Chap 13 Solution
Chap 13 Solution
C H A P T E R
Aggregate Planning
Universities have so many grants, scholarships, and in plans, or going to the restaurant early, or finding and
loans that in many universities most of the students have using those discount coupons. How much work do you
some sort of “deal”; this is revenue management for the want to do for a discount? It turns out that some people
university. will not do the work necessary to use the system to their
These yield management techniques are designed to advantage.
appeal to various market segments. And the pervasive-
ness of the techniques proves that it does work. ACTIVE M ODEL EXERCISE
From the customer’s perspective there is often
resentment at sitting next to someone on the airplane ACTIVE MODEL 13.1: Aggregate Planning
who has paid half as much for the same flight as you 1. Each worker makes five units per day. If the number of
paid—or going to a restaurant and having the customer workers is reduced from 10 to 9, dropping the daily capacity, what
who arrived 15 minutes earlier than you or who has a happens to the cost?
coupon, pay half the price for the same meal. A sense of The cost actually drops to $54,465. This is due to drops in
fairness suggests that something is wrong and some the amount of inventory that is maintained.
customers resent the difference.
2. What regular time level minimizes the total cost?
2. M ost customers have come to accept yield management 39 units
and take full advantage of the opportunities it affords.
3. How low can the regular daily capacity get before overtime
The multiple pricing of yield management by definition
will be required?
satisfies more customers (customers use the services)
At 22 units per day (4.4 workers), overtime is required.
and the firm utilizes resources more effectively.
4. How low can the regular daily capacity get before there will
3. M any customers do take exception to the variation in
not be enough capacity to meet the demand?
pricing—different prices for the same service seem
At 12 units per day (2.4 workers), demand cannot be met.
inherently wrong to many people and management need
to be prepared for the irate customer.
4. Some customers will manipulate the system by booking
END-OF-CHAPTER PROBLEMS
tickets on flights that have a stop over in a city they 13.1 Ne e de d
travel to, but which has a higher fare than the destination Production Forecast Production
flight. They exit the plane at the stopover city —saving Month Days Demand Each Day
money. For instance, if the flight from New York to Jan 22 1,000 45.5
Chicago is less than the flight to the stopover city —say Feb 18 1,100 61.1
Pittsburgh, a customer can book the flight to Chicago Mar 22 1,200 54.5
Apr 21 1,300 61.9
but get off in Pittsburgh. You might ask students to
May 22 1,350 61.4
discuss the ethics of this manipulation.
Jun 21 1,350 64.3
And, of course, customers use the system by July 21 1,300 61.9
finding the positions on the yield management curve Aug 22 1,200 54.5
that works for them. Sometimes this means shopping for Sep 21 1,100 52.4
tickets weeks in advance and taking the risk of a change Oct 22 1,100 50.0
Nov 20 1,050 52.5
Dec 20 900 45.0
252 13,950 55.4
(on average)
182 CHAPTER 13 AG G R E G A T E P L A N N I N G
Plan 5 Cost analysis: Based simply upon total cost, Plan 2 is preferable. From a pract i-
Regular production: cal viewpoint, Plans 1, 5, and 6 will likely have equivalent costs.
Practical implementation of Plan 2 may, for example, require the
CR 6 persons $80 124 $59,520 employment of eight full-time employees, rather than seven full-
Subcontract cost @ $10/unit: time and one part-time employee. When several plans have
roughly equivalent costs, other parameters gain importance—such
CSC 2,480 units $20 / unit $49,600
as the amount of control one would have over production and ex-
Total cost: cess wear on equipment and personnel. Plan 3 should be avoided.
CT $59,520 $49,600 $109,120 (not preferable
to Plan 2 at $105,152, but preferable to Plan 4 at $113,488). 13.3 Period Expected Demand
13.3 (cont’d)
Plan A
Production
(Result of
Previous Inventory Stockout Hire Layoff Personnel
Pe riod Demand Month) (Units) (Units) (Units) (Units) Cost
1 (Jan) 1,400 1,600 400 200 $15,000 (cost to go from 1,600 in Jan to 1,400 in Feb)
2 (Feb) 1,600 1,400 200 200 10,000 (cost to go from 1,400 in Feb to 1,600 in Mar)
3 (Mar) 1,800 1,600 200 10,000
4 (Apr) 1,800 1,800 —
5 (May) 2,200 1,800 400 400 20,000
6 (June) 2,200 2,200 —
7 (July) 1,800 2,200 400 400 30,000
8 (Aug) 1,400 1,800 800 400 30,000 (cost to go from 1,800 in August to 1,400 in Sept)
1,800 $400 T otal $115,000
@ $20 @ $100 Personnel Cost:
=$36,000 =$40,000
Note: December demand was 1,600, and because our strategy is chasing prior-period demand, our January production is 1,600. So 200 units remain in
inventory, and January production adds 200 units to this inventory, for a total of 400 units. Inventory units: Jan. 400 + Feb. 200 + July 400 + Aug. 800
(400 from July and 400 from August) = 1,800 units at $20 = $36,000. Stockout units: May 400 units at $100 = $40,000. Hiring and layoff costs =
$115,000. T otal costs = $36,000 + $40,000 + $115,000 = $191,000.
