Session 2b Overview • More Sensitivity Analysis – Solver Sensitivity Report • More Malcolm • Multi-period Models – Distillery Example – Project Funding Example Decision Models -- Prof. Juran 2 Solver Sensitivity Report • Provides sensitivity information about constraint “right-hand sides” and objective function coefficients • Shadow prices • Allowable increases and decreases Decision Models -- Prof. Juran 3 Malcolm Revisited A B C D E F G H 1 Microsoft Excel 15.0 Sensitivity Report 2 Worksheet: [01b-01-malc.xlsx]Optimized 3 Report Created: 9/3/2014 8:20:58 AM 4 5 6 Variable Cells 7 Final Reduced Objective Allowable Allowable 8 Cell Name Value Cost Coefficient Increase Decrease 9 $B$2 6-oz 6.428571429 0 500 40 275 10 $C$2 10-oz 4.285714286 0 450 550 33.33333333 11 12 Constraints 13 Final Shadow Constraint Allowable Allowable 14 Cell Name Value Price R.H. Side Increase Decrease 15 $E$7 Molding Capacity 60 78.57142857 60 5.5 22.5 16 $E$8 Demand for 6-oz 6.428571429 0 8 1E+30 1.571428571 17 $E$9 Storage Space 150 2.857142857 150 90 22 Decision Models -- Prof. Juran 4 Shadow Price •The effect on the value of the objective function resulting from a one-unit change in the constraint’s right-hand side •May be viewed as an upper bound on the value of one additional unit of a constrained resource Decision Models -- Prof. Juran 5 Constraints •Sensitivity to changes in constraint right-hand sides •Allowable increase and decrease define a range within which the constraint right-hand sides can vary without affecting the shadow price Decision Models -- Prof. Juran 6 Example How much would Malcolm pay for more molding capacity? How much more capacity would he buy at that price? Decision Models -- Prof. Juran 7 Malcolm's Glass Problem 10 8 8 10-oz. Glasses (100 cases) 10-oz. Glasses (100 cases) Malcolm's Glass Problem 10 6 Demand Constraint Molding Constraint Storage Constraint Profit = $2000 Profit = $4000 Profit = $6000 Profit = $8000 Corner Points 4 2 6 Demand Constraint Molding Constraint Storage Constraint Profit = $2000 Profit = $4000 Profit = $6000 Profit = $8000 Corner Points 4 2 0 0 0 2 4 6 8 10 0 2 6-oz Glasses (100 cases) Molding Capacity = 60 8 10 8 10 Malcolm's Glass Problem 10 8 8 10-oz. Glasses (100 cases) 10-oz. Glasses (100 cases) Malcolm's Glass Problem 6 Demand Constraint Molding Constraint Storage Constraint Profit = $2000 Profit = $4000 Profit = $6000 Profit = $8000 Corner Points 2 6 Molding Capacity = 62 10 4 4 6-oz Glasses (100 cases) 6 Demand Constraint Molding Constraint Storage Constraint Profit = $2000 Profit = $4000 Profit = $6000 Profit = $8000 Corner Points 4 2 0 0 0 2 4 6 6-oz Glasses (100 cases) Molding Capacity = 64 Decision Models -- Prof. Juran 8 10 0 2 4 6 6-oz Glasses (100 cases) Molding Capacity = 66 8 If the limit on molding time is exactly 65.5 hours, then three constraints all intersect at one point. Malcolm's Glass Problem 10 10-oz. Glasses (100 cases) 8 6 Demand Constraint Molding Constraint Storage Constraint Profit = $2000 Profit = $4000 Profit = $6000 Profit = $8000 Corner Points 4 2 0 0 2 4 6 8 10 6-oz Glasses (100 cases) In this situation there is no utility in further increasing molding capacity (all other things held constant). Decision Models -- Prof. Juran 9 Adjustable Cells •Sensitivity to changes in objective function coefficients •Allowable increase and decrease define a range within which the objective function coefficients can vary without affecting the decision variable values Decision Models -- Prof. Juran 10 Example How much does the profit per unit on the 6-oz product have to go up before Malcolm would want to increase production of that product? Decision Models -- Prof. Juran 11 Increases in the profitability of the 6-oz product have the effect of changing the slope of the isoprofit lines. Malcolm's Glass Problem 10 8 8 10-oz. Glasses (100 cases) 10-oz. Glasses (100 cases) Malcolm's Glass Problem 10 6 Demand Constraint Molding Constraint Profit = $2000 Profit = $4000 Profit = $6000 Profit = $8000 Storage Constraint Corner Points 4 2 6 Demand Constraint Molding Constraint Profit = $2000 Profit = $4000 Profit = $6000 Profit = $8000 Storage Constraint Corner Points 4 2 0 0 0 2 4 6 8 10 0 2 6-oz Glasses (100 cases) 6-oz profit = 300 10 8 8 10-oz. Glasses (100 cases) 10-oz. Glasses (100 cases) 8 10 8 10 Malcolm's Glass Problem 10 6 Demand Constraint Molding Constraint Profit = $2000 Profit = $4000 Profit = $6000 Profit = $8000 Storage Constraint Corner Points 2 6 6-oz profit = 400 Malcolm's Glass Problem 4 4 6-oz Glasses (100 cases) 6 Demand Constraint Molding Constraint Profit = $2000 Profit = $4000 Profit = $6000 Profit = $8000 Storage Constraint Corner Points 4 2 0 0 0 2 4 6 6-oz Glasses (100 cases) 6-oz profit = 500 Decision Models -- Prof. Juran 8 10 0 2 4 6 6-oz Glasses (100 cases) 6-oz profit = 600 12 If the profit on 6-oz glasses is $540, then the objective function is exactly parallel to the storage constraint. Malcolm's Glass Problem 10 10-oz. Glasses (100 cases) 8 6 Demand Constraint Molding Constraint Profit = $2000 Profit = $4000 Profit = $6000 Profit = $8000 Storage Constraint Corner Points 4 2 0 0 2 4 6 8 10 6-oz Glasses (100 cases) In this situation there are an infinite number of optimal solutions – every point on the line segment between two corner points. Decision Models -- Prof. Juran 13 • This allowable increase of $40 can be seen in the sensitivity report without re-solving the model. • Similarly, if the 6-oz. profit drops by $275 or more, a new corner point will be optimal. • This section of the report assesses the robustness of the current optimal solution with respect to changes in the objective function coefficients. Decision Models -- Prof. Juran 14 Multi-Period Models Example: Traverso Distillery • Traverso has 1,000 cases on hand of “Mays & McCovey”. • 2,700 cases capacity with regular-time labor, $40 per case. • Unlimited capacity with overtime labor, $60 per case. • Only 80% production yield is “Mays & McCovey” grade. – (Remaining 20%is sold under the bargain-rate brand “Asterisk 762”. ) • Employees drink or accidentally break 10% of inventory. • $15 per case cost against ending inventory. 1st Quarter 2nd Quarter 3rd Quarter Cases to ship: 3000 2000 4000 Decision Models -- Prof. Juran 15 Managerial Formulation Decision Variables We need to decide on production quantities, both regular and overtime, for three quarters (six decisions). Note that on-hand inventory levels at the end of each quarter are also being decided, but those decisions will be implied by the production decisions. Decision Models -- Prof. Juran 16 Managerial Formulation Objective Function We’re trying to minimize the total labor cost of production, including both regular and overtime labor, plus inventory cost. Decision Models -- Prof. Juran 17 Managerial Formulation Constraints Upper limit on the number of bottles produced with regular labor in each quarter. No backorders are allowed. Production quantities must be non-negative. Mathematical relationships: • Inventory balance equations • 80% yield on production • 10% Shrinkage Decision Models -- Prof. Juran 18 Managerial Formulation Note that there is also an accounting constraint: Ending Inventory for each period is defined to be: Beginning Inventory + Production – Demand This is not a constraint in the usual Solver