| Raw materials and packaging | ||||||||||||||||
| Descpription | Item number | Type of product | Shelf life (days) | Lead time (days) | Annual usage | Unit of measure(uom) | Cost per uom | Annual cost | ABC | Frequency | Total cost to count | Total hours used | ||||
| Chicken wings | 1000 | Raw material | 7 | 5 | 3,000,000.00 | lbs | $ 2.29 | $ 6,870,000 | ||||||||
| Chicken tenders | 1001 | Raw material | 10 | 5 | 7,000,000.00 | lbs | $ 1.96 | $ 13,720,000 | ||||||||
| Boneless dark meat | 1002 | Raw material | 9 | 5 | 1,000,000.00 | lbs | $ 1.56 | $ 1,560,000 | ||||||||
| Brisket | 1003 | Raw material | 14 | 5 | 8,000,000.00 | lbs | $ 4.00 | $ 32,000,000 | ||||||||
| Chopped beef | 1004 | Raw material | 14 | 5 | 15,000,000.00 | lbs | $ 3.50 | $ 52,500,000 | ||||||||
| Ends and pieces | 1005 | Raw material | 14 | 5 | 1,000,000.00 | lbs | $ 4.75 | $ 4,750,000 | ||||||||
| Sliced pork | 1006 | Raw material | 12 | 5 | 1,000,000.00 | lbs | $ 2.75 | $ 2,750,000 | ||||||||
| Pulled pork | 1007 | Raw material | 14 | 5 | 12,000,000.00 | lbs | $ 3.40 | $ 40,800,000 | ||||||||
| Ends and pieces | 1008 | Raw material | 12 | 5 | 2,000,000.00 | lbs | $ 4.50 | $ 9,000,000 | ||||||||
| BBQ base 1 | 1009 | Raw material | 180 | 10 | 200,000.00 | lbs | $ 0.25 | $ 50,000 | ||||||||
| BBQ base 2 | 1010 | Raw material | 180 | 10 | 210,000.00 | lbs | $ 0.25 | $ 52,500 | ||||||||
| BBQ base 3 | 1011 | Raw material | 180 | 10 | 12,000.00 | lbs | $ 0.25 | $ 3,000 | ||||||||
| BBQ base 4 | 1012 | Raw material | 180 | 10 | 78,000.00 | lbs | $ 0.35 | $ 27,300 | ||||||||
| BBQ base 5 | 1013 | Raw material | 180 | 10 | 24,000.00 | lbs | $ 0.35 | $ 8,400 | ||||||||
| Spice 1 | 1014 | Raw material | 360 | 25 | 1,000.00 | lbs | $ 0.15 | $ 150 | ||||||||
| Spice 2 | 1015 | Raw material | 360 | 25 | 1,400.00 | lbs | $ 0.16 | $ 224 | ||||||||
| Spice 3 | 1016 | Raw material | 360 | 25 | 1,800.00 | lbs | $ 0.31 | $ 558 | ||||||||
| Spice 4 | 1017 | Raw material | 360 | 10 | 2,200.00 | lbs | $ 0.33 | $ 726 | ||||||||
| Spice 5 | 1018 | Raw material | 360 | 12 | 2,600.00 | lbs | $ 0.35 | $ 910 | ||||||||
| Spice 6 | 1019 | Raw material | 360 | 25 | 1,200.00 | lbs | $ 0.37 | $ 444 | ||||||||
| Spice 7 | 1020 | Raw material | 360 | 12 | 780.00 | lbs | $ 0.39 | $ 304 | ||||||||
| Spice 8 | 1021 | Raw material | 360 | 25 | 671.00 | lbs | $ 0.41 | $ 275 | ||||||||
| Spice 9 | 1022 | Raw material | 360 | 25 | 98.00 | lbs | $ 0.43 | $ 42 | ||||||||
| Spice 10 | 1023 | Raw material | 360 | 25 | 238.00 | lbs | $ 0.45 | $ 107 | ||||||||
| Spice 11 | 1024 | Raw material | 360 | 20 | 378.00 | lbs | $ 0.65 | $ 246 | ||||||||
| Spice 12 | 1025 | Raw material | 360 | 14 | 518.00 | lbs | $ 0.99 | $ 513 | ||||||||
| Spice 13 | 1026 | Raw material | 360 | 20 | 658.00 | lbs | $ 1.33 | $ 875 | ||||||||
| Spice 14 | 1027 | Raw material | 360 | 20 | 798.00 | lbs | $ 1.67 | $ 1,333 | ||||||||
| Spice 15 | 1028 | Raw material | 360 | 20 | 1,600.00 | lbs | $ 2.01 | $ 3,216 | ||||||||
| Spice 16 | 1029 | Raw material | 180 | 20 | 1,800.00 | lbs | $ 2.35 | $ 4,230 | ||||||||
| Spice 17 | 1030 | Raw material | 140 | 20 | 1,000.00 | lbs | $ 2.69 | $ 2,690 | ||||||||
| Spice 18 | 1031 | Raw material | 100 | 20 | 200.00 | lbs | $ 3.03 | $ 606 | ||||||||
| Spice 19 | 1032 | Raw material | 60 | 20 | 600.00 | lbs | $ 3.37 | $ 2,022 | ||||||||
| Spice 20 | 1033 | Raw material | 20 | 20 | 1,345.00 | lbs | $ 27.98 | $ 37,633 | ||||||||
| Tray 1 | 1034 | Packaging | 360 | 21 | 120,000,000.00 | each | $ 0.25 | $ 30,000,000 | ||||||||
