Strategy not tactics drives aggregate planning

The aggregate planning model supposedly shows how manufacturers cope with seasonally biased sales. Unfortunately, industry has failed to embrace any of the sophisticated algorithms that were developed to solve the corresponding resources allocation problem. This paper reveals why such methods have proven so unattractive. Aggregate planning is a chimera. In practice, planners construct the master production schedule directly, in line with a preferred production strategy. A “chase” plan is the most popular choice. When this option proves infeasible, management plumps for another predetermined strategy. The resultant stockpiling brings certain financial risks. However, companies take various measures to reduce their exposure.

Aggregate planning for seasonal demand : reconciling theory with practice

Purpose: The paper reports on the ramifications for production planning when monthly sales exhibit predictable seasonal highs and lows. The literature first acknowledged and dealt with the (aggregate planning) problem 50 years ago. Nevertheless, there is neither evidence that industry has adopted any of the mathematical techniques that were subsequently developed, nor a convincing explanation as to why not. Hence this research sets out to discover the methods manufacturers use to cope with seasonal demand, and how germane the published algorithms really are.

Design/methodology/approach: Forty-two case studies were compiled by interviewing senior managers and then conducting plant tours. No prior assumptions were made and the list of questions covered the gamut of production planning.

Findings: The main finding is that manufacturers select a straightforward production strategy, right from the outset, so the fundamental cost-balancing format is not relevant. The majority pick a “chase” strategy, since most organizations subscribe to a “just in time” ethos. Whenever a different strategy is preferred the rationale springs from skilled labour considerations or binding facilities constraints. The chosen strategy serves as a road map for resources acquisitions, and the master production schedule is constructed directly. So, the complex issue of how to disaggregate an optimal aggregate plan never even arises. Managers do not seek perfect solutions, but strive to eliminate, or contain, the most significant marginal costs. The nature of the business determines the most appropriate tactics to employ.

Originality/value: These findings break the mould as far as orthodox aggregate planning is concerned and show why theory is at odds with practice, whilst reaffirming the importance of concepts such as “flexibility”, “integration”, and “just-in-time production”.

Hatékonyság növelése tervezéssel - avagy: aggregált tervezés alkalmazása egy magyar vállalatnál = Improving efficiency with production planning - Applying aggregate planning at a Hungarian company

A cikk alapvető kérdése, hogy miképpen használható a tervezés a termelési folyamatok, s ezzel a vállalati m}uködés egészének hatékonyságnövelése érdekében. A termeléstervezés szintjei és eszközei közül a középtávú aggregált tervezésre koncentrálunk. Ennek oka elsősorban az, hogy tapasztalatunk szerinte tervezési szint gyakorlati alkalmazása még nem tekinthető elterjedtnek, s ebből következően az eszköz alaposabb ismerete és alkalmazásának elterjedése jelentős tartalékokat tárhat fel a m}uködési hatékonyság növelése terén. A dolgozat a termeléstervezés klasszikusnak tekinthető modelljét alkalmazza egy hazai vállalat esetében. Az elemzés során vizsgáljuk a modell alkalmazhatóságát és a különböző tervezési alternatívák hatását a hatékonyság növelésére. A modell számítógépes megoldását a Microsoft Excel Solver programjával végeztük. _______ The article demonstrates how production planning, especially aggregate production planning can positively influence the competitiveness of production firms. First the structure of production planning, different, but interconnected levels of it are introduced than the aggregate planning is elaborated in more details. Reason for focusing on aggregate planning lies in the fact that according to our experience aggregate planning is an operation planning method applied least of all production planning methods in Hungary. Due to this we are convinced that demonstrating a real case study in this area can help managers to realize that adopting it can significantly influence e±ciency in operation and represent important source of development. We applied a classic aggregate planning model for a Hungarian producing company. We have tested the adaptability of the model and also the effect of different concrete planning scenarios on efficiency. Solution of the mathematical model is calculated using the program of Microsoft Excel Solver.

