Escolar Documentos
Profissional Documentos
Cultura Documentos
Thank you for your order of the Operations Manager for Excel. General Purpose Operations and Manufacturing Management Templates. Contact US: EMAIL: us@usersolutions.com, PH: (248) 486-1934 FAX: (248) 486-6376 Please visit our website, www.usersolutions.com for information on other flexible and easy-to-use solutions. For Excel 2000 and up users, run Excel and open the template of choice. If prompted, select to Enable Macros. This Document contains License Agreement, Introduction, table of contents for all templates, and detailed documentation for templates downloaded.
IMPORTANT - READ CAREFULLY BEFORE USING SOFTWARE User Solutions, Inc. License Agreement
By opening this file, or any file that accompanied this download, you agree to become bound by the terms or this license. If you do not agree with these provisions, do not use the software and promptly return all materials included with this download to the place where you obtained it, in accordance with their return policy. 1. GRANT OF LICENSE. In consideration of the payment of the license fee, which is a part of the price you paid for this product, USER SOLUTIONS, as Licensor, grants to you, the Licensee, a non-exclusive, non-transferable license and right to use and display this copy of the Software program on a single computer. 2. COPYRIGHT. The Software and the accompanying written materials are copyrighted. Unauthorized copying of the software, including software that has been modified, merged, or included with other software, or of the written materials is expressly forbidden. You may be held legally responsible for any copyright infringement that is caused or encouraged by your failure to abide by the terms of this license. Subject to these restrictions, you may make one (1) copy of the Software solely for backup purposes. You must reproduce and include the copyright notice on the back up copy. 3. RESTRICTIONS. You agree that you will not use or permit the software to be used in any manner that would enable any third party or entity to copy the software. You may not incorporate portions of the software into other software for use on computers for which a license fee has not been paid. You may electronically transfer the software over networks provided a licensed fee has been paid for each computer which will use the software. You may not modify, adapt, translate or create derivative works based on the Software or written materials without the prior written consent of USER SOLUTIONS. The EXPORT of this product is restricted by U.S. export regulations. 4. TERMINATION. This License is effective until terminated. This License will terminate immediately without notice from USER SOLUTIONS if you fail to comply with any provision of this License. Upon termination you must destroy the Software and all copies thereof. You may terminate this License at any time by destroying the Software and all copies thereof. 5. MISCELLANEOUS. This Agreement is governed by the laws of the State of Michigan, USA.
DISCLAIMER OF WARRANTY AND LIMITED WARRANTY USER SOLUTION'S WARRANTY ON THE MEDIA, INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY OF FITNESS FOR A PARTICULAR PURPOSE, IS LIMITED IN DURATION TO THIRTY (30) DAYS FROM THE DATE OF THE ORIGINAL PURCHASE OF THIS PRODUCT. AFTER THAT PERIOD, IF A DISK OR FILE FAILS TO WORK OR IF A DISK OR FILE BECOMES DAMAGED, YOU MAY OBTAIN A REPLACEMENT DISK OR FILE VIA EMAIL BY RETURNING THE ORIGINAL DISK OR COPY OF PAID INVOICE AND A CHECK OR MONEY ORDER FOR $5.00, FOR EACH REPLACEMENT DISK, TOGETHER WITH A BRIEF NOTE AND A DATED SALES RECEIPT, TO: USER SOLUTIONS, 11009 Tillson, South Lyon, MI 48178 THE REPLACEMENT WARRANTY SET FORTH ABOVE IS THE SOLE AND EXCLUSIVE REMEDY AGAINST USER SOLUTIONS FOR BREACH OF WARRANTY, EXPRESS OR IMPLIED, OR FOR ANY DEFAULT WHATSOEVER RELATING TO THE CONDITION OF THE SOFTWARE. USER SOLUTIONS MAKES NO OTHER WARRANTIES OR REPRESENTATION, EITHER EXPRESSED OR IMPLIED, WITH RESPECT TO THIS SOFTWARE OR DOCUMENTATION, ITS QUALITY, MERCHANTABILITY, PERFORMANCE, OR