生产计划与控制作业Problem4.docx
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生产计划与控制作业Problem4.docx
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生产计划与控制作业Problem4
P4-1
HaroldGreyownsasmallfarmintheSalinasValleythatgrowsapricots.Theapricotsaredriedonthepremisesandsoldtoanumberoflargesupermarketchains.Basedonpastexperienceandcommittedcontracts,heestimatesthatsalesoverthenextfiveyearsinthousandsofpackageswillbeasfollows:
Year
ForecastedDemand
(thousandsofpackages)
1
300
2
120
3
200
4
110
5
135
Assumethateachworkerstaysonthejobforatleastoneyear,andthatGreycurrentlyhasthreeworkersonthepayroll.Heestimatesthathewillhave20,000packagesonhandattheendofthecurrentyear.Assumethat,ontheaverage,eachworkerispaid$25,000peryearandisresponsibleforproducing30,000packages.Inventorycostshavebeenestimatedtobe4centsperpackageperyear,andshortagesarenotallowed.Basedontheeffortofinterviewingandtrainingnewworkers,FarmerGreyestimatesthatitcosts$500foreachworkerhired.Severancepayamountsto$1,000perworker.
a.Assumingthatshortagesarenotallowed,determinetheminimumconstantworkforcethathewillneedoverthenextfiveyears.
b.Evaluatethecostoftheplanfoundinpart(a).
P4-2
ForthedatagiveninP4-1,graphthecumulativenetdemand.
a.Graphicallydetermineaproductionplanthatchangestheproductionrateexactlyonceduringthefiveyears,andevaluatethecostofthatplan.
b.Graphicallydetermineaproductionplanthatchangestheproductionrateexactlytwiceduringthefiveyears,andevaluatethecostofthatplan.
P4-3
AnimplicitassumptionmadeinP4-1wasthatdriedapricotsunsoldatthe'L.endofayearcouldbesoldinsubsequentyears.Supposethatapricotsunsoldattheendofanyyearmustbediscarded.Assumeadisposalcostof$0.20perpackage.ResolveProblem9undertheseconditions.
P4-4
ThepersonaldepartmentoftheA&MCorporationwantstoknowhowmanyworkerswillbeneededeachmonthforthenextsi5-monthproductionperiod.Thefollowingisamonthlydemandforecastforthesix-monthperiod.
MONTH
ForecastedDemand
June
1,250
August
1,100
September
950
October
900
November
1,000
December
1,150
TheinventoryonhandattheendofJunewas500units.Thecompanywantstomaintainaminimuminventoryof300unitseachmonthandwouldliketohave400unitsonhandattheendofDecember.Eachunitrequires5employee-hourstoproduce,thereare20workingdayseachmonth,andeachemployeeworksan8-hourday.TheworkforceattheendofJunewas35workers.
a.Determineaminimuminventoryproductionplan(i.e.,onethatallowsarbitraryhiringandfiring).
b.Determinetheproductionplanthatmeetsdemandbutdoesnothireorfireworkersduringthesix-monthperiod.
P4-5
Alocalsemiconductorfirm,Superchip,isplanningitsworkforceandproductionlevelsoverthenextyear.Thefirmmakesavarietyofmicroprocessorsandusessalesdollarsasitsaggregateproductionmeasure.Basedonordersreceivedandsalesforecastsprovidedbythemarketingdepartment,theestimateofdollarsalesforthenextyearbymonthisasfollows:
Month
Productiondays
PredictedDemand
(in$10,000)
January
22
340
February
16
380
March
21
220
April
19
100
May
23
490
June
20
625
July
24
375
August
12
310
September
19
175
October
22
145
November
20
120
December
16
165
Inventoryholdingcostsarebasedona25percentannualinterestcharge.Itisanticipatedthattherewillbe675workersonthepayrollattheendofthecurrentyearandinventorieswillamountto$120,000.Thefirmwouldliketohaveatleast$100,000ofinventoryattheendofDecembernextyear.Itisestimatedthateachworkeraccountsforanaverageof$60,000ofproductionperyear(assumethatoneyearconsistsof250workingdays).Thecostofhiringanewworkeris$200,andthecostoflayingoffaworkeris$400.
a.Determinetheminimumconstantworkforcethatwillmeetthepredicted
b.Evaluatethecostoftheplandeterminedinpart(a).
P4-6
ForthedatainP4-5,determinethecostoftheplanthatchangestheworkforcesizeeachperiodtomostcloselymatchthedemand.
P4-7
GraphthecumulativenetdemandfortheSuperchipdataofP4-5.Graphicallydetermineaproductionplanthatchangesproductionlevelsnomorethanthreetimes,anddeterminethetotalcostofthatplan.
P4-8.
ExcelsiorSprings,Ltd.,schedulesproductionofoneendproduct,Hi-Sulphur,inbatchesof80unitswhenevertheprojectedendinginventorybalanceinaquarterfallsbelow10units.Ittakesonequartertomakeabatchof80units.Excelsiorcurrentlyhas30unitsonhand.Thesalesforecastforthenextfourquartersis:
Forecast
Quarter
1
2
3
4
20
70
70
20
a.Prepareatime-phasedMPSrecordshowingthesalesforecastandMPSforHi-Sulphur.
b.Whataretheinventorybalancesattheendofeachquarter?
c.Duringthefirstquarter,nounitsweresold.Therevisedforecastfortherestoftheyearis:
Forecast
Quarter
2
3
4
30
50
70
HowdoestheMPSchange?