Desarrollo de un nuevo protocolo de cirugía general, que disminuya las devoluciones de medicamentos e insumos al almacén de cirugía del Hospital Méderi

Esta tesis surge como una oportunidad de mejora en el almacén de cirugías del Hospital MÉDERI, debido a la recurrente devolución de medicamentos e insumos solicitados por las auxiliares de enfermería para las cirugías generales, lo cual repercute directamente en pérdidas de productividad laboral por los re-procesos, un aumento en los errores humanos y posibles pérdidas de medicamentos e insumos. Tras esta clara oportunidad de mejora, se toma la decisión de evaluar el proceso interno del almacén de cirugías con el fin de conocer el punto crítico que genera esta situación; dando como resultado los protocolos de cirugías, los cuales al haber sido diseñados varios años atrás basados en una demanda presentada en ese momento, no están acorde con la realidad que se vive actualmente el almacén de cirugía. Por lo tanto se decidió implementar un pronóstico de promedio móvil, para identificar la demanda real que se presentan en el Hospital MÉDERI, esto seguido de una identificación gráfica comparativa que permitiera definir el nuevo protocolo de cirugía general, lo cual permite disminuir la cantidad de material solicitado, con lo cual se generan disminuciones significativas en el inventario, perdidas y un aumento en la productividad.

Mejoramiento Productivo "Apparel Basic Ltda"

Para el presente trabajo realizado en la Universidad del Rosario, buscamos hacer un mejoramiento productivo de la empresa Apparel Basic Ltda. Teniendo en cuenta todas las herramientas aprehendidas durante la academia y aplicando esto a una empresa del sector real de confecciones. Se centrara el análisis principalmente en las tres áreas donde se observan los mayores problemas organizacionales: Producción, manejo de inventarios y entrega de producto. En el primer análisis se realizara todo el estudio del proceso de producción, teniendo en cuenta la distribución en planta, las rutas críticas de proceso, los diagramas de flujo de producto, el análisis de las principales referencias, entre otros. Todo esto con el fin de identificar los principales errores y poder proponer herramientas y procesos de mejora que sean de ayuda para esta organización. El siguiente análisis se desarrollara en el manejo de inventarios; dentro de este aspecto se analizaran la distribución de las bodegas de producto, la identificación de los productos de mayor rotación, el planteamiento de indicadores de gestión, entre otros procesos, con el fin de identificar procesos benéficos para la empresa que aceleren y mejoren el flujo de producto al interior de la organización. Luego de esto, se analiza todo el proceso de alistamiento y entrega de producto ya que es uno de los principales problemas dentro de la organización porque se esta incumpliendo con los pedidos de los clientes lo que genera un problema de insatisfacción por parte de los clientes.

A Fuzzy Goal Programming model for solving aggregate production-planning problems under uncertainty: A case study in a Brazilian sugar mill

This paper proposes a Fuzzy Goal Programming model (FGP) for a real aggregate production-planning problem. To do so, an application was made in a Brazilian Sugar and Ethanol Milling Company. The FGP Model depicts the comprehensive production process of sugar, ethanol, molasses and derivatives, and considers the uncertainties involved in ethanol and sugar production. Decision-makings, related to the agricultural and logistics phases, were considered on a weekly-basis planning horizon to include the whole harvesting season and the periods between harvests. The research has provided interesting results about decisions in the agricultural stages of cutting, loading and transportation to sugarcane suppliers and, especially, in milling decisions, whose choice of production process includes storage and logistics distribution. (C)2014 Elsevier B.V. All rights reserved.

Knowledge-Based Urban Development : Planning and Applications in the Information Era

In the globalizing world, knowledge and information (and the social and technological settings for their production and communication) are now seen as keys to economic prosperity. The economy of a knowledge city creates value-added products using research, technology, and brainpower. The social benefit of knowledge-based urban development (KBUD); however, extends beyond aggregate economic growth.

Remote sensing and core data needed to support planning and policy decision making

A variety of sustainable development research efforts and related activities are attempting to reconcile the issues of conserving our natural resources without limiting economic motivation while also improving our social equity and quality of life. Land use/land cover change, occurring on a global scale, is an aggregate of local land use decisions and profoundly impacts our environment. It is therefore the local decision making process that should be the eventual target of many of the ongoing data collection and research efforts which strive toward supporting a sustainable future. Satellite imagery data is a primary source of data upon which to build a core data set for use by researchers in analyzing this global change. A process is necessary to link global change research, utilizing satellite imagery, to the local land use decision making process. One example of this is the NASA-sponsored Regional Data Center (RDC) prototype. The RDC approach is an attempt to integrate science and technology at the community level. The anticipated result of this complex interaction between research and the decision making communities will be realized in the form of long-term benefits to the public.