sense, but useful to link the quarters together in this multi-period model. Decision Models -- Prof. Juran 19 Mathematical Formulation Decision Variables Xij = Production of type i in period j. Let i index labor type; 0 is regular and 1 is overtime. Let j index quarters; 1 through 3 Decision Models -- Prof. Juran 20 Mathematical Formulation Non-Decision Variables Define Ij to be ending inventory for quarter j 1 𝐼𝑗 = 0.9 𝐼𝑗−1 + 𝑋𝑖𝑗 − 𝐷𝑗 𝑖=0 Decision Models -- Prof. Juran 21 Mathematical Formulation Parameters Define Ci to be the production cost of type i Define Dj to be demand during quarter j Decision Models -- Prof. Juran 22 Mathematical Formulation Objective Function Minimize 1 3 𝑧= 3 𝑋𝑖𝑗 𝐶𝑖 + 15 𝑖=0 𝑗=1 Decision Models -- Prof. Juran 𝐼𝑗 𝑗=1 23 Mathematical Formulation Constraints For each quarter, 𝑋0𝑗 ≤ 2,700 𝐼𝑗 ≥ 0 Decision Models -- Prof. Juran 24 Solution Methodology A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Beginning Inventory Regular Time B C D 1st Quarter 2nd Quarter 3rd Quarter 1000 -1799 -3417 1 1 1 Capacity 2700 2700 2700 Overtime 1 1 1 2 2 3000 -1998 -200 -1799 2 2 2000 -3797 -380 -3417 2 2 4000 -7416 -742 -6674 Total Production Usable for Mays Demand Inventory Breakage, etc. Ending Inventory Decision Models -- Prof. Juran E F =C15 =D4+D8 =D10*$H$11 =D2+D11-D12 =D13*$H$12 =D2+D11-D12-D14 G H Objective $ (178,049) Regular Cost Overtime Cost Inventory Cost $ 120 $ 180 $ (178,349) Yield Shrinkage Regular cost Overtime cost Inventory cost $ $ $ I J =SUM(H4:H6) =SUM(B4:D4)*H13 =SUM(B8:D8)*H14 =SUM(B15:D15)*H15 0.8 0.1 40.00 60.00 15.00 25 K Decision Models -- Prof. Juran 26 Decision Models -- Prof. Juran 27 Solution Methodology A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Beginning Inventory B C D 1st Quarter 2nd Quarter 3rd Quarter 1000 0 144 Regular Time 2500 2700 2700 Capacity 2700 2700 2700 Overtime 0 0 2120 2500 2000 3000 0 0 0 2700 2160 2000 160 16 144 4820 3856 4000 0 0 0 Total Production Usable for Mays Demand Inventory Breakage, etc. Ending Inventory Decision Models -- Prof. Juran E F =C15 =D4+D8 =D10*$H$11 =D2+D11-D12 =D13*$H$12 =D2+D11-D12-D14 G H Objective $ 445,360 Regular Cost Overtime Cost Inventory Cost $ 316,000 $ 127,200 $ 2,160 Yield Shrinkage Regular cost Overtime cost Inventory cost 0.8 0.1 40.00 60.00 15.00 $ $ $ I J =SUM(H4:H6) =SUM(B4:D4)*H13 =SUM(B8:D8)*H14 =SUM(B15:D15)*H15 28 K Optimal Solution 1st Quarter 2nd Quarter 3rd Quarter 2500 2700 2700 0 0 2120 2500 2700 4820 Regular Time Overtime Total Production Decision Models -- Prof. Juran 29 Sensitivity Analysis Investigate changes in the holding cost, and determine if Traverso would ever find it optimal to eliminate all inventory. Prepare some graphs showing how Traverso’s optimal decision depends on the holding cost. Decision Models -- Prof. Juran 30 Decision Models -- Prof. Juran 31 $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00 11.00 12.00 13.00 14.00 15.00 16.00 17.00 18.00 19.00 20.00 21.00 22.00 23.00 24.00 25.00 26.00 27.00 28.00 29.00 30.00 H I J 1st Quarter2nd Quarter3rd Quarter1st Quarter2nd Quarter3rd Quarter1st Quarter2nd Quarter3rd Quarter 2700 2700 2700 0 0 1958 144 274 0 $ 2700 2700 2700 0 0 1958 144 274 0 $ 2700 2700 2700 0 0 1958 144 274 0 $ 2700 2700 2700 0 0 1958 144 274 0 $ 2700 2700 2700 0 0 1958 144 274 0 $ 2700 2700 2700 0 0 1958 144 274 0 $ 2700 2700 2700 0 0 1958 144 274 0 $ 2500 2700 2700 0 0 2120 0 144 0 $ 2500 2700 2700 0 0 2120 0 144 0 $ 2500 2700 2700 0 0 2120 0 144 0 $ 2500 2700 2700 0 0 2120 0 144 0 $ 2500 2700 2700 0 0 2120 0 144 0 $ 2500 2700 2700 0 0 2120 0 144 0 $ 2500 2700 2700 0 0 2120 0 144 0 $ 2500 2700 2700 0 0 2120 0 144 0 $ 2500 2700 2700 0 0 2120 0 144 