SOP Optimisation
SOP Optimisation
Contribution
and limits of linear programming
André Thomas, Patrick Genin, Samir Lamouri
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Chapter 14
SALES AND OPERATIONS PLANNING
OPTIMISATION
Contribution and limits of linear programming
1. INTRODUCTION
Today, Supply chain Management becomes the function that chooses the
global level of production and the performance of the other activities in
order to satisfy the actual sales forecasts. Planning production allows to
make arrangements on time to satisfy sales with needed quantities and
promised delays at the smallest cost. These three objectives cannot be
simultaneously achieved. The planning decisions are always the result of a
balance between on-time deliveries, risks on inventories and operations
costs.
The Sales and Operations Plan process (S&OP) builds the sales and
operations strategy that realises the best balance, on a time fence at least as
long as the budget, for product groups [13]. The expected performance for
other activities is deduced on a mid/long term.
2 Patrick Genin, Samir Lamouri and André Thomas
OBJECTIVES
Sales &
Resources Demand
Requirements Operations
Planning Management
Planning
Master
Production MANAGEMENT
Schedule SYSTEM
VPE produces steal tubes in parts or full length for automotive markets
(layer 1, 2 and 3 supplier) and for mechanical markets (heaters, boilers,
circuits). The Supply Chain initiative reengineers business process
(industrial and administrative) in order to reach 98 % of on-time delivery.
Settled in 4 production entities, The 10 flow-shops ensure the production
of the 70 commercial families by working 5 days out of 7 in 3x8. The
demand by products family "the load” is different each month. On the
contrary the capacity is relatively stable.
The S&OP is the monthly process for updating the tactical planning by
consolidating production and demand on a 12 months time-fence. The steps
are (Figure 14-2) [2]:
1. Demand Forecast calculation in the sales department in families and
production lines;
2. Load calculation and load and capacity balancing on each line by its
manager and parallel calculation by the supply chain manager at the firm
level;
3. Scenario construction and actions plan by line and for the whole
company;
4. Consolidation of resources requirements and availabilities and action
plans validation by the supply chain manager;
5. Monthly meeting to present the scenarios and choice of the strategy by the
steering comity.
SALES AND OPERATIONS PLANNING OPTIMISATION 5
Lines
Mangers Scenarios
Chosen S&OP
scenario
Production
parameters
evolution
The firm adjusts a set of logistic variables to spread the workload during
its S&OP process:
– Seasonal inventories;
– Capacity adjustments (working during weekends and public holidays);
– Subcontracting (limited for strategic reasons);
– Backorders or inventories;
– Priorities by products family on production resources.
The determination of scenarios and associated total costs is difficult to
make by hands. Linear Programming makes it possible to find the optimum
for a whole set of given conditions.
negative. It thus lies between 0 and 195 T. That last constraint does not
consider the seasonal inventory.
t is the period index. T is the number of periods (it is the horizon lenght :
12 in our case). D(t) represents the forecasted demand for period t. N(t)
corresponds to the standard working days in period t, N*(t) is the maximum
of working days per period t. u(t) is the standard capacity in period t. It is
determined by the formula (1). O*(t) is the maximum overtime capacity in
period t. Relation (2) gives it. The values used are presented in Table 14-1.
∀ t , u (t ) = e × N (t ) (1)
∀ t , O (t ) = e × [ N (t ) − N (t )]
x x
(2)
∑c
t =1
OV
×O(t) + cNP × N(t) + cSC × S(t) + cI × I (t) + cB × B(t) (3)
Constraints (4) state that in each period the whole production is obtained
with the standard capacity plus or minus what is produced in overtime or not
produced, and subcontracting. The balance equations among the whole
production and inventories, total demand and backlogs are established
through constraints (5). Clearly, constraints (5) may easily be modified to
accommodate alternative assumptions concerning lost demand. Constraints
(7) are constraint conditions, stating that the amount stored must be less than
the storage capacity, for each time period. Similarly, constraints (8) stipulate
an analogous condition for subcontracted units limited by management.
Upper limits on overtime workforce capacity are given by inequalities (9).
Working out the problem and using of EXCEL solver determine the
optimal solution according to the given conditions. The results are shown
below (Figure 14-3 and Figure 14-4).