Form-based planning and liveable urban environments

This review article discusses form-based planning an din details analise the following books: Stepehn Marshall (2012) Urban Coding and Planning (Routledge, New York, USA, 272pp. pISBN 1135689202). Emily Talen (2012) City Rules: How Regulations Affects Urban Form (Island Press, Washington DC, USA, 254 pp. ISBN 9781597266925). Richard Tomlinson (2012) Australia’s Unintended Cities: the Impact of Housing on Urban Development (CSIRO Publishing, Collingwood, Australia, 194pp. ISBN 9780643103771). The history of the city has been written and rewritten many times: the seminal works of Benevolo (1980) and Mumford (1989) reconstruct how settlements, particularly their urban form, have changed over centuries. Rowe and Koetter (1978), Kostof (1991, 1992), Krier (2003), and Rossi and Eisenmann (1982) address instead the components that shape the urban environment: the architect can aggregate and manipulate squares, streets, parks and public buildings to control urban design. Generally these studies aim to reveal the secret of the traditional city in contraposition to the contemporary townscape characterized by planning and zoning, which are generally regarded as problematic and sterile (Woodward, 2013). The ‘secret rules’ that have shaped our cities have a bearing on the relationship of spaces, mixed uses, public environments and walkability (Walters, 2011)...

Accessibility Planning tools for sustainable and integrated Land Use/Transport (LUT) development: an application to Rome

The paper fits into the themes of sustainable accessibility planning in urban areas, that can be defined as the integration of transport and land use planning to achieve sustainable development. In particular the study proposes a tool to support the choices of activities location, which is based on a new aggregate (zone-specific) indicator: the ‘Marginal Activity Access Cost’, providing estimation in monetary terms of the impacts on mobility and on the environment of locating one new activity in a specific zone of the urban area. The proposed indicator is validated through an application to the urban area of Rome.

Decision aggregation in an agent-based financial investment planning system

Agent technology provides a new way to model many complex problems like financial investment planning. With this observation in mind, a financial investment planning system was developed from agent perspectives with 12 different agents integrated. Some of the agents have similar problem solving and decision making capabilities. The results from these agents require to be combined. Ordered Weighted Averaging (OWA) operator was chosen to aggregate different results. Details on how OWA was applied as well as appropriate evaluation are presented.

A production planning system for plastic footwear in a seasonal market

Modern injection-moulding machinery which produces several, pairs of plastic footwear at a time brought increased production planning problems to a factory. The demand for its footwear is seasonal but the company's manning policy keeps a fairly constant production level thus determining the aggregate stock. Production planning must therefore be done within the limitations of a specified total stock. The thesis proposes a new production planning system with four subsystems. These are sales forecasting, resource planning, and two levels of production scheduling: (a) aggregate decisions concerning the 'manufacturing group' (group of products) to be produced in each machine each week, and (b) detailed decisions concerning the products within a manufacturing group to be scheduled into each mould-place. The detailed scheduling is least dependent on improvements elsewhere so the sub-systems were tackled in reverse order. The thesis concentrates on the production scheduling sub-systems which will provide most. of the benefits. The aggregate scheduling solution depends principally on the aggregate stocks of each manufacturing group and their division into 'safety stocks' (to prevent shortages) and 'freestocks' (to permit batch production). The problem is too complex for exact solution but a good heuristic solution, which has yet to be implemented, is provided by minimising graphically immediate plus expected future costs. The detailed problem splits into determining the optimal safety stocks and batch quantities given the appropriate aggregate stocks. It.is found that the optimal safety stocks are proportional to the demand. The ideal batch quantities are based on a modified, formula for the Economic Batch Quantity and the product schedule is created week by week using a priority system which schedules to minimise expected future costs. This algorithm performs almost optimally. The detailed scheduling solution was implemented and achieved the target savings for the whole project in favourable circumstances. Future plans include full implementation.