FITNESS FOR A PARTICULAR PURPOSE. AS A RESULT, THIS SOFTWARE IS SOLD WITH ONLY THE LIMITED WARRANTY WITH RESPECT TO DISKETTE REPLACEMENT AS PROVIDED ABOVE, AND YOU, THE LICENSEE, ARE ASSUMING ALL OTHER RISKS AS TO ITS QUALITY AND PERFORMANCE. IN NO EVENT WILL USER SOLUTIONS OR ITS DEALERS, DISTRIBUTORS, AGENTS, EMPLOYEES OR AFFILIATES BE LIABLE FOR DIRECT, INCIDENTAL, INDIRECT, SPECIAL , OR CONSEQUENTIAL DAMAGES (INCLUDING DAMAGES FOR LOSS OF BUSINESS PROFITS, BUSINESS INTERRUPTION, LOSS OF BUSINESS INFORMATION AND THE LIKE) RESULTING FROM ANY DEFECT IN THIS SOFTWARE OR ACCOMPANYING DOCUMENTATION EVEN IF USER SOLUTIONS, AN AUTHORIZED USER SOLUTIONS REPRESENTATIVE, OR A USER SOLUTIONS AFFILIATE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGE. USER SOLUTIONS MAKES NO REPRESENTATION OR WARRANTY REGARDING THE RESULTS OBTAINABLE THROUGH THE USE OF THE SOFTWARE. NO ORAL OR WRITTEN INFORMATION OR ADVICE GIVEN BY USER SOLUTIONS, ITS DEALERS, DISTRIBUTORS, AGENTS, AFFILIATES, DEVELOPERS, DIRECTORS, OFFICERS, OR EMPLOYEES SHALL CREATE A WARRANTY OR IN ANY WAY INCREASE THE SCOPE OF THIS WARRANTY. Questions regarding this Agreement should be addressed to: User Solutions, 11009 Tillson, South Lyon, MI 48178
41 Production Planning
THE SPREADSHEET OPERATIONS MANAGER CONTENTS (Chapter 1 plus Chapter containing downloaded files included)
Chapter 1 Chapter 2 Introduction 1.1 Scope 1.2 References Forecasting 2.1 Simple exponential smoothing (SIMPLE) 2.2 Smoothing linear, exponential, and damped trends (TRENDSMOOOTH) 2.3 Introduction to seasonal adjustment 2.4 Ratio-to-moving-average seasonal adjustment for monthly data (MULTIMON) 2.5 Difference-to-moving-average seasonal adjustment for monthly data (ADDITMON) Inventory Management 3.1 Economic order quantity (EOQ) 3.2 EOQ with backorders (EOQBACK) 3.3 EOQ with quantity discounts (EOQDISC) 3.4 EOQ for production lot sizes (EOQPROD) 3.5 Reorder points and safety stocks (ROP) Material Requirements Planning 4.1 MRP inventory plan (MRP1) 4.2 Period-order-quantity (POQ) Production Planning 5.1 Aggregate production planning (APP) 5.2 Run-out time production planning (RUNOUT) 5.3 Learning curves (LEARN) Facility Location 6.1 Center-of-gravity method for locating distribution centers (CENTER) Scheduling 7.1 Job sequencing for a single work station (SKED1A) 7.2 Job sequencing for 2 work stations in series (SKED2A) 7.3 Job sequencing for 3 work stations in series (SKED3A) Quality Control 8.1 Acceptance sampling (ACCEPTSA) 8.2 Control chart for mean and range (MR-CHART) 8.3 Control chart for individual observations (I-CHART) 8.4 Control chart for percent defective (P-CHART) 8.5 Control chart for number of defects (CU-CHART) 8.6 Control limit calculator (LIMIT) Analysis of Waiting Lines 9.1 Single-server queues (SINGLEQ) 9.2 Multiple-server queues (MULTIQ) 1 2 2 3 4 8 13 15 18 21 22 25 27 30 32 35 36 39 41 42 45 47 49 50 53 54 56 58 61 62 65 71 73 75 78 79 80 83
Chapter 3
Chapter 4 Chapter 5
Chapter 6 Chapter 7
Chapter 8
Chapter 9
42 Production Planning
1.2 References
The worksheets in SOM perform most of the quantitative analysis in three textbooks: Chase, R. B., Aquilano, N. J., and Jacobs, F. R., Production and Operations Management (Ninth Edition), Homewood, Illinois: Irwin/McGraw-Hill, 2001. Heizer, J. and Render, B., Operations Management (Fifth Edition), Prentice-Hall, 1999. Levin, R. I., Rubin, D. S., Stinson, J. P., and Gardner, E. S., Jr., Quantitative Approaches to Management (Eighth Edition), New York: McGraw-Hill, 1995.
43 Production Planning
APP is a strategic planning model that helps management develop targets for aggregate production and inventory quantities, work force levels, and overtime usage for up to 12 months ahead. RUNOUT is a tactical model that balances production for a group of stock items, usually on a weekly basis. The aim is to give each item in the group the same run-out time, defined as the number of weeks stock will last at current demand rates. LEARN is a tool for projecting costs or production hours per unit as cumulative production increases.