13.4 Plan B
Pe riod Demand Production Ending Inv. Subcon (Units) Extra Cost
0 200
1 1,400 1,400 200 — $4,000
2 1,600 1,400 0 — —
3 1,800 1,400 0 400 30,000
4 1,800 1,400 0 400 30,000
5 2,200 1,400 0 800 60,000
6 2,200 1,400 0 800 60,000
7 1,800 1,400 0 400 30,000
8 1,400 1,400 0 —
T otal Extra Cost: $214,000
13.5 (a)
Plan C
Pe riod Demand Production* Ending Inv. Stockouts (Units) Extra Cost
0 200
1 1,400 1,775 575 $11,500
2 1,600 1,775 750 15,000
3 1,800 1,775 725 14,500
4 1,800 1,775 700 14,000
5 2,200 1,775 275 5,500
6 2,200 1,775 0 150 15,000
7 1,800 1,775 0 25 2,500
8 1,400 1,775 375 7,500
T otal Extra Cost: $85,500
(b) Plan E
Pe riod Demand Production Subcont (Units) Ending Inv. Extra Cost
0 200
1 1,400 1,600 400 $8,000
2 1,600 1,600 400 8,000
3 1,800 1,600 200 4,000
4 1,800 1,600 0
5 2,200 1,600 600 45,000
6 2,200 1,600 600 45,000
7 1,800 1,600 200 15,000
8 1,400 1,600 200 4,000
T otal Extra Cost: $129,000
All other things being equal, it would appear that Plan D,
with a cost of $122,000, should be recommended over
Plan E (cost = $129,000).
Note that of all the plans discussed, it would appear
that Plan C, with a cost of $85,500, should be recom-
mended over all others.
13.7 Month Expected Demand
Jul 400
Aug 500
Sep 550
Oct 700
Nov 800
Dec 700
Production per person per day: 8 hr/person 4 hours/dis k
Therefore, each person can produce 2 disks per day,
or 40 disks per month.
(a) Aggregate plan, hiring/layoff only:
Beg. Personnel
Inventory Hours Required Production Costs
Unit O ver Units Required at 20 days Personnel Units O ver Layoff Hire : 40
Pe riod Demand (or Short) Required at 4 each at 8 hrs on staff Produced (or Short) Hire $40 $80 Layoff: 80
Jun 150 8
Jul 400 150 250 1,000 6.25 6 240 –10 2 $160
Aug 500 –10 510 2,040 12.75 13 520 10* 7 $280
Sep 550 10 540 2,160 13.50 14 560 20* 1 $40
Oct 700 20 680 2,720 17.00 17 680 0 3 $120
Nov 800 0 800 3,200 20.00 20 800 0 3 $120
Dec 700 0 700 2,800 17.50 17 680 –20 3 $240
T otal Cost: $960
* Inventory (August = 10 and Sept. = 20) = 30 × 8 = $240
Inventory Cost = 30 × 8 = $240
Hiring/Layoff Cost = 960
$1,200
Note: In computing cost, we assumed that, if the capacity of a fraction of a worker was needed (was excess), one worker was hired
(layed off). Solution by POM for Windows, in which the increase cost is $1 per unit and the decrease cost is $2 per unit, yields a
similar result, with a total extra cost of $890.
