Suppose you have been given responsibility for developing the six-month aggregate production plan at Soda Galore,...

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General Management

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.

January16,000 cases
February24,000 cases
March32,000 cases
April32,000 cases
May60,000 cases
June88,000 cases
Total Demand252,000 cases
Average Monthly demand42,000 cases
Current workforce10 workers
Average monthly output per workder2000 cases per month
Inventory holding cost$0.30 cases per month
Regular wage rate$36 per hour
Regular production hours/month/worker100 hours
Overtime wage rate$54 per hour
Hiring cost$1000 per worker
Firing cost$1500 per worker
Subcontracting cost$2.90 per cases
Beginning inventory7000 (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.

Answer & Explanation Solved by verified expert
3.9 Ratings (483 Votes)

A. For Level Production: We get 21 workers as regular only

Level Jan Feb Mar Apr May Jun Total Safety stock
Demand 16000 24000 32000 32000 60000 88000 252000
Safety Stock 7000 7000 7000 7000 7000 7000
Prod per worker Starting worker Begin Inv 7000 26000 44000 54000 64000 46000 Man power 21 (252000/6*2000)
2000 10 Total requirement 23000 5000 -5000 -15000 3000 49000
Hours/month 100 Regular worker 21 21 21 21 21 21
Act production 42000 42000 42000 42000 42000 42000
(Demand+Safety stock-Act Production-Begin Inv) Closing inv 26000 44000 54000 64000 46000 0
(Regular-Starting worker) Hire 11 0 0 0 0 0
Rate Fire 0 0 0 0 0 0
(Rate*Hour/month *Regular worker) 40 Labor cost 84000 84000 84000 84000 84000 84000
(Hire*Rate) 1000 Hiring cost 11000 0 0 0 0 0
(Fire*Rate) 1500 Firing cost 0 0 0 0 0 0
(Closing inv+Safety stock*Rate) 0.3 Inventory cost 9900 15300 18300 21300 15900 2100
(Sum of all costs) Total cost 597800

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