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Optimal Truck Production Analysis

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Rhea Sanjay
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0% found this document useful (0 votes)
5 views2 pages

Optimal Truck Production Analysis

jnfwetiojoijedfknejklgnjrktnhjkernt

Uploaded by

Rhea Sanjay
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Machine hours required

per truck

Total machine
Department M101 M102 hours available
per month
Engine
1 2 4000
Assembly
Metal Stamping 2 2 6000
M101 Assembly 2 0 5000
M102 Assembly 0 3 4500

Standard product cost


M101 M102
Direct materials $24000 $20000
Direct labor
Engine
1200 2400
assembly
Metal stamping 800 600
Final assembly 2000 1500
4000 4500

Variable overhead
8000 8500
per unit

Selling price per


$39000 $38000
unit
1. (a) Find the best product mix.
(b) What would be the best product mix if engine assembly capacity were raised by
one unit, from 4000 to 4001 machine hours? What is the extra unit of capacity
worth?
(c) Assume that a second unit of engine assembly capacity worth the same as the
first. Verify that if capacity were increased to 4100 machine hours, then increase in
contribution would be 100 times that in part (b).
(d) How many units of engine assembly capacity can be added before there is a
change in the value of an additional unit of capacity?
2. What is the maximum rent it should be willing to pay for a machine hour of engine
assembly capacity, if any purchased from outside supplier? What is the maximum number of
machine hours it should rent?
3. Company is considering the introduction of a new truck M103. Each M103 would give a
contribution of $2000. The total engine assembly capacity would be sufficient to produce
5000 M103s per month, and the total metal stamping capacity would be sufficient to
produce 4000 M103s per month. The new truck would be assembled in the M101 assembly
department, each M103 requiring only half as much time as a M101.
(a) Should company produce M103?
(b) How high would be the contribution on each M103 have to be before it became
worthwhile to produce the new model?
4. Engine can be assembled on overtime in the engine assembly department. Suppose
production efficiencies do not change and 2000 machine hours of engine assembly overtime
capacity are available. Direct labor costs are higher by 50% for overtime production. While
variable overhead would remain the same, monthly fixed overhead in the engine assembly
department would increase by $0.75 million. Should company assembly engines on
overtime?
5. It was agreed to maximize the monthly contribution as long as number of M101 produced
was at least three times the number of M102s. What is the resulting product mix?

Common questions

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The criteria for determining max rent for additional machine hours should include a comparison of contribution margin per product enabled by extra hours versus rental costs. The rent should not exceed the marginal profit achievable per additional hour. Additionally, assessment factors include machine hour criticality in the production process, alternative cost-efficient solutions (e.g., overtime), and potential impact on achieving optimal product mix .

Production of M103 would not be preferable if its contribution per unit does not exceed opportunity costs linked with reduced M101 and M102 production. This could occur if current capacity constraints—especially in engine assembly and metal stamping—are already fully optimized with existing models. If M103's assembly time advantage does not align with capacity availability or if its market demand doesn't justify the transition cost, it may not bring a net benefit over current operations, despite the potential throughput increase .

The differential in assembly time—where M103 requires half the time of M101—enhances production flexibility, potentially doubling the assembly throughput for M103 or freeing capacity for other products. This time efficiency is critical in assessing whether M103 can be integrated without compromising current output levels of M101 or incurring additional costs. A decision hinges on whether M103's contribution can cover variable costs and provide margins comparable to or exceeding current product configurations .

Introducing the M103 model would affect operations by utilizing engine assembly and metal stamping capacities differently. Since the truck uses half the assembly time compared to M101, it may allow for a greater number of M103s to be produced, up to the limits of available machine hours. However, profitability depends on the contribution margin of $2000 per M103 and whether this exceeds the opportunity cost of not producing M101s or M102s. A thorough cost-benefit analysis comparing the contribution margins of all three products would determine whether M103 production is advantageous .

Increasing engine assembly capacity to 4100 hours could potentially enhance financial metrics significantly by easing a key production bottleneck. This expansion could allow the production of more units, thus increasing total contribution margins. Given that the prior increase's valuation showed a linear relation, it would be expected that a 100-hour increase would have a linear relation. This additional capacity might maximize the utilization of other departments, optimize fixed cost allocation, and elevate overall profitability .

To maximize contribution while adhering to the constraint where M101 production is at least three times M102, the company should employ a constrained optimization strategy. This involves setting up a linear programming model where the primary objective is profit maximization with the additional production ratio constraint. By graphically or computationally solving this model, the optimal production levels can be identified, ensuring that increased production of the more profitable M101 is prioritized while still producing M102 to a permissible extent .

Increasing the engine assembly capacity directly increases the feasible production volumes of M101 and M102, as it alleviates a key bottleneck. The value of additional capacity is calculated by evaluating the change in profit when capacity is incrementally increased. This includes assessing the contribution margin per additional unit of production enabled by the capacity increase. For instance, using linear programming dual values, it can be computed that each extra unit of capacity could increase profits due to overcoming constraints in engine assembly time .

To determine the optimal production mix, the company should analyze the constraints on machine hours in different departments—Engine Assembly, Metal Stamping, and the respective assembly lines for M101 and M102. Using these constraints, a linear programming model can be constructed to maximize the company's profit, defined as the difference between sales revenues and costs (materials, labor, variable overheads). Solving this model typically involves using the simplex method or software like Excel Solver to find the mix that utilizes available hours most effectively and maximizes the objective function representing profit .

The company's cost structure—comprising direct materials, labor, variable, and fixed overheads—shapes the decision to rent additional machine hours versus using existing capacities or overtime. If the variable and fixed costs of utilizing existing capacity outweigh those of renting, outsourcing becomes favorable. Evaluation must include comparing the rental cost per hour against the cost of increased overtime rates and additional fixed costs. The decision should align with whether the rented hours provide enough throughput to appreciably boost the contribution margin without elevating cost excessively .

The decision to use overtime for engine assembly should be driven by an analysis of marginal cost versus marginal benefit. Factors include the direct labor cost increase of 50% during overtime, the unchanged variable overhead, and the $0.75 million rise in fixed overheads. Despite these costs, if the contribution margin per unit produced with overtime exceeds combined additional costs, overtime production can be justified. This requires a breaking-even analysis where the benefit from higher production volume and resultant revenue surplus must offset the extra costs involved .

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