(b) Aggregate plan, overtime only:
Production Production Ending Inventory Holding Cost
Pe riod Demand (Regular) (O vertime) Inv. @ $8/unit/month
Jun 150
Jul 400 320 70 560
Aug 500 320 110
Sep 550 320 230
Oct 700 320 380
Nov 800 320 480
Dec 700 320 380
T otal 1,580 $560
1,580 ($72 – $48) = $37,920 = Extra total (OT) cost $560 holding cost = $38,480
Units made on $72 = 4 hr $48 = 4 hr
overtime (OT ) each $18 each $12
186 CHAPTER 13 AG G R E G A T E P L A N N I N G
Plan A
Pe riod Demand Production Ending Inv. Subcont. (Units) Extra Cost
Jul 1,000 1,000 0 — 0
Aug 1,200 1,000 0 200 12,000
Sep 1,400 1,000 0 400 24,000
Oct 1,800 1,000 0 800 48,000
Nov 1,800 1,000 0 800 48,000
Dec 1,600 1,000 0 600 36,000
T otal Extra Cost: $168,000
CHAPTER 13 AG G R E G A T E P L A N N I N G 187
Plan B
Pe riod Demand Production (Existing) Hire (Units) Layoffs (Units) Extra Cost
Jul 1,000 1,300 — 300 $18,000
Aug 1,200 1,000 200 6,000
Sep 1,400 1,200 200 6,000
Oct 1,800 1,400 400 12,000
Nov 1,800 1,800 — —
Dec 1,600 1,800 — 200 12,000
T otal Extra Cost: $54,000
(b) Plan B is best because of cost. But note that production is only 8,500 units.
Overtime production = $0
Subcontract = $0 and
Inventory holding and shortage cost = $0
(b) The Level plan:
Reg. Time
Pe riod Demand Production Inventory Holding Shortage Change Hiring Layoffs
Quarter 1 1,400 1,350 –50 0 50 –150 0 150
Quarter 2 1,200 1,350 100 100 0 0 0 0
Quarter 3 1,500 1,350 –50 0 50 0 0 0
Quarter 4 1,300 1,350 0 0 0 0 0
T otal 5,400 * 5,400 100 100 0 150
Cost $162,000 $1,000 $5,000 $0 $12,000
T otal Cost: $180,000
* (5,400/4) = 1,350 = average demand.
(c) A Level plan will cost $180,000, while a Chase plan
will cost $214,000.
13.12 Initial data:
13.14 Assuming that back orders are not permitted, the solution is:
13.17 (a) The cost matrix and the optimal plan are shown below:
13.18 Assuming that back orders are not permitted, one solution,
of multiple optional solutions, is:
Summary Table
Type Units Cost
Regtm 2,260 $2,260,000
Ovrtm 189 $245,700
Subcon 57 $102,600
Holdng 0 $0
Shortg 0 $0
Increase 75 $0
Decrease 20 $0
T otal cost = $2,608,300
Summary Table
Type Units Cost
Regtm 2,180 $2,180,000
Ovrtm 187 $243,100
Subcon 90 $162,000
Holdng 0 $0
Shortg 49 $0
Increase 20 $0
Decrease 0 $0
T otal cost = $2,585,100, or about $50,000 savings
13.25 Even though back orders are permitted, note they are not
used. One of the multiple optimal solutions is:
(a) Re g Time
Pe riod Demand Production Inventory Holding Shortage Change Increase De cre ase
Jan 400 400 250 250 0 80 80 0
Feb 500 500 250 250 0 100 100 0
Mar 550 550 250 250 0 50 50 0
Apr 700 700 250 250 0 150 150 0
May 800 800 250 250 0 100 100 0
June 700 700 250 250 0 –100 0 100
T otal 3650 3650 1500 0 480 100
Cost $175,200 $12,000 $0 $19,200 $8,000
T otal Cost $214,400
CHAPTER 13 AG G R E G A T E P L A N N I N G 199
4. How much does it currently cost the university to provide rather complex set of transportation problems. Four different
police services for football games? What would be the pros configurations of operating plants have to be tested. The solutions,
and cons of subcontracting this work completely to outside although requiring relatively few iterations to optimality, involve
law enforcement agencies? degeneracy if solved manually.