0 $ 2500 2700 2700 0 0 2120 0 144 0 $ 2500 2700 2700 0 0 2120 0 144 0 $ 2500 2700 2700 0 0 2120 0 144 0 $ 2500 2700 2700 0 0 2120 0 144 0 $ 2500 2500 2700 0 0 2300 0 0 0 $ 2500 2500 2700 0 0 2300 0 0 0 $ 2500 2500 2700 0 0 2300 0 0 0 $ 2500 2500 2700 0 0 2300 0 0 0 $ 2500 2500 2700 0 0 2300 0 0 0 $ 2500 2500 2700 0 0 2300 0 0 0 $ 2500 2500 2700 0 0 2300 0 0 0 $ 2500 2500 2700 0 0 2300 0 0 0 $ 2500 2500 2700 0 0 2300 0 0 0 $ 2500 2500 2700 0 0 2300 0 0 0 $ 2500 2500 2700 0 0 2300 0 0 0 $ Decision Models -- Prof. Juran K L M N O P Sensitivity of Total Cost to Inventory cost Q Data for chart 441,480 441,898 442,315 442,733 443,150 443,568 443,986 444,208 444,352 444,496 444,640 444,784 444,928 445,072 445,216 445,360 445,504 445,648 445,792 445,936 446,000 446,000 446,000 446,000 446,000 446,000 446,000 446,000 446,000 446,000 446,000 10 Total Cost 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 G Total Cost A B C D E F 1 Oneway analysis for Solver model in Model worksheet 2 3 Inventory cost (cell $H$15) values along side, output cell(s) along top When you select an output from the dropdown list in cell $M$4, the chart will adapt to that output. 441480 441897.6 442315.2 442732.8 443150.4 443568 443985.6 444208 444352 444496 444640 444784 444928 445072 445216 445360 445504 445648 445792 445936 446000 446000 446000 446000 446000 446000 446000 446000 446000 446000 446000 32 • Never optimal to hold inventory at end of 3rd quarter • 1st and 2nd Quarters the optimal level depends on cost Decision Models -- Prof. Juran 33 Decision Models -- Prof. Juran 34 Decision Models -- Prof. Juran 35 • “Tipping points” are at about $6.287 and $19.444. Decision Models -- Prof. Juran 36 Sensitivity Analysis Conclusions: It is never optimal to completely eliminate overtime, but sometimes it is optimal to eliminate inventory. In general, as holding costs increase, Traverso will decide to reduce inventories and therefore produce more cases on overtime. Even if holding costs are reduced to zero, Traverso will need to produce at least 1958 cases on overtime. Demand exceeds the total capacity of regular time production. Critical cost points at $6.287 and $19.444. Decision Models -- Prof. Juran 37 Multi-Period Models Example: Project Funding It is January 1, 2008. Director of Special Projects Rakesh Parameshwar has a planned $20.5 million project, which will require the following expected cash flows between 2008 and 2012: Date 01-Jul-08 01-Jan-09 01-Jul-09 01-Jan-10 01-Jul-10 01-Jan-11 01-Jul-11 01-Jan-12 Decision Models -- Prof. Juran Cash Requirement ($ millions) 7.50 4.50 1.00 1.00 1.00 1.00 1.00 3.50 38 Rakesh turns to his Director of Financial Planning, Christine Reyling, and asks her to ensure that funding is available for the project. Christine is considering buying a portfolio of bonds, with cash flows from the bonds arranged to coincide with the needs of Rakesh’s project. The following bonds are available, and can be purchased in any quantity: Maturity 01-Jul-08 01-Jan-09 01-Jul-09 01-Jan-10 01-Jul-10 01-Jan-11 01-Jul-11 01-Jan-12 Coupon 7.00% 7.50% 6.75% 0.00% 10.00% 9.00% 10.25% 10.00% Price 1.00 1.03 1.02 0.81 1.16 1.15 1.23 1.25 What is the minimum cost portfolio of these bonds that will meet the project’s requirements? Assume that any cash can be reinvested at an annual rate of 4%, and don’t worry about discounting. Decision Models -- Prof. Juran 39 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 A B C D Reinv E 0.02 F G H I J Purchased Bonds 8.650 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 Coupon Price 01-Jul-08 1 7.00% 1.00 01-Jan-09 2 7.50% 1.03 01-Jul-09 3 6.75% 1.02 01-Jan-10 4 0.00% 0.81 01-Jul-10 