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Importance of Aggregate
Planning
✔Without sufficiently long-term view,
an organization may make short-term
decisions that hurt the organization in
the long-term
Aggregate Planning
– Key element of the Sales and
Operations Planning Process
– Game plan for
production/operations to meet
expected demand
Planning Horizon
Intermediate
range
Short
range
Business
or annual
plan
Aggregate
plan –
production
and
MPS or
staffing
workforce
plan
schedule
Aggregate Planning Inputs
✔ Resources ✔ Costs
– Workforce – Inventory carrying
– Facilities – Back orders
✔ Demand forecast – Hiring/firing
✔ Policies – Overtime
– Inventory changes
– Subcontracting
– Subcontracting
– Overtime
– Inventory levels
– Back orders
Aggregate Planning Outputs
✔ Total cost of a plan
✔ Projected levels of
– Inventory
– Output
– Employment
– Subcontracting
– Backordering
Aggregate planning options: capacity
✔ Pluses
– increased flexibility
– increased quality (?)
– decreased costs (?)
✔ Minuses
– decreased control
– can be very expensive in certain situations
– suppliers can become competitors
Aggregate planning options: demand
management
Level Chase
Strateg Strate
y gy
Producti
Production on
rate is
equals
constant
demand
Chase Approach
✔ Advantages
– Investment in inventory is low
– Labor utilization in high
✔ Disadvantages
– The cost of adjusting output rates and/or
workforce levels
Level Approach
✔ Advantages
– Stable output rates and workforce
✔ Disadvantages
– Greater inventory costs
– Increased overtime and idle time
– Resource utilizations vary over time
Cumulative Graph
Cumulative output/demand
Cumulative
production
Cumulative
demand
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Aggregate Planning in Services
Disaggregation
Master
Schedule
Disaggregating the Aggregate Plan
✔ Master schedule: The result of
disaggregating an aggregate plan; shows
quantity and timing of specific end items
for a scheduled horizon.
✔ Rough-cut capacity planning: Approximate
balancing of capacity and demand to test
the feasibility of a master schedule.
Master Scheduling Process
Inputs Outputs
Beginning inventory Projected inventory
Master
Forecast Scheduling Master production
schedule
Customer orders
Uncommitted inventory
Time Fences
Period
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