Cost of police officers for football games: The costs are:
18 officers work 8 hours overtime @ $18/hr
Total Total Total
8 officers work 16 hours overtime @ $18/hr Configuration Variable Cost Fixed Cost Cost
40 outside officers work 9 hours @ $18/hr
All plants operating $179,730 $41,000 $220,730
25 part-timers work 9 hours @ $9/hr 1 & 2 operating, 3 closed 188,930 33,500 222,430
5 football games per year 1 & 3 operating, 2 closed 183,430 34,000 217,430
2 & 3 operating, 1 closed 188,360 33,000 221,360
Cost [(18 8 18) (8 16 18) (40 9 18)
(25 9 9)] 5
The lowest weekly total cost, operating plants 1 and 3 with 2
[2,592 2,304 6,480 2,025] 5 closed, is $217,430. This is $3,300 per week ($171,600 per year)
[13,401] 5 $67,005 or 1.5% less than the next most economical solution, operating all
3 plants. Closing a plant without expanding capacity of the
Subcontracting security for football games would relieve the
remaining plants means unemployment. The optimum solution,
weary campus police and allow them to perform their normal
using plants 1 and 3, indicates overtime production of 4,000 units
duties more effectively. However, football security is highly
at 3 and 0 overtime at 1. The all-plant optima have no use of
visible, and the absence of campus police may hurt their
overtime and include substantial idle regular time capacity:
image in the university community and rob them of the
11,000 units (55%) in plant 2 and either 5,000 units in 1 (19% of
opportunity to work closely with law enforcement personnel
capacity) or 5,000 in 3 (20% of capacity). The idled capacity
from agencies in a noncrisis situation. It may also be difficult
versus unemployment question is an interesting, nonquantitative
for the university to maintain the same level of control over
aspect of the case and could lead to discussion of the forecasts for
subcontracted work, especially in terms of discretionary
the housing market and thus the plant’s product.
treatment of students and alumni.
The optimum producing and shipping pattern is:
In terms of cost, it is doubtful that the work could be
subcontracted as cheaply as it is currently performed because From To (Amount)
the cost of supervisory and managerial personnel would have Plant 1 (R.T .) W2 (13,000); W4 (14,000)
to be included in the package (and currently no supervisors or Plant 3 (R.T .) W1 (5,000); W3 (11,000); W4 (1,000); W5 (8,000)
managers are paid overtime for their work). Plant 3 (O.T .) W1 (4,000)
5. Can you propose any other alternatives?
There are three alternative optimal producing and shipping
M any of the innovative suggestions for handling the
patterns.
variability in demand for services involve using part-time
Getting the solution manually should not be attempted.
workers. Police officers require extensive training, so this
It will take eight tableaux to do the “All Plants” configuration,
alternative usually means hiring off-duty police officers from
with degeneracy appearing in the seventh tableau; the “1 & 2”
other agencies. Under these circumstances, the hours that off-
configuration takes five tableaux, etc. It is strongly suggested that
duty officers can moonlight are limited, and, except for
POM for Windows, Excel, or other software be used.
football Saturdays, may be hard to schedule (i.e., all part-time
agencies are busy at the same time). Another way to handle
part-time or seasonal requirements for work is to find ADDITIONAL CASE STUDY*
complementary work for the full-time employees that follows
CORNWELL GLASS
a different demand pattern. In this case, the nonpeak period
for police services falls during the summer months. What Entering the data provided into software, then toggling the pure
other university services increase during those months? strategies and trying them yields the following costs:
Perhaps the idled officers could be used as campus guides Plan 1 (smooth production): $849,077
during summer orientation, as aides for the summer camps Plan 2 (meet demand exactly): $104,575
and other summer programs held on campus, or as part of the Plan 3 (produce 1,900 as base, then use
grounds crew. At least one small private college utilizes its OT and subcontracting): $82,858
police officers in this expanded fashion. It certainly increases At this point, the question is, can we do better with trial and
the officers’ involvement with the university community. error? A better solution follows.
2 ANDREW-CARTER, INC. * T his case is found on our Companion Web site,
www.pearsonhighered.com/heizer.