5 10.00% 1.16 01-Jan-11 6 9.00% 1.15 01-Jul-11 7 10.25% 1.23 01-Jan-12 8 10.00% 1.25 01-Jul-08 01-Jan-09 01-Jul-09 01-Jan-10 01-Jul-10 01-Jan-11 01-Jul-11 01-Jan-12 1.0350 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0450 0.0450 0.0450 0.0450 0.0450 1.0450 0.0000 0.0000 0.0513 0.0513 0.0513 0.0513 0.0513 0.0513 1.0513 0.0000 0.0500 0.0500 0.0500 0.0500 0.0500 0.0500 0.0500 1.0500 Maturity Periods 1 2 3 4 5 6 7 8 0.0375 0.0338 0.0000 0.0500 =IF($A11>C$6,0,(IF(C$6=$A11,(C$7/2)+1,(C$7/2)))) 1.0375 0.0338 0.0000 0.0500 0.0000 1.0338 0.0000 0.0500 0.0000 0.0000 1.0000 0.0500 0.0000 0.0000 0.0000 1.0500 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 Decision Models -- Prof. Juran 40 Decision Models -- Prof. Juran 41 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 A B C D Reinv E 0.02 F G H I J Purchased Bonds 8.650 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 Coupon Price 01-Jul-08 1 7.00% 1.00 01-Jan-09 2 7.50% 1.03 01-Jul-09 3 6.75% 1.02 01-Jan-10 4 0.00% 0.81 01-Jul-10 5 10.00% 1.16 01-Jan-11 6 9.00% 1.15 01-Jul-11 7 10.25% 1.23 01-Jan-12 8 10.00% 1.25 Periods 1 2 3 4 5 6 7 8 01-Jul-08 01-Jan-09 01-Jul-09 01-Jan-10 01-Jul-10 01-Jan-11 01-Jul-11 01-Jan-12 1.0350 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0375 1.0375 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0338 0.0338 1.0338 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 1.0000 0.0000 0.0000 0.0000 0.0000 0.0500 0.0500 0.0500 0.0500 1.0500 0.0000 0.0000 0.0000 0.0450 0.0450 0.0450 0.0450 0.0450 1.0450 0.0000 0.0000 0.0513 0.0513 0.0513 0.0513 0.0513 0.0513 1.0513 0.0000 0.0500 0.0500 0.0500 0.0500 0.0500 0.0500 0.0500 1.0500 1 2 3 4 5 6 7 8 01-Jul-08 01-Jan-09 01-Jul-09 01-Jan-10 01-Jul-10 01-Jan-11 01-Jul-11 01-Jan-12 Maturity Cash In from Prev Cash from Bonds Cash to Project Surplus Cash 0.00 1.30 7.50 -6.20 >= 0 -6.32 1.27 4.50 -9.55 >= 0 -9.75 1.23 1.00 -9.52 >= 0 -9.71 1.20 1.00 -9.51 >= 0 -9.70 1.20 1.00 -9.50 >= 0 =F24*(1+$E$1) -9.69 1.15 1.00 -9.55 >= 0 =SUMPRODUCT($C$3:$J$3,C16:J16) -9.74 1.10 1.00 -9.64 >= 0 =C27+D27-E27 -9.83 1.05 3.50 -12.28 >= 0 Decision Models -- Prof. Juran 42 Decision Models -- Prof. Juran 43 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 A B C D Reinv E 0.02 F G H I J Purchased Bonds 18.198 11.446 0.000 0.967 7.117 0.000 0.000 0.000 0.000 Coupon Price 01-Jul-08 1 7.00% 1.00 01-Jan-09 2 7.50% 1.03 01-Jul-09 3 6.75% 1.02 01-Jan-10 4 0.00% 0.81 01-Jul-10 5 10.00% 1.16 01-Jan-11 6 9.00% 1.15 01-Jul-11 7 10.25% 1.23 01-Jan-12 8 10.00% 1.25 Periods 1 2 3 4 5 6 7 8 01-Jul-08 01-Jan-09 01-Jul-09 01-Jan-10 01-Jul-10 01-Jan-11 01-Jul-11 01-Jan-12 1.0350 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0375 1.0375 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0338 0.0338 1.0338 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 1.0000 0.0000 0.0000 0.0000 0.0000 0.0500 0.0500 0.0500 0.0500 1.0500 0.0000 0.0000 0.0000 0.0450 0.0450 0.0450 0.0450 0.0450 1.0450 0.0000 0.0000 0.0513 0.0513 0.0513 0.0513 0.0513 0.0513 1.0513 0.0000 0.0500 0.0500 0.0500 0.0500 0.0500 0.0500 0.0500 1.0500 1 2 3 4 5 6 7 8 01-Jul-08 01-Jan-09 01-Jul-09 01-Jan-10 01-Jul-10 01-Jan-11 01-Jul-11 01-Jan-12 >= >= >= >= >= >= >= >= 0 0 0 0 0 0 0 0 Maturity Cash In from Prev Cash from Bonds Cash to Project Surplus Cash 0.00 11.88 7.50 4.38 4.47 0.03 4.50 0.00 0.00 1.00 1.00 0.00 0.00 7.12 1.00 6.12 6.24 0.00 1.00 5.24 5.34 0.00 1.00 4.34 4.43 0.00 1.00 3.43 3.50 0.00 3.50 0.00 Decision Models -- Prof. Juran 44 Summary • More Sensitivity Analysis – Solver Sensitivity Report • More Malcolm • Multi-period Models – Distillery Example – Project Funding Example Decision Models -- Prof. Juran 45