230 230 350 350 350 350 350 350 230 230 230
5060 4600 5290 6650 7700 7700 7000 8050 3850 5060 5060 4140 70160
*' ก ' + +
56 56 56 56 56
23
*' ก ' + +
1064 1232 1232 1120 1288
414 6350 46
60*22 244
2 *' ก ' ก 0 , / ' / ( - - ) . . ก. . . . . . . . . . ก. . . . ก. . . . . . %. .
5060 4600 5290 7714 8932 8932 8120 9338 3850 5060 5060 4554
5,000 3,700 4,000 5,300 7,400 9,300 11,600 8,400 6,000 6,000 4,800 5,000 76,500
60 900 1290 2414 1532 - 368 -3480 938 -2150 -940 260 -446
# 60 960 2250 4664 6196 5828 2348 3286 1136 196 456 10
# % ( , )u 5.41 78.69 212.09 363.18 558.66 525.48 192.46 309.75 51.21 17.67 41.11 0.74
2356.4
47
%1 2 ) , / #!, ก , กC( ก # i"Eก , ,
, ) (ก$ ก , / #!, & ก
= = = = = = =
2,356.4 x 50 117,820 ( 6350 x 10 ( 63,500 ( (120+120) x 200 48,000 ( 229,320 (
48
3 ) ( " ( )A , a "# ก $ , # !# E# ( , 4 . - . 250/ !# 250 4 . - . 350 , / !# 1 &;- 100 01 1 " (ก$ ก ! ก 250 , , )A 350 , , 4 ก . " (ก 410 , / ( / , , 60 , / !# E# ( , %ก 1700 , 4 . " (ก 370 , / ( / , , %ก 20 , / ) 4 ก . " (ก 410 , / ( / , , 60 , / !# E# ( , %ก 1380 ,
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3 ( " ) ) ( " ( )A , a "# ก $ , # !# E# ( , 4 . " (ก 273 , / ) " ก 100 01 " " (ก$ ก ! ก 350 , , )A 250 , , $ ก / , , %ก 23 , , 4 - " (ก 250 , / !# 250 , "
50
3 . . ก. . . . . . . . . . ก. . . . ก. . . . . . %. .
) ก *' ก ' *' ก ' *' ก ' *' ก ' !# E# ( ' 0ก + 0ก + + + + + , 22 20 23 19 22 22 20 23 11 22 22 18 244
250 250 250 250 350 350 350 350 350 250 250 250
5500 5000 5750 4750 7700 7700 7000 8050 3850 5500 5500 4500 70800
60 20 60 23
1200 460 660 506
1700
2826
3080
1380
51
3 *' ก ' ก 0 , / ' / ( - - ) . . ก. . . . . . . . . . ก. . . . ก. . . . . . %. .
5500 5000 5750 4750 7700 7700 9900 8510 5890 6006 5500 4500 76706
5,000 3,700 4,000 5,300 7,400 9,300 11,600 8,400 6,000 6,000 4,800 5,000 76,500
500 1300 1750 -550 300 -1600 -1700 110 -110 6 700 -500
#
# % ( , )u
500 1800 3550 3000 3300 1700 0 110 0 6 706 206
45.08 147.54 334.63 223.61 297.54 153.28 0 10.30 0 0.54 63.66 15.20
1301.45
52
%1 3 ) , / #!, ก , กC( ก # i"Eก , ,
, ) (ก$ ก , !# E# ( , , / #!, & ก
= = = = = = = = =
1,301.4 x 50 65,070 ( 2,826 x 10 ( 28,260 ( (100+100) x 200 40,000 ( 3080 x 15 46,220 179,530 ( 53
+ " $ " ภ+ 0 " $ " " "
1
1 + & Inventory
" ภC ภ<
157,380
334,980
" (
193,450
2 63,500
3 28,260
117,820
65,070
" " "
46,220
" + ภ" $ "
350,830
334,980
48,000
40,000
229,320
179,530 54
The END
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