P4-9.
NeptuneManufacturingCompany’sproductionmanagerwantsamasterproductionschedulecoveringnextyear’sbusiness.Thecompanyproducesacompletelineofsmallfishingboatsforbothsaltwaterandfreshwateruseandmanufacturesmostofthecomponentpartsusedinassemblingtheproducts.ThefirmusesMRPtocoordinateproductionschedulesofthecomponentpartmanufacturingandassemblyoperations.Theproductionmanagerhasjustreceivedthefollowingsalesforecastfornextyearfromthemarketingdivision:
Productslines
Salesforecast(standardboatsforeachseries)
1stquarter
2ndquarter
3rdquarter
4thquarter
FunRayseries
8,000
9,000
6,000
6,000
SunRayseries
4,000
5,000
2,000
2,000
StingRayseries
9,000
10,000
6,000
7,000
Total
21,000
24,000
14,000
15,000
Thesalesforecastisstatedintermsof”standardboats,”reflectingtotalsalesvolumeforeachofthefirm’sthreemajorproductlines.Anotheritemofinformationsuppliedbythemarketingdepartmentisthetargetendinginventorypositionforeachproductline.Themarketingdepartmentwouldliketheproductionmanagertoplanonhavingthefollowingnumberofstandardboatsonhandattheendofeachquarterofnextyear:
Productline
Quarterlytarget
endinginventory
(instandardboats)
FunRayseries
3,000boats
SunRayseries
1,000boats
StingRayseries
3,000boats
Theinventorypositionforeachproductis:
Productline
Current
Inventorylevel
(instandardboats)
FunRayseries
3,000boats
SunRayseries
1,000boats
StingRayseries
3,000boats
Themasterproductionscheduleistospecifythenumberofboats(instandardunits)tobeproducedforeachproductlineineachquarterofnextyearonthefirm’ssingleassemblyline.Theassemblylinecanproduceupto15,000standardboatsperquarter(250boatsperdayduringthe60daysinaquarter).
Twoadditionalfactorsaretakenintoaccountbytheproductionmanagerinpreparingthemasterproductionschedule:
theassemblylinechangeovercostandtheinventorycarryingcostforthefinishedgoodsinventory.Eachassemblylinechangeovercosts$5,000,reflectingmaterialhandlingcostsofchangingthestockingofcomponentpartsontheline,adjustingthelayout,andsoon.Aftersomediscussionwiththecompanycomptroller,theproductionmanagerconcludedthatthefirm’sinventorycarryingcostis10percentofstandardboatcostperyear.Theitemvalueforeachoftheproductlinestandardunitsis:
Productline
Standardboatscost
FunRayseries
$100
SunRayseries
150
StingRayseries
200
Themasterproductionschedulerhascalculatedtheproductionlotsizesas5,000,3,000,and4,000units,respectively.
a.Developamasterproductionschedulefornextyear,byquarter,foreachofNeptune’sfishingboatlines.Identifyanyproblems.
b.VerifythelotsizecalculationsusingtheEOQformula.
P4-10.
TheMPSplanneratMurphyMotorsusesMPStime-phasedrecordsforplanningenditemproduction.TheplanneriscurrentlyworkingonaschedulefortheP24,oneofMurphy’stop-sellingmotors.Theplannerusesaproductionlotsizeof70andasafetystockof5fortheP24motor.
Week
1
2
3
4
5
6
7
8
Forecast
30
30
30
40
40
40
45
45
Orders
13
8
4
Available
Availabletopromise
MPS
Onhand=20
a.CompletetheMPStime-phasedrecordforproductP24.
b.CanMurphyacceptthefollowingorders?
UpdatetheMPStime-phasedrecordforacceptedorders.
Order
Amount
Desiredweek
1
40
4
2
30
6
3
30
2
4
25
3
P4-11.
NinoSpirellihasconstructedthefollowing(partial)time-phasedMPSrecord:
Week
1
2
3
4
5
6
Forecast
20
30
20
30
20
30
Orders
14
8
6
Available
Availabletopromise
MPS
50
50
50
50
Onhand=5
a.Completetherecord.
b.Arethereanyproblems?
c.What'stheearliestNinocanpromiseanorderfor44units?
d.Assumethatanorderfor15isbookedforweek4.Assumetheorderfor44
unitsinpartcisnotbooked;recomputetherecord.
P4-12.
TheNonameComputerCompanybuildsacomputerdesignatedmodelICU2.ItimportsthemotherboardofthecomputerfromTaiwan,butthecompanyinsertsthesocketsforthechipsandboardsinitsplantinLubbock,Texas.Eachcomputerrequiresatotalof9064KDRAM(dynamicrandomaccessmemory)chips.Nonamesellsthecomputerswiththreeadd-inboardsandtwodiskdrives.ThecompanypurchasesboththeDRAMchipsandthediskdrivesfromanoutsidesupplier.TheproductstructurediagramfortheICU2computerisgiveninFigure4-1.Supposethattheforecastedde
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