...Memorandum To: Richard Merton, President, Merton Truck Company From: Khushdeep Kaur Date: October 22, 2013 ------------------------------------------------- RE: Merton truck company financial performance and product mix concerns Introduction: As requested an analysis was done to find out the most suitable product mix for Merton Truck Company in an effort to find out the combination that maximizes contribution and whether Truck 101 is really losing money or not. Analysis also aimed at finding out that whether the company should rent additional capacity by purchasing additional engines from an outside supplier to relieve the capacity problem in the engine assembly department. The calculations were based on the revenue for each model, machine hours required for each job, total machine hours available per month and variable cost per truck. Discussion: Currently Merton’s is producing 1000 model 101 trucks per month and 1500 model 102 trucks per month. At this level Model 102 assembly and engine assembly were operating at capacity and metal stamping at 83.3% capacity and Model 101 assembly at 40% capacity. Data used for analysis: Data regarding given capacity of the engine assembly line, machine hours availability and requirement for completing various manufacturing jobs, standard product costs for each model and the overhead budget for 2012. Method: For finding the product mix that maximizes contribution a linear programming model was prepared using, maximize monthly...
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...assembly - 2X1 <=5000 hoursModel 102 assembly – 3X2<= 4500 hoursX1, X2 >= 0Hours here refer to no. of machine hours3) OPTIMUM RANGE Range Objective Coeff. X1 (2500 to 5000) | 3000 | X2 (3000 to 6000) | 5000 | {If the current unit contribution moves outside the range then our decisions would change} | 4) FEASIBILITY RANGE Engine (3500 to 4500) | 4000 | Metal stamp(5000 to 6500) | 6000 | Model 101(4000 to IE+30) | 5000 | Model 102(3000 to IE+30) | 4500 | | {If the current capacity moves outside the range, then the constraint's binding status will change} 5) No, Merton cannot continue to produce with the old optimal mix. They would now have to produce 1000 units of X1 and 1500 units of X2. This will be because of model 101 assembly now functioning only at 40% of its original capacity thus leading to loss of capacity of metal stamping too making it function at only 83.3% of its capacity. Solving by excel, optimal range for obj coeff. For X1 is 2500 -3000, since the contribution changes below 2500, therefore it will have an impact on the decision changing the number of units in the optimal mix. 6) Monthly availability of machine hours came down by 400 hours in metal stamping ie. 5600 hours department. This would not influence the binding status because this decrease is within the feasibility range of...
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...In the summer of 1988, Merton Truck Company (“Merton”) was struggling with financial performance. A manufacturer of two specialized trucks (model 101 and model 102), Merton was conflicted with how to manage production and improve financial results. The executive team offered many different options to improve performance, but many were conflicted. For example, the sales manager suggested cancelling all production of model 101 trucks, whereas the controller suggested increasing model 101 production and curtailing model 102 production. To determine the best course of action for the company, an in-depth analysis of their current practices and optimal position is required. Currently, Merton produces 1,000 of Model 101 trucks and 1,500 of Model 102 trucks. The company is constrained by monthly machine hours available in their production facilities for each activity (SEE EXHIBIT 1). The contribution margins for each model are $3,000 for Model 101, $5,000 for Model 102 (SEE EXHIBIT 2). Each model provides contribution margin, so increasing production in any capacity should increase overall profits. However, the decision on which product to increase production of has caused some internal conflict because of the allocation of shared resources. At the moment, the production facilities are maximizing the engine assembly capacity. This is a shared resource by both Model 101 production and Model 102 production. On one hand, Model 101 production has lower contribution margin ($3,000), but...
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...MERTON TRUCK COMPANY Answer 1: Decision Variables: X1: Number of model 101 trucks to be produced X2: Number of model 102 trucks to be produced Objective: To maximise operational profit by optimally producing Model 101 and Model 102 trucks Maximise Z= 3000X1+5000X2 Subject to: X1+2X2<=4000 (Total machine hours available per month for engine assembly) 2X1+2X2<=6000 (Total machine hours available per month for Metal Stamping) 2X1<=5000 (Total machine hours available per month for Model 101 assembly) 3X2<=4500 (Total machine hours available per month for Model 102 assembly) X1, X2>=0 (Non-negativity constraints) Also X1 and X2 should be integers Answer 2: Optimal solution for maximum profit Model 101: 2000 units Model 102: 1000 units Optimum total contribution= 11,000,000$ Answer 3: Optimality range for objective variable: Objective coefficient | Lower side of range | Higher side of range | 3000 | 2500 | 5000 | 5000 | 3000 | 6000 | If the objective variables move outside the optimality range, the optimal solution for for number of units of Model 101 and Model 102 will change. Answer 4: Feasibility range for constraint’s capacity: Constraint | Final value | Lower side of range | Higher side of range | 4000 | 4000 | 3500 | 4500 | 6000 | 6000 | 5500 | 7000 | 5000 | 4000 | 4000 | Infinity | 4500 | 3000 | 3000 | Infinity | If the current capacity moves outside the optimality range, the optimal solution for number of units of Model 101 and Model 102 will change...
