A multistage approach for production and workforce planning in long-cycle product environments

Aggregate production planning (APP) has been studied extensively for the past two decades. The APP problem, also called production and workforce scheduling, is to determine the optimal workforce and production level in each period of the planning horizon in order to satisfy demand forecasts for these periods. The advantages of the APP are low cost of data collection and computational cost of the running model; the accuracy of data; and, effective managerial understanding of the results. If the product of concern takes longer than one period, it is called a long-cycle product. Examples of long-cycle products are aircraft, ships, buildings and special machines. A detailed model incorporating dynamic productivity and long-cycle products considerations is presented to solve the problem of production and workforce planning. Using a multistage production system approach, a search technique is developed to solve this class of problems where the objective function is linear and some of the constraint coefficients are dynamically nonlinear. The model provides a better solution than an aggregate production planning model, often used to solve these problems.