| Tray 2 | 1035 | Packaging | 360 | 21 | 80,000,000.00 | each | $ 0.25 | $ 20,000,000 | ||||||||
| Tray 3 | 1036 | Packaging | 360 | 21 | 40,000,000.00 | each | $ 0.25 | $ 10,000,000 | ||||||||
| Carton 1 | 1037 | Packaging | 360 | 21 | 2,000,000.00 | each | $ 0.15 | 166,666.67 | $ 300,000 | |||||||
| Carton 2 | 1038 | Packaging | 360 | 21 | 3,000,000.00 | each | $ 0.15 | 250,000.00 | $ 450,000 | |||||||
| Carton 3 | 1039 | Packaging | 360 | 21 | 15,000,000.00 | each | $ 0.15 | 1,250,000.00 | $ 2,250,000 | |||||||
| Carton 4 | 1040 | Packaging | 360 | 21 | 20,000,000.00 | each | $ 0.15 | 1,666,666.67 | $ 3,000,000 | |||||||
| Carton 5 | 1041 | Packaging | 360 | 21 | 1,500,000.00 | each | $ 0.15 | 125,000.00 | $ 225,000 | |||||||
| Carton 6 | 1042 | Packaging | 360 | 21 | 2,000,000.00 | each | $ 0.15 | 166,666.67 | $ 300,000 | |||||||
| Carton 7 | 1043 | Packaging | 360 | 21 | 2,500,000.00 | each | $ 0.15 | 208,333.33 | $ 375,000 | |||||||
| Carton 8 | 1044 | Packaging | 360 | 21 | 3,000,000.00 | each | $ 0.15 | 250,000.00 | $ 450,000 | |||||||
| Carton 9 | 1045 | Packaging | 360 | 21 | 3,500,000.00 | each | $ 0.15 | 291,666.67 | $ 525,000 | |||||||
| Carton 10 | 1046 | Packaging | 360 | 21 | 4,000,000.00 | each | $ 0.15 | 333,333.33 | $ 600,000 | |||||||
| Carton 11 | 1047 | Packaging | 360 | 21 | 4,500,000.00 | each | $ 0.15 | 375,000.00 | $ 675,000 | |||||||
| Carton 12 | 1048 | Packaging | 360 | 21 | 5,000,000.00 | each | $ 0.15 | 416,666.67 | $ 750,000 | |||||||
| Carton 13 | 1049 | Packaging | 360 | 21 | 5,500,000.00 | each | $ 0.15 | 458,333.33 | $ 825,000 | |||||||
| Carton 14 | 1050 | Packaging | 360 | 21 | 6,000,000.00 | each | $ 0.15 | 500,000.00 | $ 900,000 | |||||||
| Carton 15 | 1051 | Packaging | 360 | 21 | 6,500,000.00 | each | $ 0.15 | 541,666.67 | $ 975,000 | |||||||
| Carton 16 | 1052 | Packaging | 360 | 21 | 7,000,000.00 | each | $ 0.15 | 583,333.33 | $ 1,050,000 | |||||||
| Carton 17 | 1053 | Packaging | 360 | 21 | 7,500,000.00 | each | $ 0.20 | 625,000.00 | $ 1,500,000 | |||||||
| Carton 18 | 1054 | Packaging | 360 | 21 | 8,000,000.00 | each | $ 0.20 | 666,666.67 | $ 1,600,000 | |||||||
| Carton 19 | 1055 | Packaging | 360 | 21 | 8,500,000.00 | each | $ 0.20 | 708,333.33 | $ 1,700,000 | |||||||
| Carton 20 | 1056 | Packaging | 360 | 21 | 9,000,000.00 | each | $ 0.20 | 750,000.00 | $ 1,800,000 | |||||||
| Carton 21 | 1057 | Packaging | 360 | 21 | 9,500,000.00 | each | $ 0.20 | 791,666.67 | $ 1,900,000 | |||||||
| Carton 22 | 1058 | Packaging | 360 | 21 | 7,500,000.00 | each | $ 0.20 | 625,000.00 | $ 1,500,000 | |||||||
| Carton 23 | 1059 | Packaging | 360 | 21 | 9,800,000.00 | each | $ 0.20 | 816,666.67 | $ 1,960,000 | |||||||
| Carton 24 | 1060 | Packaging | 360 | 21 | 4,960,000.00 | each | $ 0.20 | 413,333.33 | $ 992,000 | |||||||
| Carton 25 | 1061 | Packaging | 360 | 21 | 9,400,000.00 | each | $ 0.20 | 783,333.33 | $ 1,880,000 | |||||||
| Carton 26 | 1062 | Packaging | 360 | 21 | 9,200,000.00 | each | $ 0.20 | 766,666.67 | $ 1,840,000 | |||||||
| Carton 27 | 1063 | Packaging | 360 | 21 | 6,900,000.00 | each | $ 0.20 | 575,000.00 | $ 1,380,000 | |||||||
| Carton 28 | 1064 | Packaging | 360 | 21 | 8,800,000.00 | each | $ 0.20 | 733,333.33 | $ 1,760,000 | |||||||
| Carton 29 | 1065 | Packaging | 360 | 21 | 8,600,000.00 | each | $ 0.20 | 716,666.67 | $ 1,720,000 | |||||||
| Carton 30 | 1066 | Packaging | 360 | 21 | 3,840,000.00 | each | $ 0.20 | 320,000.00 | $ 768,000 | |||||||
| Carton 31 | 1067 | Packaging | 360 | 21 | 4,200,000.00 | each | $ 0.20 | 350,000.00 | $ 840,000 | |||||||