8 Patrick Genin, Samir Lamouri and André Thomas
Sales & Operations Planning
Parameters
Beginning inv entory 100 T Carrying costs 190 €/T
Capacity 65 T/d Production over-costs in ov ertime 700 €/T
Production over-costs in non-working hours 1300 €/T
Backlog over-costs 2300 €/T
Subcontracting over-costs 600 €/T
Results
Period t 1 2 3 4 5 6 7 8 9 10 11 12
Demand D(t) 1 475 510 1 655 1 320 1 757 1 210 1 603 1 475 1 320 1 685 1 199 1 782 16 991 T
Production 1 235 585 1 365 1 430 1 365 1 040 1 430 1 300 1 430 1 300 1 300 1 381 15 161 T
Subcontracting ST(t) 140 0 215 0 282 170 173 175 0 275 0 300 1 730 T
Total prod 1 375 585 1 580 1 430 1 647 1 210 1 603 1 475 1 430 1 575 1 300 1 681 16 891 T
Inventory S(t) 100 0 75 0 110 0 0 0 0 110 0 101 0 T
Production in overtime HS(t) 0 0 0 0 0 0 0 0 0 0 0 81 81 T
Over-costs 84 14 129 21 169 102 104 105 21 165 19 237 1 170 K€
2 000
1 800
1 600
1 400
1 200
Tons
1 000 Demand
Inventory
800
Subcontracting
600 Production + Subcontracting)
400
200
0
1 2 3 4 5 6 7 8 9 10 11 12
Months
Parameters
Beginning inv entory 50 T Carrying costs 190 €/T
Capacity 65 T/d Production over-costs in ov ertime 700 €/T
Production over-costs in non-working hours 1300 €/T
Backlog over-costs 2300 €/T
Change Subcontracting over-costs 600 €/T
Results
Period t 1 2 3 4 5 6 7 8 9 10 11 12
Demand D(t) 1 475 510 1 655 1 320 1 757 1 210 1 603 1 475 1 320 1 685 1 199 1 782 16 991 T
Production 1 235 585 1 365 1 430 1 365 1 040 1 430 1 300 1 430 1 300 1 300 1 381 15 161 T
Subcontracting ST(t) 190 0 215 0 282 170 173 175 0 275 0 300 1 780 T
Total prod 1 425 585 1 580 1 430 1 647 1 210 1 603 1 475 1 430 1 575 1 300 1 681 16 941 T
Inventory S(t) 50 0 75 0 110 0 0 0 0 110 0 101 0 T
Production in overtime HS(t) 0 0 0 0 0 0 0 0 0 0 0 81 81 T
Over-costs 114 14 129 21 169 102 104 105 21 165 19 237 1 200 K€
2 000
1 800
1 600
1 400
1 200
Tons
1 000 Demand
Inventory
800
Subcontracting
600 Production + Subcontracting)
400
200
0
1 2 3 4 5 6 7 8 9 10 11 12
Months
Parameters
Beginning inv entory 100 T Carrying costs 190 €/T
Capacity 65 T/d Production over-costs in ov ertime 700 €/T
Production over-costs in non-working hours 1300 €/T
Backlog over-costs 2300 €/T
Subcontracting over-costs 600 €/T
Results
Period t 1 2 3 4 5 6 7 8 9 10 11 12
Demand D(t) 1 475 510 1 655 1 320 1 757 1 210 1 603 1 475 1 320 1 685 1 199 1 782 16 991 T
Production 1 235 585 1 365 1 430 1 407 1 040 1 430 1 300 1 430 1 335 1 300 1 441 15 298 T
Subcontracting ST(t) 140 0 215 0 240 170 173 175 0 240 0 240 1 593 T
Total prod 1 375 585 1 580 1 430 1 647 1 210 1 603 1 475 1 430 1 575 1 300 1 681 16 891 T
Inventory S(t) 100 0 75 0 110 0 0 0 0 110 0 101 0 T
Production in overtime HS(t) 0 0 0 0 42 0 0 0 0 35 0 141 218 T
Over-costs 84 14 129 21 173 102 104 105 21 169 19 243 1 184 K€
300
Inventory Subcontracting
250
200
Tons
150
100
50
0
1 2 3 4 5 6 7 8 9 10 11 12
Months
Subcontracting is now limited to 240 tons per month (Figure 14-7 and
Figure 14-8). Additional days are to be envisaged for the overload periods.
The resulting over-cost is of 14 K€.