This case presents some of the basic concepts of aggregate
planning by the transportation method. The case involves solving a
Note: December
demand was
1,600, and
because our
strategy is CHAPTER 13 A G G R E G A T E P L A N N I N G 201
chasing prior-
period demand,
our January Aggregate Planning
production is Time periods 52
1,6000. So 200Shortages: Back orders—Carry shortages from period to pe riod
units remain inAll pds 1,900 0 0 $0 $8.00 $10 $0.12 $20.0 $5.63 $15.73
inventory, and Schedule Units
January Pd Demnd Regtm O vrtm Subcon Regtm O vrtm Subcon Holdng Shortg Incre s De cre s
production addsInit 73 1,900 0 0
200 units to thisApril 15 1,829 1,900 250 0 1,900 250 0 394 0 0 0
inventory, for a 22 1,820 1,900 250 0 1,900 250 0 724 0 0 0
total of 400 units. 29 1,887 1,900 250 0 1,900 250 0 987 0 0 0
Inventory unitsMay 6 1,958 1,900 250 0 1,900 250 0 1,179 0 0 0
(Jan. 400 + Feb. 13 2,011 1,900 250 0 1,900 250 0 1,318 0 0 0
200 + July 400 + 20 2,063 1,900 250 0 1,900 250 0 1,405 0 0 0
27 2,104 1,900 250 0 1,900 250 0 1,451 0 0 0
Aug. 800 (400
June 3 2,161 1,900 250 0 1,900 250 0 1,440 0 0 0
from July and
10 2,258 1,900 250 0 1,900 250 0 1,332 0 0 0
400 from 17 2,307 1,900 250 0 1,900 250 0 1,175 0 0 0
August) = 1,800 24 2,389 1,900 250 0 1,900 250 0 936 0 0 0
units at $20. =July 1 2,434 1,900 250 0 1,900 250 0 652 0 0 0
$36,000. 8 2,402 1,900 250 0 1,900 250 0 400 0 0 0
Stockout units: 15 2,385 1,900 250 0 1,900 250 0 165 0 0 0
May 400 units at 22 2,330 1,900 250 15 1,900 250 15 0 0 0 0
$100 = $40,000. 29 2,323 1,900 250 173 1,900 250 173 0 0 0 0
Hiring and layoffAug. 5 2,317 1,900 250 167 1,900 250 167 0 0 0 0
12 2,222 1,900 250 72 1,900 250 72 0 0 0 0
costs - $115,000.
19 2,134 1,900 234 0 1,900 234 0 0 0 0 0
T otal costs =
26 2,065 1,900 165 0 1,900 165 0 0 0 0 0
$36,000 +Sept. 2 1,973 1,900 73 0 1,900 73 0 0 0 0 0
$40,000 + 9 1,912 1,900 12 0 1,900 12 0 0 0 0 0
$115,000 = 16 1,854 1,900 0 0 1,900 0 0 46 0 0 0
$191,000. 23 1,763 1,900 0 0 1,900 0 0 183 0 0 0
30 1,699 1,900 0 0 1,900 0 0 384 0 0 0
Oct. 7 1,620 1,900 0 0 1,900 0 0 664 0 0 0
14 1,689 1,900 0 0 1,900 0 0 875 0 0 0
21 1,754 1,900 0 0 1,900 0 0 1,021 0 0 0
28 1,800 1,900 207 0 1,900 207 0 1,328 0 0 0
Nov. 4 1,864 1,900 250 0 1,900 250 0 1,614 0 0 0
11 1,989 1,900 250 0 1,900 250 0 1,775 0 0 0
18 2,098 1,900 250 0 1,900 250 0 1,827 0 0 0
25 2,244 1,900 250 0 1,900 250 0 1,733 0 0 0
Dec. 2 2,357 1,900 250 0 1,900 250 0 1,526 0 0 0
9 2,368 1,900 250 0 1,900 250 0 1,308 0 0 0
16 2,387 1,900 250 0 1,900 250 0 1,071 0 0 0
23 2,402 1,900 250 0 1,900 250 0 819 0 0 0
30 2,418 1,900 250 0 1,900 250 0 551 0 0 0
Jan. 6 2,417 1,900 250 0 1,900 250 0 284 0 0 0
13 2,324 1,900 250 0 1,900 250 0 110 0 0 0
20 2,204 1,900 250 0 1,900 250 0 56 0 0 0
27 2,188 1,900 250 0 1,900 250 0 18 0 0 0
Feb. 3 2,168 1,900 250 0 1,900 250 0 0 0 0 0
10 2,086 1,900 186 0 1,900 186 0 0 0 0 0
17 1,954 1,900 54 0 1,900 54 0 0 0 0 0
24 1,877 1,900 0 0 1,900 0 0 23 0 0 0
Mar. 3 1,822 1,900 0 0 1,900 0 0 101 0 0 0
10 1,803 1,900 0 0 1,900 0 0 198 0 0 0
17 1,777 1,900 0 0 1,900 0 0 321 0 0 0
24 1,799 1,900 0 0 1,900 0 0 422 0 0 0
31 1,803 1,900 0 0 1,900 0 0 519 0 0 0
Apr. 7 1,805 1,900 0 0 1,900 0 0 614 0 0 0
T otal 107,544 98,800 8,931 427 98,800 8,931 427 32,949 0 0 0
Subtotal Costs 0 71,448 4,270 3,953.9 0 0 0
T otal cost = $79,671.88