| Carton 32 | 1068 | Packaging | 360 | 21 | 8,000,000.00 | each | $ 0.20 | 666,666.67 | $ 1,600,000 | |||||||
| Carton 33 | 1069 | Packaging | 360 | 21 | 13,800,000.00 | each | $ 0.25 | 1,150,000.00 | $ 3,450,000 | |||||||
| Carton 34 | 1070 | Packaging | 360 | 21 | 5,600,000.00 | each | $ 0.25 | 466,666.67 | $ 1,400,000 | |||||||
| Carton 35 | 1071 | Packaging | 360 | 21 | 200,000.00 | each | $ 0.25 | 16,666.67 | $ 50,000 | |||||||
| Carton 36 | 1072 | Packaging | 360 | 21 | 190,000.00 | each | $ 0.25 | 15,833.33 | $ 47,500 | |||||||
| Carton 37 | 1073 | Packaging | 360 | 21 | 180,000.00 | each | $ 0.25 | 15,000.00 | $ 45,000 | |||||||
| Carton 38 | 1074 | Packaging | 360 | 21 | 170,000.00 | each | $ 0.25 | 14,166.67 | $ 42,500 | |||||||
| Carton 39 | 1075 | Packaging | 360 | 21 | 4,160,000.00 | each | $ 0.25 | 346,666.67 | $ 1,040,000 | |||||||
| Carton 40 | 1076 | Packaging | 360 | 21 | 155,000.00 | each | $ 0.25 | 12,916.67 | $ 38,750 | |||||||
| Carton 41 | 1077 | Packaging | 360 | 21 | 385,000.00 | each | $ 0.25 | 32,083.33 | $ 96,250 | |||||||
| Carton 42 | 1078 | Packaging | 360 | 21 | 130,000.00 | each | $ 0.25 | 10,833.33 | $ 32,500 | |||||||
| Carton 43 | 1079 | Packaging | 360 | 21 | 120,000.00 | each | $ 0.25 | 10,000.00 | $ 30,000 | |||||||
| Carton 44 | 1080 | Packaging | 360 | 21 | 110,000.00 | each | $ 0.25 | 9,166.67 | $ 27,500 | |||||||
| Carton 45 | 1081 | Packaging | 360 | 21 | 100,000.00 | each | $ 0.25 | 8,333.33 | $ 25,000 | |||||||
| Shipping case 1 | 1082 | Packaging | 120 | 5 | 3,000,000.00 | each | $ 0.75 | $ 2,250,000 | ||||||||
| Shipping case 2 | 1083 | Packaging | 120 | 5 | 4,000,000.00 | each | $ 0.75 | $ 3,000,000 | ||||||||
| Shipping case 3 | 1084 | Packaging | 120 | 5 | 2,500,000.00 | each | $ 0.75 | $ 1,875,000 | ||||||||
| Shipping case 4 | 1085 | Packaging | 120 | 5 | 9,000,000.00 | each | $ 0.75 | $ 6,750,000 | ||||||||
| Shipping case 5 | 1086 | Packaging | 120 | 5 | 900,000.00 | each | $ 0.75 | $ 675,000 | ||||||||
| Shipping case 6 | 1087 | Packaging | 120 | 5 | 600,000.00 | each | $ 1.25 | $ 750,000 | ||||||||
| Film 1 | 1088 | Packaging | 360 | 21 | 200,000,000.00 | each print | $ 0.05 | $ 10,000,000 | ||||||||
| Film 2 | 1089 | Packaging | 360 | 21 | 35,000,000.00 | each print | $ 0.05 | $ 1,750,000 | ||||||||
| Film 3 | 1090 | Packaging | 360 | 21 | 5,000,000.00 | each print | $ 0.05 | $ 250,000 | ||||||||
| Vegetable 1 | 1091 | Raw material | 120 | 30 | 30,000,000.00 | lbs | $ 0.27 | $ 8,100,000 | ||||||||
| Vegetable 2 | 1092 | Raw material | 120 | 30 | 18,000,000.00 | lbs | $ 0.47 | $ 8,460,000 | ||||||||
| Vegetable 3 | 1093 | Raw material | 120 | 30 | 5,000,000.00 | lbs | $ 0.67 | $ 3,350,000 | ||||||||
| Vegetable 4 | 1094 | Raw material | 120 | 30 | 6,000,000.00 | lbs | $ 0.87 | $ 5,220,000 | ||||||||
| Vegetable 5 | 1095 | Raw material | 120 | 60 | 1,000,000.00 | lbs | $ 1.07 | $ 1,070,000 | ||||||||
| Frozen beef | 1096 | Raw material | 180 | 15 | 1,400,000.00 | lbs | $ 1.65 | $ 2,310,000 | ||||||||
| Fresh beef | 1097 | Raw material | 14 | 15 | 300,000.00 | lbs | $ 1.79 | $ 537,000 | ||||||||
| Deboned chicken | 1098 | Raw material | 10 | 15 | 3,000,000.00 | lbs | $ 1.98 | $ 5,940,000 | ||||||||
| Labels (shipping) 1 | 1099 | Packaging | 180 | 14 | 1,000,000.00 | each | $ 0.10 | $ 100,000 | ||||||||
| Labels (shipping) 2 | 1100 | Packaging | 180 | 14 | 1,000,000.00 | each | $ 0.10 | $ 100,000 | ||||||||
| Labels (shipping) 3 | 1101 | Packaging | 180 | 14 | 2,500,000.00 | each | $ 0.10 | $ 250,000 | ||||||||