Parameters
Beginning inv entory 100 T Carrying costs 190 €/T
Capacity 65 T/d Production over-costs in ov ertime 700 €/T
Production over-costs in non-working hours 1300 €/T
Backlog over-costs 2300 €/T
Subcontracting over-costs 600 €/T
Results
Period t 1 2 3 4 5 6 7 8 9 10 11 12
Demand D(t) 1 475 510 1 655 1 320 1 757 1 210 1 603 1 475 1 320 1 685 1 199 1 782 16 991 T
Production 988 468 1 365 1 430 1 365 1 040 1 430 1 300 1 430 1 300 1 300 1 381 14 797 T
Subcontracting ST(t) 300 42 290 0 282 170 173 175 0 275 0 300 2 007 T
Total prod 1 288 510 1 655 1 430 1 647 1 210 1 603 1 475 1 430 1 575 1 300 1 681 16 804 T
Inventory S(t) 100 0 0 0 110 0 0 0 0 110 0 101 0 T
Production in overtime HS(t) 87 0 0 0 0 0 0 0 0 0 0 81 168 T
Over-costs 241 25 174 21 169 102 104 105 21 165 19 237 1 383 K€
300
Inventory Subcontracting
250
200
Tons
150
100
50
0
1 2 3 4 5 6 7 8 9 10 11 12
Months
Parameters
Beginning inv entory 100 T Carrying costs 190 €/T
Capacity 65 T/d Production over-costs in ov ertime 700 €/T
Production over-costs in non-working hours 1300 €/T
Backlog over-costs 2300 €/T
Subcontracting over-costs 600 €/T
Results
Period t 1 2 3 4 5 6 7 8 9 10 11 12
Demand D(t) 1 475 510 1 655 1 320 1 757 1 210 1 603 1 475 1 320 1 685 1 199 1 782 16 991 T
Production 1 235 510 1 365 1 320 1 457 1 040 1 430 1 300 1 320 1 385 1 199 1 482 15 043 T
Subcontracting ST(t) 140 0 290 0 300 170 173 175 0 300 0 300 1 848 T
Total prod 1 375 510 1 655 1 320 1 757 1 210 1 603 1 475 1 320 1 685 1 199 1 782 16 891 T
Inventory S(t) 100 0 0 0 0 0 0 0 0 0 0 0 0 T
Production in overtime HS(t) 0 -75 0 -110 92 0 0 0 -110 85 -101 182 -37 T
Over-costs 84 97 174 143 244 102 104 105 143 240 131 307 1 875 K€
350
Inventory Subcontracting
300
250
200
Tons
150
100
50
0
1 2 3 4 5 6 7 8 9 10 11 12
-50
Months
How can the models that use Linear Programming be extended? The
answer will be to seek models using the non-linear and dynamic
programming. Certain authors suggested, in particular cases, other
approaches (stochastic optimisation models, Monte Carlo) [7, 10]. How can
the S&OP be approached in the industrial case of multiple production lines?
A deep research in the scheduling techniques must provide a suitable
answer. How can the scenario suggested by the linear program be
reinforced? The answer is by using the S&OP …
The S&OP is the process that drives the capacity level and actions to be
implemented so that Master Production Schedules can be completed. It must
thus be relatively stable, because of the weight of the taken decisions. For
example, the inventory level is limited by the storage capacity. In case of
events, the scenario of replacement can become then extremely expensive
for the firm whereas a simple contract with a storage partner could be signed
to provide a more robust scenario.
14 Patrick Genin, Samir Lamouri and André Thomas
The S&OP becomes the decision tool to make robust the scenario
suggested by the model according to the given set of conditions
(parameters). The Decision Support System must give an average answer
that will be the best possible response for several sets of conditions. The
S&OP will not be then mathematically optimised but will vary little when a
change in parameters will occur.
Design plans are the traditional tool used to establish the robustness of
the system answer (i.e. reduce the variability of the answers) by influencing
the control parameters (of adjustment) [9].
In the case of our S&OP models, the input parameters represent the Sales
forecasts. The control parameters are those that make possible to control the
system: costs of overtime, subcontracting, maximum inventory … They are
the action levers for the planner. The parameters of disturbance are all those
which intervene on the system independently of the will of the planner. It is
the case for example for the beginning inventory, the capacity of the line …
Taguchi calls the not-controllable parameters “noises” [11]. The more
“robust” a system will be, the lower the variability in scenario. A scenario
will be robust if it is not called in question by non-controlled external factors
(noises).
Use of Design plans allows to test, with a restricted number of trials, the
average scenarios that optimise the S&OP while limiting their variability.
The planner must fix, during the process, the nominal values of the control
parameters according to a double optimisation:
– the optimum operation of the system,
– the resulting robustness.
We neglect too often the second optimisation. We then work out
strategies on paper that cannot to be implemented or lead to the sub-optima
in a “disturbed” environment.
8. CONCLUSION
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