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...MERTON TRUCK COMPANY COST SPECIFICATIONS | MODEL 101 | MODEL 102 | Direct Materials | 24000 | 20000 | Direct Labour | Engine assembly | 1200 | 2400 | Metal Stamping | 800 | 600 | Final Assembly | 2000 | 1500 | Total Direct Labour | 4000 | 4500 | Overhead | Engine assembly | 2100 | 4000 | Metal Stamping | 2400 | 3000 | Final Assembly | 3500 | 2500 | Total Overhead | 8000 | 8500 | | Selling Price | 39000 | 38000 | Total Variable Cost | 36000 | 33000 | Contribution Margin per Unit | 3000 | 5000 | | | | Fixed Overhead | Engine assembly | 1700000 | Metal Stamping | 2700000 | Final Assembly | 2700000 | 1500000 | Total Fixed Overhead | 8600000 | Objective is to: To maximise operational profit by optimally producing Model 101 and Model 102 trucks Maximise Profit = 3000 Model 101 + 5000 Model 102 Maximize Profit =? Model 101* units Model 101 + ? Model 102* units Model 102 – Fixed Overheads Subject to constraints: Engine assembly 1(Model 101) + 2 (Model 102) <= 4000 Metal Stamping 2(Model 101) + 2 (Model 102) <= 6000 Model 101 assembly 2(Model 101) + 0 (Model 102) <= 5000 Model 102 assembly 0(Model 101) + 3 (Model 102) <= 4500 Nonnegative Model 101 0(Model 101) >= 0 Non Negative Model 102 0(Model 102) >= 4000 ANSWER REPORT | | | | | | | | Objective Cell (Max) | | | | | | | Cell | Name | Original Value | Final Value |...
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...Operations Research Assignment 1: Merton Truck Company Submitted to Professor Sumit Kumar By Sneh Chandel PGPX 2015-16 Roll No – 1503010 On 27/01/2015 Problem 1 1. (a) The best product mix can be found out by plotting out the corner points of graph obtained to maximize function p = 3000x + 5000y – 8600000 The above function was derived by subtracting cost price of ‘Truck model 101’ & ‘Truck Model 102’ from sales price of ‘Truck model 101’ & ‘Truck Model 102’. Sales price is quoted in text as $39,000 for ‘Model 101’ and $38,000 for ‘Model 102’ Cost Price of truck was obtained from following table: | | | Model 101 | | | Model 102 | Direct Materials | | | $24000 | | | $20000 | Direct Labor | | | | | | | | Engine assembly | 1200 | | | 2400 | | | Metal Stamping | 800 | | | 600 | | | Final Assembly | 2000 | | | 1500 | | Total Direct Labor | | | $4000 | | | $4500 | Overhead | | | | | | | | Engine Assembly | 2525 | | | 4850 | | | Metal stamping | 3480 | | | 3080 | | | Final Assembly | 6200 | | | 3500 | | | | | 12205 | | | 11430 | Total | | | 40205 | | | 35930 | & the below table to calculate the variable overhead for individual trucks: Department | Variable overhead/unit 101 | Variable overhead/unit 102 | Engine assembly | 2100 | 4000 | Metal stamping | 2400 | 2000 | Model 101 Assembly | 3500 | | Model 102 Assembly | | 2500 | Total | 8000 |...
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...Executive Summary The Problem: Merton Truck Company has been experiencing difficulties related to their financial performance, and they do not know which is the optimal product mix to maximize profits and performance. Group 2 was asked to make recommendations and analyze the given situation to eliminate the difficulties and come up with the right product mix and the optimal solutions considering different alternatives and scenarios. The Solution: Linear Programming was used to analyze the different alternatives to arrive at the optimal solution. The optimal product mix was calculated to be 2000 units of model 101 and 1000 units of model 102. In the next pages you will see the answers to the different questions asked which shows how different alternatives and interpretations could affect the optimal solution and the final decision. Recommendations and conclusion: We recommend that Merton Truck Company adopt the suggest solutions in our analysis in order to achieve better financial results and impose new policies later on to avoid such setbacks in the future. Following our recommendations, the firm should be able to maximize the profits using the optimal product mix. Model Description The Problem Merton Truck Company is not optimizing contribution from its truck lines especially model 101. The company is contemplating stopping the production of model 101 trucks. Management is in a dilemma on what approach to take in resolving this problem. In addition, two of its...