| Labels (shipping) 4 | 1102 | Packaging | 180 | 14 | 1,000,000.00 | each | $ 0.10 | $ 100,000 | ||||||||
| Labels (shipping) 5 | 1103 | Packaging | 180 | 14 | 720,000.00 | each | $ 0.10 | $ 72,000 | ||||||||
| Labels (shipping) 6 | 1104 | Packaging | 180 | 14 | 50,000.00 | each | $ 0.10 | $ 5,000 | ||||||||
| Labels (shipping) 7 | 1105 | Packaging | 180 | 14 | 10,000.00 | each | $ 0.10 | $ 1,000 | ||||||||
| Labels (shipping) 8 | 1106 | Packaging | 180 | 14 | 1,000,000.00 | each | $ 0.10 | $ 100,000 | ||||||||
| Labels (shipping) 9 | 1107 | Packaging | 180 | 14 | 1,000,000.00 | each | $ 0.10 | $ 100,000 | ||||||||
| Labels (shipping) 10 | 1108 | Packaging | 180 | 14 | 1,000,000.00 | each | $ 0.10 | $ 100,000 | ||||||||
| Labels work in process 1 | 1109 | Packaging | 180 | 14 | 5,000,000.00 | each | $ 0.45 | $ 2,250,000 | ||||||||
| Labels work in process 2 | 1110 | Packaging | 180 | 14 | 2,500,000.00 | each | $ 0.35 | $ 875,000 | ||||||||
| Dry food ingredient 1 | 1111 | Raw material | 180 | 5 | 350,000.00 | lbs | $ 0.50 | $ 175,000 | ||||||||
| Dry food ingredient 2 | 1112 | Raw material | 180 | 7 | 375,000.00 | lbs | $ 0.52 | $ 195,000 | ||||||||
| Dry food ingredient 3 | 1113 | Raw material | 180 | 9 | 400,000.00 | lbs | $ 0.54 | $ 216,000 | ||||||||
| Dry food ingredient 4 | 1114 | Raw material | 180 | 11 | 425,000.00 | lbs | $ 0.56 | $ 238,000 | ||||||||
| Dry food ingredient 5 | 1115 | Raw material | 180 | 13 | 450,000.00 | lbs | $ 0.58 | $ 261,000 | ||||||||
| Dry food ingredient 6 | 1116 | Raw material | 180 | 15 | 475,000.00 | lbs | $ 0.60 | $ 285,000 | ||||||||
| Dry food ingredient 7 | 1117 | Raw material | 180 | 17 | 500,000.00 | lbs | $ 0.62 | $ 310,000 | ||||||||
| Dry food ingredient 8 | 1118 | Raw material | 180 | 19 | 525,000.00 | lbs | $ 0.64 | $ 336,000 | ||||||||
| Dry food ingredient 9 | 1119 | Raw material | 200 | 21 | 550,000.00 | lbs | $ 0.66 | $ 363,000 | ||||||||
| Dry food ingredient 10 | 1120 | Raw material | 200 | 23 | 575,000.00 | lbs | $ 0.68 | $ 391,000 | ||||||||
| Dry food ingredient 11 | 1121 | Raw material | 200 | 25 | 600,000.00 | lbs | $ 0.70 | $ 420,000 | ||||||||
| Dry food ingredient 12 | 1122 | Raw material | 200 | 27 | 625,000.00 | lbs | $ 0.66 | $ 412,500 | ||||||||
| Dry food ingredient 13 | 1123 | Raw material | 200 | 29 | 1,650,000.00 | lbs | $ 0.62 | $ 1,023,000 | ||||||||
| Dry food ingredient 14 | 1124 | Raw material | 200 | 31 | 1,675,000.00 | lbs | $ 0.58 | $ 971,500 | ||||||||
| Dry food ingredient 15 | 1125 | Raw material | 200 | 33 | 700,000.00 | lbs | $ 0.54 | $ 378,000 | ||||||||
| Dry food ingredient 16 | 1126 | Raw material | 240 | 35 | 725,000.00 | lbs | $ 0.50 | $ 362,500 | ||||||||
| Dry food ingredient 17 | 1127 | Raw material | 240 | 37 | 750,000.00 | lbs | $ 0.46 | $ 345,000 | ||||||||
| Dry food ingredient 18 | 1128 | Raw material | 240 | 39 | 775,000.00 | lbs | $ 0.42 | $ 325,500 | ||||||||
| Dry food ingredient 19 | 1129 | Raw material | 240 | 41 | 800,000.00 | lbs | $ 0.38 | $ 304,000 | ||||||||
| Dry food ingredient 20 | 1130 | Raw material | 240 | 43 | 825,000.00 | lbs | $ 0.34 | $ 280,500 | ||||||||
| Dry food ingredient 21 | 1131 | Raw material | 225 | 45 | 850,000.00 | lbs | $ 0.30 | $ 255,000 | ||||||||
| Dry food ingredient 22 | 1132 | Raw material | 210 | 47 | 875,000.00 | lbs | $ 0.26 | $ 227,500 | ||||||||
| Dry food ingredient 23 | 1133 | Raw material | 195 | 49 | 900,000.00 | lbs | $ 0.22 | $ 198,000 | ||||||||
| Dry food ingredient 24 | 1134 | Raw material | 180 | 51 | 925,000.00 | lbs | $ 0.18 | $ 166,500 | ||||||||
