Suppose you have been given responsibility for developing thesix-month aggregate production plan at Soda Galore, a manufacturerof soft drinks. Your company makes three types of soft drinks:regular, diet, and super-caffeinated. Fortunately, all three typesare made using the same production process, and the costs relatedto switching between the three types are so minimal that they canbe ignored. Thus, you can treat your problem as an aggregateplanning exercise where the planning unit is cases of soft drinks,regardless of what types of drinks they are.
January | 16,000 cases |
February | 24,000 cases |
March | 32,000 cases |
April | 32,000 cases |
May | 60,000 cases |
June | 88,000 cases |
Total Demand | 252,000 cases |
Average Monthly demand | 42,000 cases |
Current workforce | 10 workers |
Average monthly output per workder | 2000 cases per month |
Inventory holding cost | $0.30 cases per month |
Regular wage rate | $36 per hour |
Regular production hours/month/worker | 100 hours |
Overtime wage rate | $54 per hour |
Hiring cost | $1000 per worker |
Firing cost | $1500 per worker |
Subcontracting cost | $2.90 per cases |
Beginning inventory | 7000 (all safety stock) |
Assume that employees negotiate an increase in the regularproduction wage rate to $40 per hour and $60 per hour for overtime.Also assume that Soda Galore always plans to hold at least 7,000cases of safety stock to meet unanticipated customer demand. Assumethat hiring and layoff/firing, if necessary, occur at the beginningof the month.
a) Determine the cost of the level production plan.
b)Determine the cost of the chase production plan.
Total cost is workforce size adjusted | ??? |
Total cost if overtime production used | ??? |
Total cost if subtracting used | ??? |
c)After much internal discussion, the company decides tomaintain a permanent workforce of 10 production workers. Given thesame planning information and this new requirement, develop asix-month production plan based on hybrid production. Determine thecost of the hybrid production plan. Use the overtime cost.