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...1 Mathematical Programming The Mathematical Programming Add-in constructs models that can be solved using the Solver Add-in or one of the solution add-ins provided in the collection. When the Math Programming add-in is installed, several new command lines are added to the OR_MM menu. The menu items under the title Math Programming create models of the different types. Selecting an item from this list causes a dialog box to be presented which constructs a mathematical programming model. The models created by the add-in are solved with the Excel Solver, the Jensen Network Solver or the Jensen LP/IP Solver. All are Excel add-ins. Documentation for these programs can be reached by clicking the links on the lower left. The Solver add-in comes with Excel, and it can solve linear programming, integer programming and nonlinear programming models. The Math Programming add-in automatically builds Solver models and calls the computational procedures that solve the problems. All four model types can be can be solved in this way. The Jensen LP/IP Solver solves linear or integer programming problems. It is available for the Linear/Integer Programming and Network Flow Programming model types. The Jensen Network Solver can solve pure or generalized network flow models. Both linear and integer problems can be solved. It is available for the Network Flow Programming or Transportation model types. Parametric analysis can be applied to any of the math programming models. Here one parameter...
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...Merton Trucks Case Note Abstract We discuss Merton Trucks [Dhe90a] as a case to introduce linear programming in the MBA program. This case adapted from Sherman Motor Company case, was used to introduce Linear Programming formulations as well as duality. Refer to the teaching note [Dhe90b]. Our approach differs from the approach suggested by Dhebar [Dhe90b]. First, our audience consists pre-dominantly of engineers with not too much work experience. As a result, handling math and algebra is relatively easy. Explaining the algebraic formulation, graphical approach and using the Excel solver do not consume that much time. Second, because this case is used during the first week of the MBA program, students are still unfamiliar with the case methodology and we spend significant time in understanding case facts. The circular logic used in allocating fixed costs based on the product mix that in turn is used in deciding the product mix takes some time to understand. Third, because of the participant background, they have difficulty in translating the model to the specific business situation and interpreting the trade-offs involved in various what-if analyses that are prompted by the case questions. We return to the case when we teach duality. After explaining duality, we analyze the case to show how some of the questions and what-if analyses can be simplified using duality. This note is based on our experiences with teaching three large batches of students in our MBA programs. 1 1 Without...
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...tC op y 9-189-163 REV. APRIL 18, 1990 ANIRUDH DHEBAR Merton Truck Company At Merton's monthly planning meeting in July 1988, the company's president expressed dissatisfaction with Merton's financial performance during the six-month period January-June 1988. "I know we are operating at capacity in some of our production lines," he remarked to Merton's controller and sales and production managers. "But surely we can do something to improve our financial position. Maybe we should change our product mix. We don't seem to be making a profit on our Model 101 truck. Why don't we just stop making it altogether? Maybe we should purchase engines from an outside supplier, relieving the capacity problem in our engine assembly department. Why don't the three of you get together, consider the different options, and come up with a recommendation?" Production Possibilities and Standard Costs No The Merton Truck Company manufactured two specialized models of trucks, Model 101 and Model 102, in a single plant in Wheeling, Michigan. Manufacturing operations were grouped into four departments: engine assembly, metal stamping, Model 101 assembly, and Model 102 assembly. Do Capacity in each department was expressed in manufacturing machine-hours available (net of maintenance downtime). Machine-hours available, in conjunction with machine-hours required for each truck model in each department, determined Merton's "production possibilities." For example, the...
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...Problem The main problem with OMC’s corporate strategy was that it failed to examine the current and anticipated factors associated with customers and competitors (external environment) and the firm itself (internal environment), envisioning a new or effective role for the firm in a creative manner, and aligning policies, practices, and resources to realize that vision. Utilizing empirical data, this case illustrates the evolution of the commercial vehicle industry in Turkey, changes in industry conditions, and competitive strategies employed by the incumbent and its Japanese rivals in various life cycle stages. The product’s quality of OMC was not up to the mark compared to the competitors. The technology utilized in Isuzu and Mitsubishi was far better than OMC. They failed to view Japanese companies as their competitors initially. Timely decisions were not taken. The product leadership, being market leader and first mover advantage all was lost by OMC. Alternatives OMC’s alternatives are: 1) increase Iveco’s share to 50 percent and provide new technology platforms; 2) sell 100 percent of OMC’s assets and business; 3) Concentrate on dominant products by improving quality, and improving on service and distribution making it competitive while eliminating all the weaker products. Recommendation Otoyol’s best options are to eliminate all the weak products and start investing in new technology to improve the quality of their dominant products or leave the market completely...