| Dry food ingredient 25 | 1135 | Raw material | 165 | 53 | 950,000.00 | lbs | $ 0.25 | $ 237,500 | ||||||||
| Dry food ingredient 26 | 1136 | Raw material | 150 | 55 | 975,000.00 | lbs | $ 0.35 | $ 341,250 | ||||||||
| Dry food ingredient 27 | 1137 | Raw material | 130 | 57 | 10,000,000.00 | lbs | $ 0.45 | $ 4,500,000 | ||||||||
| Dry food ingredient 28 | 1138 | Raw material | 110 | 59 | 8,000,000.00 | lbs | $ 0.55 | $ 4,400,000 | ||||||||
| Dry food ingredient 29 | 1139 | Raw material | 90 | 61 | 6,000,000.00 | lbs | $ 0.65 | $ 3,900,000 | ||||||||
| Dry food ingredient 30 | 1140 | Raw material | 70 | 63 | 4,000,000.00 | lbs | $ 0.75 | $ 3,000,000 | ||||||||
| Dry food ingredient 31 | 1141 | Raw material | 50 | 65 | 2,000,000.00 | lbs | $ 0.75 | $ 1,500,000 | ||||||||
| Dry food ingredient 32 | 1142 | Raw material | 30 | 67 | 1,500,000.00 | lbs | $ 0.75 | $ 1,125,000 | ||||||||
| Total column F | – 0 | Total columns | FTE | |||||||||||||
| – 0 |
| All yellow boxes on Materials and packaging tab must be populated using an Excel formula. Usiing material from Skills Development in the Final Assignment tab you will sort the items as needed and develop a workable ABC analysis and a cycle count plan. Column K will be the total cost on an annual basis. It is your choice to conduct the ABC anlaysis using either total annual usage in pounds or unit of measure, total annual cost, or any other method as referenced in the powerpoint. Column L will have a designation in each cell either A, B, C. Column M will be the frequency that the counts occur. A items should be less than 8 days (weekly). B items should be 30 to 60 days, and C items 90 to 180 days. You may choose to make all A items the same time (recommended) or some combination of frequency as long as it is within the paramenters stated above. All B items and C items will follow this same pattern. Example and Exception: If you decide to count all A items weekly but identify one item as problematic and wish to count it more frequently that is allowable. Column N is the cost to count. Assume each count takes 27 minutes to complete using one employee that is paid $18.75 per hour with a fully loaded labor rate with fringes of $25.50 per hour. The sum of column N will be the total annual cost. The sum of column M will be the total number of counts needed annually. Column O will be the time in hours to count each item and will be needed to calculate final cost. The rationale and decisions that go into your analysis will be included in the Executive Summary and should include a chart, table or graph similar to the examples in the powerpoint The Finance and accounting Departments of your company remind you a rule exists that states that every item wheter a material or a finished good must be counted at least twice per year. The reason you are conducting the ABC analysis is the plant has an issue with running out of material and either making a mid shift unplanned changeover or losses the last 15 to 90 minutes of a shift as the changeover cannot be accomplished in a manner that makes it worthwhile to hold the crew. Estimates are that up to 2.5% of run time is lost to short shifts and unplanned changes. Studies suggest than 1% could be eliminated with a rodust cycle count program. Approximately 1% is related to changeovers that cannot be avoided and .5% is related to supplier issues. You are permitted to recommend the cycle count program that just meets the company requirements (which is already in place) and you will get 70% on this problem as long as you |