44 Production Planning
45 Production Planning
Figure 5-1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 A B A P P .X L S C D E F G H I A G G R E G A T E P R O D U C T IO N P L A N N IN G P a g e d o w n to e nte r d e m a n d a n d w o rk fo rc e in fo rm a tio n N o te : P ro d u c tio n d a y s a n d d e m a n d d a ta a re re q u ire d in B 3 7 :C 4 8 . IN P U T : O U TPUT - TO TAL C O STS: B e g in n in g w o rk fo rce 121 W a g e s - re g . tim e $ 3 ,96 3 ,3 4 8 L e v e l m o nth ly w o rkfo rce (o ptio n a l) 190 H irin g cost $ 27 4 ,9 5 0 B e g in n in g in ve n to ry 970 L a yo ff co st $ 26 1 ,1 2 0 H o u rs to p ro d u ce 1 u n it 2 0 .0 0 In v. h o ld in g co s t $5 8 ,2 0 0 H o u rs in n o rm a l w o rk d a y 8 .0 0 S h o rta g e c o st $0 H o ld in g cost p e r u n it-m o n th $ 5 .0 0 T o ta l co st $ 4 ,55 7 ,6 1 8 H irin g c o st $975 L a y o ff co s t $ 1 ,2 8 0 H o u rly w a g e - re g . tim e $ 8 .9 0 H o u rly w a g e - o v ertim e $ 1 3 .3 5 S h o rta g e c o st p e r u n it $ 8 2 .5 0 In v e n to ry q u a n tity u s e d to 2 c o m p u te h o ld in g co st 1 = e n d o f m o n th b a la n ce 2 = a vg . b a la n ce fo r m o n th E n te r p ro d u c tio n d a y s a v aila b le a n d d e m a n d in c o lu m n s B & C . T h e n s e lec t a m a c ro . Y o u c a n a ls o e n ter y o u r o w n p ro d u c tio n ra tes a n d w o rk e rs in c o lu m n s D & E . P R O D U C T IO N P L A N N IN G M A C R O S C trl + S h ift + A vg . d e m a n d , m o s.1 -1 2 = 1 ,8 51 S = C h a s e s trate g y : p ro d . = d e m a n d , va ria b le W F , n o O T A vg . d e m a n d , m o s. 1 -6 = 1 ,4 50 P = Le v e l p ro d . fo r 1 2 m o n th s , v aria b le W F , n o O T (R a te = a v g . m o n. d e m a nd ) A vg . d e m a n d , m o s. 7 -1 2 =2 ,2 50 T = 2 le v e l p ro d . ra te s (m o s . 1 -6 a nd m o s . 7-1 2 ), v a riab le W F , n o O T (R ate = a vg . m o n . d e m a n d )l = T o ta 4 ,5 5 7 ,61 8 W = Le v e l W F fo r 1 2 m o s., p ro d . = d e m a n d , O T u s e d a s n e ce s s a ry (W o rk fo rc e fro m c e ll E 6 ) J K L M N
R E Q U IR E D IN P U T O P T IO N A L IN P U T N B R P ro d. D e m a n d A ctu a l A c tu a l W K R S da ys in u nits w o rke rs R Q R D M o n th a va il. u n its p ro d . u se d 0 121 1 21 1 ,6 0 0 1 ,60 0 191 191 2 22 1 ,4 0 0 1 ,40 0 160 160 3 22 1 ,2 0 0 1 ,20 0 137 137 4 21 1 ,0 0 0 1 ,00 0 120 120 5 23 1 ,5 0 0 1 ,50 0 164 164 6 21 2 ,0 0 0 2 ,00 0 239 239 7 21 2 ,2 5 0 2 ,25 0 268 268 8 20 2 ,5 0 0 2 ,50 0 313 313 9 20 2 ,6 5 0 2 ,65 0 332 332 10 20 2 ,2 5 0 2 ,25 0 282 282 11 19 2 ,1 0 0 2 ,10 0 277 277 12 22 1 ,7 5 0 1 ,75 0 199 199
P R O D U C T IO N U N IT S REG O VERT IM E T IM E 1,6 0 0 1,4 0 0 1,2 0 0 1,0 0 0 1,5 0 0 2,0 0 0 2,2 5 0 2,5 0 0 2,6 5 0 2,2 5 0 2,1 0 0 1,7 5 0 0 0 0 0 0 0 0 0 0 0 0 0
O V E R T IM E D a ily h o u rs To ta l pe r w o rker h o u rs 0 .0 0 .0 0 .0 0 .0 0 .0 0 .0 0 .0 0 .0 0 .0 0 .0 0 .0 0 .0 0 0 0 0 0 0 0 0 0 0 0 0
W ORKFORCE CHANGE NBR NBR BOM H IR E S LA Y O F F S 970 70 0 970 0 31 970 0 23 970 0 17 970 44 0 970 75 0 970 29 0 970 45 0 970 19 0 970 0 50 970 0 5 970 0 78 970
IN V E N T O R Y EOM
97 0 97 0 97 0 97 0 97 0 97 0 97 0 97 0 97 0 97 0 97 0 97 0
46 Production Planning
Another option is to level production over the planning horizon using Ctrl Shift P. This plan builds inventory to meet peak demand and is less expensive, with total costs of $4,318,930. Endof-month inventory builds to a peak of 3,525 units in month 5 and then gradually declines as we work though the peak season. The work force is more stable, although there are layoffs in months 2, 5, and 12. The layoffs in months 2 and 5 are relatively small although the layoff in month 12 is about 15% of the work force. A refinement on the P macro is to use two level production rates with Ctrl Shift T. For the first 6 months, we produce at the average demand rate for the first half of the year. During the last 6 months, we switch to the average demand rate for the last half of the year. This is cheaper still, with total costs of $4,289,004. Compared to the single level production rate, inventories are lower and the work force is more stable. We can also operate with a level work force of 190 people, with production equal to demand and overtime used as necessary. Select Ctrl Shift W to generate this plan. Total cost is only $3,534,531 but there is substantial overtime during the last half of the year, over 5 hours per worker per day in months 8 and 9. It might make sense to increase the level work force in cell E6. Change E6 to 210 workers and run the macro again. This increases costs to $3,912,879 but cuts the overtime burden substantially. You can fine-tune this or any other plan by changing the actual units produced and actual workers used in columns D and E. If actual units produced in column D exceed regular time units in column G, the model automatically makes two adjustments: (1) the number of workers required is recomputed in column F, and (2) the model applies overtime as necessary to make up the difference between total units produced and those produced on regular time. APP is a flexible model that can deal with a variety of complications in aggregate planning: (1) What if you don't like any of the plans? Enter your own choices month-by-month for total units produced and workers actually used. (2) What if you want to plan for less than 12 months? For example, suppose you want to plan for 6 months. Enter 0 in all unused cells (B43..E48) for days available, demand in units, actual units produced, and actual workers used. The model stops all calculations after month 6. The graph will look a little strange because production, demand, and inventory will fall to 0 in month 7. (3) What if you must maintain a minimum inventory level each month? Check the list of inventory values in column N. If any value falls below the minimum, increase total production in columns G and H as necessary. (4) What if the ending inventory for the plan must hit a target value? Again, adjust the production in columns G and H as necessary. (5) What if there is some limit on the amount of overtime worked per month, either in total or per worker? Check columns I and J for problems, then decrease production in columns G and H or increase the number of workers actually used in column F. The model will automatically hire new workers if necessary.
47 Production Planning
48 Production Planning
Figure 5-2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 A B C D E RUNOUT.XLS RUNOUT-TIME PRODUCTION PLAN INPUT: A. Stock production hours available next week OUTPUT: B. Inventory on hand in production hours C. Demand forecast for next week in production hours D. Target ending inventory in production hours E. Run-out time in weeks of stock F Week of: G 01-Dec H I J K L M
INPUT: Prod. hours per unit 0.0250 0.0375 0.0400 0.0500 0.1500 0.1000 0.0200 Inventory on-hand in units 21 155 100 145 52 200 0
# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Item description 8" omelet pans 14" omelet pans 12" skillets 18" skillets teapots sauce pans roasters
OUTPUT: Demand Inventory forecast on-hand in units in hours 50 0.53 175 5.81 150 4.00 200 7.25 60 7.80 120 20.00 40 0.00
45.39
Demand forecast in hours 1.25 6.56 6.00 10.00 9.00 12.00 0.80 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 45.61
Inventory in weeks current planned 0.42 0.76 0.89 0.76 0.67 0.76 0.73 0.76 0.87 0.76 1.67 0.76 0.00 0.76
Production plan units hours 67 1.68 153 5.75 164 6.57 207 10.37 54 8.06 11 1.15 70 1.41
35.00
49 Production Planning
50 Production Planning
Figure 5-3
A LEARN.XLS B C LEARNING CURVE D
300
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
Learning Curve
INPUT: Hours to produce first unit Percent slope OUTPUT: Unit Hours number per unit 1 250.0 2 200.0 3 175.5 4 160.0 5 148.9 6 140.4 7 133.6 8 128.0 9 123.2 10 119.1 11 115.5 12 112.3 13 109.5 14 106.9 15 104.5 16 102.4 17 100.4 18 98.6 19 96.9 20 95.3 21 93.8 22 92.4 23 91.1 24 89.9 25 88.7
250 80.00%
250
200
150
100
50
0 1 11 21 31 41 51 61 71 81 91
Unit number
51 Production Planning