1. BA 357:Work Assignment 1 One optimized aggregate plan (Sales and Operations Plan) using the chase strategy
The assignment must be submitted before 11:59 PMPDT on May 10th. One submission is required if done as a group per group.
Keep in mind that “pure” chase strategies do not use overtime. However, in a level-utilizationstrategy the staffing is kept level, but production is varied to meet demand. In the level-utilization strategy overtime is used for peak periods of demand to help keep the average level lower, and the desired inventory levels are the same as for the “pure” chase strategy. In the level-inventory strategy, anticipation inventory is the primary tool to maintain level staffing. All plans should seek to minimize the total cost of meeting your forecasted demand from the first part of the assignment.
Assignment Details (70 points total):
Given the operational data and constraints below, groups are to prepare, using the supplied form:
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(20 points) Assignment 1 SP21 Template (1) (1).
(20 points) One optimized aggregate plan (Sales and Operations Plan) using the level-utilization strategy.
(20 points) One optimized aggregate plan (Sales and Operations Plan) using a mixed strategy.
(15 points) An Executive Summary explaining your mixed plan in the context of the other three plans and constraints given.
Your submitted plan will comply with all operating constraints specified in the operational data given below. Plan total costs are to include appropriate end-of-the-year adjustments to return to the desired staffing and ending inventory levels specified in the following Data section.
All four plans will be completed using the provided forecast, fill in the summary sheet with a half-page executive summary explaining your choicesin your optimized mixed plan. Include the recommended plan’s total annual cost and cost per unit shipped. Your analysis should include quantitative factors (i.e.- Total Cost) and qualitative factors (i.e.- effects on morale and productivity) that drove your mixed plan.
There is an Excel template in the assignment 2 item in Canvas. The completed assignment file should consist of five sheets in the supplied Excel template in the following order:
Your names and the executive summary with recommended plan cost and cost per unit shipped
Your Chase Plan
Your Level-Utilization Plan
Your Mixed Plan
Plan formats: You are to use the spreadsheet template for your assignment. This form is now available as an Excel file in the Assignment 2 item in Canvas.
Your aggregate plan is to be completed on its designated sheet. There will be sufficient space below the spreadsheet form for you to add any comments or explanations you care to add regarding your plans.
Values within the main body of the spreadsheets (demand, production rates, staffing levels, etc.) are to be number of units or people (not $). They are to be expressed in whole numbers (no decimal values). Cost calculations will appear in the designated row at the bottom and the rightmost column of each spreadsheet only. Cost calculations, of course, will need to retain at least 2 decimal points (cents) but whole $ should be reported. The sum of the blue cells in the bottom row and the sum of the cells in the rightmost column should both equal the total cost of your aggregate plan and should be reported in the green cell in the lower right corner.
Enter the executive summary in the text box on the first sheet
Do not make the reader guess what you are doing – include explanations on each page.
Required format for aggregate plans is in the provided template.
Use the following monthly forecast to create your aggregate plans:
Assume 20 production days per month (4 weeks of 5 days each)
The ending inventory (for December of 2012) is 3000 units
Assume 0 units on Backorder at the end of 2012
The number of Units produced by each worker is 250 units per month
The desired safety stock level is 2000 units (you can only fall below this level to avoid having backorders, even in the Chase Strategy)
Average pay applies for the first 40 hours an employee works in a week. Overtime pay applies for any time over 40 hours in a given week. The maximum level of overtime any employee can work in a month is 40 hours.
You must employ whole people – there are no part time employees. (However, you can underutilize)
Employees do not produce more per month than is required by the plan (ie- No efficiency gains), however than can under produce to satisfy the conditions of the type of plan that you choose.
The firm wants exactly 4000 units to be left in inventory at the end of the fiscal year (after forecasted December 2013 demand is satisfied). This is a firm requirement for all plans.
The staffing level at the beginning of 2014 is to be the same as the original staffing level given below (any staffing changes needed to achieve this are made after the forecasted December 2013 demand is satisfied). This is a firm requirement for all plans.
Any backorder (negative on-hand inventory) is shown as a positive value in the backorder column instead of in the inventory column since it has a different monthly cost per unit. That is, if there is backorder for a period, there will be zero on-hand inventories for that period. Be sure to fulfill backorders as soon as possible in the plan.
Assignment 2 Cost Information Table:
Inventory holding cost $2 per unit per month based on ending inventory for month
Average pay rate $10 an hour
Overtime pay rate $15 an hour
Costs of hiring one additional employee $3000
Costs of firing one employee $2000
Original Staffing Level (12/2012) 21 employees
Material cost to produce one unit This cost in dollars per unit will be the average of the last two digits of the student ID numbers of all members of your group.
Backorder Costs $5 per unit per month held based on ending backorder level for month
Assignment 2 Operating Constraints Table:
Maximum inventory level 25,000 units due to limited warehouse capacity and increasing interest levels.
Maximum production capacity 20,000 units/month using regular time
Satisfying Demand Priorities Use Regular production time to meet demand if you can do so without violating the two previous constraints or the constraints of your plan type. After that, choose between using safety stock, anticipation inventory, Backorder or Overtime production. Choose the strategy that will lead to the lowest cost plan.