| H | |
| The goal of this portion of the assignment is to conduct an SKU rationalization to address the capacity issue from the Statement of Facts document in Content/Material for Final Project/Problems in D2L. There are three tabs in this workbook that will be used. Finished goods Before, FG after productivity improve, and FG after SKU. You will need to conduct an analysis of the Finished goods Before and determine which if any of the SKUs are candidates to be eliminated. I would sort the data provided by cases from highest to lowest before starting on the rationalization. All the yellow boxes on Finished goods Before must be populated. Highlight the SKUs you are considering for elimination in red. On the FG after productivity improve tab you will adjust the numbers in columns D and H to reflect the increased productivity from the results of your ABC analysis (reduces downtime 1.5%) and carton machine downtime reduction (1%) project. All yellow boxes must be populated. Again I would sort by Cases. Totals for Cases and Productivity in Finished Goods After should all be higher than the original numbers. On the FG after SKU tab:To remove the skus from the final calculations place a 0 in the appropriate rows of Column F. For example if you choose to eliminate FG 1080a and FG 1081a you would place a 0 in cells F46 and F 47. Hint: These are the first two I would eliminate. By removing SKUS from the calculation you will have additional cases available to add to some of the remaining skus to get back tp 2000 shifts. Your findings and conclusions will be summarized in the executive summary. All yellow boxes must be populated. |
| Finished goods Before | ||||||||||||||||
| SKU | Profit per case (Total Revenue- Total Cost) | Cases | Profit before taxes | avg cases per line hour | line hrs per case | Required line hours | Required shifts | number of lines | Shifts per day | Days per week | Weeks per year | minutes per line shift | Shifts per year | |||
| FG 1037 | $ 0.16 | 58,000 | 1160 | 0.000862 | ||||||||||||
| FG 1038 | $ 0.20 | 74,000 | 1200 | 0.000833 | ||||||||||||
| FG 1039 | $ 0.20 | 1,620,000 | 1333 | 0.000750 | ||||||||||||
| FG 1040 | $ 0.20 | 2,100,000 | 1333 | 0.000750 | ||||||||||||
| FG 1041 | $ 0.16 | 55,000 | 1150 | 0.000870 | ||||||||||||
| FG 1042 | $ 0.16 | 62,000 | 1140 | 0.000877 | ||||||||||||
| FG 1043 | $ 0.24 | 66,000 | 1180 | 0.000847 | ||||||||||||
| FG 1044a | $ 0.16 | 71,905 | 980 | 0.001020 | ||||||||||||
| FG 1045 | $ 0.20 | 78,000 | 1220 | 0.000820 | ||||||||||||
| FG 1046 | $ 0.20 | 90,000 | 1220 | 0.000820 | ||||||||||||
| FG 1047 | $ 0.20 | 98,000 | 1220 | 0.000820 | ||||||||||||
| FG 1048 | $ 0.12 | 106,000 | 1220 | 0.000820 | ||||||||||||
| FG 1049a | $ 0.20 | 475,000 | 980 | 0.001020 | ||||||||||||
| FG 1050 | $ 0.20 | 500,000 | 1240 | 0.000806 | ||||||||||||
| FG 1051 | $ 0.20 | 541,666 | 1250 | 0.000800 | ||||||||||||
| FG 1052 | $ 0.20 | 583,333 | 1270 | 0.000787 | ||||||||||||
| FG 1053 | $ 0.23 | 525,000 | 1300 | 0.000769 | ||||||||||||
| FG 1054 | $ 0.20 | 620,000 | 1310 | 0.000763 | ||||||||||||
| FG 1055 | $ 0.19 | 700,000 | 1260 | 0.000794 | ||||||||||||
| FG 1056 | $ 0.20 | 550,000 | 1325 | 0.000755 | ||||||||||||
| FG 1057a | $ 0.20 | 601,000 | 1275 | 0.000784 | ||||||||||||
| FG 1058 | $ 0.20 | 625,000 | 1280 | 0.000781 | ||||||||||||
| FG 1059 | $ 0.23 | 1,516,680 | 1100 | 0.000909 | ||||||||||||
| FG 1060 | $ 0.20 | 102,000 | 1220 | 0.000820 | ||||||||||||
| FG 1061 | $ 0.20 | 1,415,600 | 1325 | 0.000755 | ||||||||||||