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...Toyota Toyota is one of the leading car manufactures in the world, it has produced many car models and they are renowned to the world. Toyota is a Japan based firm. Toyota Business Process is one of the world’s most renowned processes; it is called the Toyota production system (TPS) and (JIT) Just In Time (“Toyota Business Strategy”). This is the common strategy used by Toyota to manufacture their products. The main objectives of TPS are to eliminate overburden, inconsistency and to eliminate waste. Using this strategy Toyota manufactures their products. Toyota also focuses on Just In Time (JIT) manufacturing. JIT means that the products are manufactured on time without any delays. In Toyota’s business process there are seven key points, which says not to carry out during their production, and they are over production, motion, waiting, conveyance, processing itself, inventory and correction. These may decrease the efficiency of production. Toyota reinvented their business strategy from the oldest and popular car company ford. In the E-Commerce sector Toyota has positioned itself into limited Internet marketing strategy. Toyota runs its own IT sector (“Toyota Goes E-Commerce”). There are no middlemen for Toyota to manage its promotion. Toyota must ensure that they get more involved in Internet promotions and also add values to their internet promotion by trying to enable customers to book cars online and sell old Toyota cars by the customers to upgrade to a new one. These...
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...headquarters in Brazil that focuses in manufacturing and assembly front axles for truck and buses (heavy and light duty). One of the products that WestportAxle plans to introduce in the U.S. market is the new 24K front axle for Trucks Class 8 Fire/Crash (picture 1). Company expects to use its 25 years of expertise to bring new alternatives for the Class 8 Truck builders offering a new product with better maneuverability that can be used in the narrow streets of big cities. Picture 1 – 24K Front Axle 2.2 Market Segment In the front axle business there is a specific market that we call “Niche Market”. This market is dedicated to special vehicle builders such as Fire Trucks, Garbage Trucks, Cement Mixers and so on. These trucks are common identified as “Class 8 Trucks”. The 24K front axle is largely used for these trucks, however there are some limitations. And one of these limitations is the maneuverability of the vehicle, sometimes is really difficult to maneuver the truck in the narrow streets. So, our product will fill this gap offering a 55 degrees wheel cut (the angle that the wheels can turn). Basically, the idea is to segment the customers Psychologically (they want and need this kind of product with this wheel cut) and Geographically (they have to use their vehicles in urban areas). 2. Discuss the target market and why these customers will be targeted. The Class 8 Trucks market has been showing growth in the past years. In the table 1 it...
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...for the location and a loan for the machines and suppliers that will be needed. The concrete factory will not be a new operational business as it will be bought from an earlier proprietor who has gone bankrupt. Though I am acquiring the business all the machines and factory are for sale. The building itself will sit on 5 acres land and have a total of 10 vehicles associated with the company. The vehicles will contain 8 ready mix trucks, one hauling truck and one bulker truck. The total expense to purchase the factory is estimated at $1,086,742.30. The bank is ready to finance the loan at a 5.50% fixed rate of interest during a period of 5 years, which would result in the monthly installments of $20,758.04. The next stage is to acquire financing that would be for all ten trucks which will be purchased with plant. The total amount for the trucks will be $310,000. `The bulker truck that will be used in the business will cost $22,000. The dump truck on the other hand will cost $48,000 primarily because it is an older model. The remaining eight mix trucks will have a total cost of $240,000. The fix rate of interest in...
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...8610 Hansen Ave. Shakopee, MN 55379 BIFFS, INC. Instructions for New Hire Packet – Applicant Directions 1. Page 2 – Checklist - Fill in or verify your name and social security number. Supervisor to fill in the date of hire & Company assigned (EID) employee identification number. 2. Pages 3 – 7 – DOT Application - must all be completed including 10 years (if CDL holder); 3 years (if non-CDL holder) of previous work history, addresses, & phone numbers. ** If there is any time frame for unemployment or selfemployment please list. DOT is looking for a complete trail of information provided by the driver representing where they have been from date to date. Please complete this form and provide a signature/ date at bottom of page 7. Read “Driver Rights” provided by your company. 3. Page 8 - Previous Employer form – Only sign the top box on the first page where it states Applicant signature and date. Company / Supervisors will send out to the previous employers listed on driver’s application. 4. Page 9 – DISCLOSURE - sign and date bottom *Company is required to order and obtain a current MVR for driver prior to hiring or being moved into a driving position. Driver written authorization is required. 5. Page 10 top Record of Violations form – Fill in any moving traffic violations you have had within the past 12 months; provide a signature & date. If no violations check box. Page 10 bottom – Annual Review (SKIP) to be completed by supervisor with a current MVR. MVR=Motor...
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