| FG 1062 | $ 0.26 | 850,000 | 1325 | 0.000755 | ||||||||||||
| FG 1063 | $ 0.20 | 575,000 | 1260 | 0.000794 | ||||||||||||
| FG 1064 | $ 0.20 | 739,000 | 1325 | 0.000755 | ||||||||||||
| FG 1065 | $ 0.20 | 718,000 | 1240 | 0.000806 | ||||||||||||
| FG 1066a | $ 0.15 | 86,000 | 1220 | 0.000820 | ||||||||||||
| FG 1067 | $ 0.20 | 94,000 | 1220 | 0.000820 | ||||||||||||
| FG 1068 | $ 0.21 | 535,000 | 1300 | 0.000769 | ||||||||||||
| FG 1069 | $ 0.20 | 1,333,000 | 1333 | 0.000750 | ||||||||||||
| FG 1070 | $ 0.20 | 466,670 | 1230 | 0.000813 | ||||||||||||
| FG 1071 | $ 0.16 | 48,000 | 1145 | 0.000873 | ||||||||||||
| FG 1072a | $ 0.17 | 19,000 | 1000 | 0.001000 | ||||||||||||
| FG 1073a | $ 0.18 | 16,980 | 925 | 0.001081 | ||||||||||||
| FG 1074a | $ 0.18 | 15,570 | 990 | 0.001010 | ||||||||||||
| FG 1075 | $ 0.20 | 82,000 | 1220 | 0.000820 | ||||||||||||
| FG 1076a | $ 0.18 | 14,212 | 1000 | 0.001000 | ||||||||||||
| FG 1077 | $ 0.16 | 50,000 | 1150 | 0.000870 | ||||||||||||
| FG 1078a | $ 0.18 | 10,900 | 1000 | 0.001000 | ||||||||||||
| FG 1079a | $ 0.18 | 10,200 | 780 | 0.001282 | ||||||||||||
| FG 1080a | $ 0.16 | 9,300 | 770 | 0.001299 | ||||||||||||
| FG 1081a | $ 0.14 | 8,670 | 650.0 | 0.001538 | ||||||||||||
| Total cases | 18,915,686 | Totals | ||||||||||||||
| Productivity | Average cases/line hr | |||||||||||||||
| Average profit per case |
| SKU | Profit per case (Total Revenue- Total Cost) | Cases Before | Cases After ABC and Downtime projects | Profit after | avg cases per line hour before | avg cases per line hour after ABC and Downtime project | Required line hours | Required shifts | ||
| FG 1037 | $ 0.16 | 58,000 | 1160 | |||||||
| FG 1038 | $ 0.20 | 74,000 | 1200 | |||||||
| FG 1039 | $ 0.20 | 1,620,000 | 1333 | |||||||
| FG 1040 | $ 0.20 | 2,100,000 | 1333 | |||||||
| FG 1041 | $ 0.16 | 55,000 | 1150 | |||||||
| FG 1042 | $ 0.16 | 62,000 | 1140 | |||||||
| FG 1043 | $ 0.24 | 66,000 | 1180 | |||||||
| FG 1044a | $ 0.16 | 71,905 | 980 | |||||||
| FG 1045 | $ 0.20 | 78,000 | 1220 | |||||||
| FG 1046 | $ 0.20 | 90,000 | 1220 | |||||||
| FG 1047 | $ 0.20 | 98,000 | 1220 | |||||||
| FG 1048 | $ 0.12 | 106,000 | 1220 | |||||||
| FG 1049a | $ 0.20 | 475,000 | 980 | |||||||
| FG 1050 | $ 0.20 | 500,000 | 1240 | |||||||
| FG 1051 | $ 0.20 | 541,666 | 1250 | |||||||
| FG 1052 | $ 0.20 | 583,333 | 1270 | |||||||
| FG 1053 | $ 0.23 | 525,000 | 1300 | |||||||
| FG 1054 | $ 0.20 | 620,000 | 1310 | |||||||
| FG 1055 | $ 0.19 | 700,000 | 1260 | |||||||
| FG 1056 | $ 0.20 | 550,000 | 1325 | |||||||
| FG 1057a | $ 0.20 | 601,000 | 1275 | |||||||
| FG 1058 | $ 0.20 | 625,000 | 1280 | |||||||
| FG 1059 | $ 0.23 | 1,516,680 | 1100 | |||||||
| FG 1060 | $ 0.20 | 102,000 | 1220 | |||||||
| FG 1061 | $ 0.20 | 1,415,600 | 1325 | |||||||
| FG 1062 | $ 0.26 | 850,000 | 1325 | |||||||
| FG 1063 | $ 0.20 | 575,000 | 1260 | |||||||
| FG 1064 | $ 0.20 | 739,000 | 1325 | |||||||
| FG 1065 | $ 0.20 | 718,000 | 1240 | |||||||
| FG 1066a | $ 0.16 | 86,000 | 1220 | |||||||
| FG 1067 | $ 0.20 | 94,000 | 1220 | |||||||
| FG 1068 | $ 0.22 | 535,000 | 1300 | |||||||
| FG 1069 | $ 0.20 | 1,333,000 | 1333 | |||||||
| FG 1070 | $ 0.20 | 466,670 | 1230 | |||||||
| FG 1071 | $ 0.16 | 48,000 | 1145 | |||||||
| FG 1072a | $ 0.17 | 19,000 | 1000 | |||||||
| FG 1073a | $ 0.18 | 16,980 | 925 | |||||||
| FG 1074a | $ 0.18 | 15,570 | 990 | |||||||
| FG 1075 | $ 0.20 | 82,000 | 1220 | |||||||
| FG 1076a | $ 0.19 | 14,212 | 1000 | |||||||
| FG 1077 | $ 0.16 | 50,000 | 1150 | |||||||
| FG 1078a | $ 0.19 | 10,900 | 1000 | |||||||
| FG 1079a | $ 0.18 | 10,200 | 780 | |||||||
| FG 1080a | $ 0.16 | 9,300 | 770 | |||||||
| FG 1081a | $ 0.14 | 8,670 | 650 | |||||||
| Totals | 18,915,686 | Totals | ||||||||
| Productivity | Average cases/line hr | |||||||||
| % change in cases after | ||||||||||
| % change in cases per hour after | ||||||||||
| % change in shifts after (should be close to no change) | ||||||||||
| change in profit |
| SKU | Profit per case (Total Revenue- Total Cost) | Cases Before | Cases After ABC and Downtime Project | Cases After Sku | Profit after sku rationalization | avg cases per line hour before | avg cases per line hour after ABC and Downtime project | Required line hours | Required shifts | |||
| FG 1037 | $ 0.16 | 58,000 | – 0 | 1160 | 0 | |||||||
| FG 1038 | $ 0.21 | 74,000 | – 0 | 1200 | 0 | |||||||
| FG 1039 | $ 0.21 | 1,620,000 | – 0 | 1333 | 0 | |||||||
| FG 1040 | $ 0.21 | 2,100,000 | – 0 | 1333 | 0 | |||||||
| FG 1041 | $ 0.16 | 55,000 | – 0 | 1150 | 0 | |||||||
| FG 1042 | $ 0.16 | 62,000 | – 0 | 1140 | 0 | |||||||
| FG 1043 | $ 0.25 | 66,000 | – 0 | 1180 | 0 | |||||||
| FG 1044a | $ 0.16 | 71,905 | – 0 | 980 | 0 | |||||||
| FG 1045 | $ 0.21 | 78,000 | – 0 | 1220 | 0 | |||||||
| FG 1046 | $ 0.21 | 90,000 | – 0 | 1220 | 0 | |||||||
| FG 1047 | $ 0.21 | 98,000 | – 0 | 1220 | 0 | |||||||
| FG 1048 | $ 0.12 | 106,000 | – 0 | 1220 | 0 | |||||||
| FG 1049a | $ 0.21 | 475,000 | – 0 | 980 | 0 | |||||||
| FG 1050 | $ 0.21 | 500,000 | – 0 | 1240 | 0 | |||||||
| FG 1051 | $ 0.21 | 541,666 | – 0 | 1250 | 0 | |||||||
| FG 1052 | $ 0.21 | 583,333 | – 0 | 1270 | 0 | |||||||
| FG 1053 | $ 0.23 | 525,000 | – 0 | 1300 | 0 | |||||||
| FG 1054 | $ 0.21 | 620,000 | – 0 | 1310 | 0 | |||||||
| FG 1055 | $ 0.19 | 700,000 | – 0 | 1260 | 0 | |||||||
| FG 1056 | $ 0.20 | 550,000 | – 0 | 1325 | 0 | |||||||
| FG 1057a | $ 0.20 | 601,000 | – 0 | 1275 | 0 | |||||||
| FG 1058 | $ 0.21 | 625,000 | – 0 | 1280 | 0 | |||||||
| FG 1059 | $ 0.24 | 1,516,680 | – 0 | 1100 | 0 | |||||||
| FG 1060 | $ 0.21 | 102,000 | – 0 | 1220 | 0 | |||||||
| FG 1061 | $ 0.21 | 1,415,600 | – 0 | 1325 | 0 | |||||||
| FG 1062 | $ 0.26 | 850,000 | – 0 | 1325 | 0 | |||||||
| FG 1063 | $ 0.21 | 575,000 | – 0 | 1260 | 0 | |||||||
| FG 1064 | $ 0.21 | 739,000 | – 0 | 1325 | 0 | |||||||
| FG 1065 | $ 0.21 | 718,000 | – 0 | 1240 | 0 | |||||||
| FG 1066a | $ 0.16 | 86,000 | – 0 | 1220 | 0 | |||||||
| FG 1067 | $ 0.21 | 94,000 | – 0 | 1220 | 0 | |||||||
| FG 1068 | $ 0.22 | 535,000 | – 0 | 1300 | 0 | |||||||
| FG 1069 | $ 0.21 | 1,333,000 | – 0 | 1333 | 0 | |||||||
| FG 1070 | $ 0.21 | 466,670 | – 0 | 1230 | 0 | |||||||
| FG 1071 | $ 0.16 | 48,000 | – 0 | 1145 | 0 | |||||||
| FG 1072a | $ 0.18 | 19,000 | – 0 | 1000 | 0 | |||||||
| FG 1073a | $ 0.18 | 16,980 | – 0 | 925 | 0 | |||||||
| FG 1074a | $ 0.19 | 15,570 | – 0 | 990 | 0 | |||||||
| FG 1075 | $ 0.21 | 82,000 | – 0 | 1220 | 0 | |||||||
| FG 1076a | $ 0.19 | 14,212 | – 0 | 1000 | 0 | |||||||
| FG 1077 | $ 0.16 | 50,000 | – 0 | 1150 | 0 | |||||||
| FG 1078a | $ 0.19 | 10,900 | – 0 | 1000 | 0 | |||||||
| FG 1079a | $ 0.18 | 10,200 | – 0 | 780 | 0 | |||||||
| FG 1080a | $ 0.16 | 9,300 | – 0 | 770 | 0 | |||||||
| FG 1081a | $ 0.14 | 8,670 | – 0 | 650 | 0 | |||||||
| Totals | Totals | |||||||||||
| Productivity | Average cases/line hr | |||||||||||
| % change in cases after | ||||||||||||
| % change in cases per hour after | ||||||||||||
| % change in shifts after (should be close to no change) | ||||||||||||
| change in profit |
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