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Question: O'Brien Chemicals makes three types of products: industrial cleaning, chemical treatment, and some miscellaneous products. Each is sold in 55-gallon drums. The selling price and unit manufacturing cost are shown below:
Manufacturing
Product Type
Selling Price/drum
Cost/drum
Industrial Cleaning
Alkaline Cleaner
$700.00
$275.00
Acid Cleaner
$600.00
$225.00
Neutral Cleaner
$450.00
$150.00
Chemical Treatment
Iron Phosphate
$920.00
$400.00
Zirconium
$1,350.00
$525.00
Zinc Phosphate
$1,400.00
$625.00
Other
Sealant
$850.00
$350.00
Rust Prevention
$260.00
Fixed costs are assumed normal with a mean of $5 million and a standard deviation of $20,000. Demands are all assumed to be normally distributed with the following means and standard deviations:
Mean Demand
Standard Deviation
5,000
100
2,000
500
350
5,500
250
2,800
130
4,350
300
8,000
4,250
The operations manager has to determine the quantity to produce in the face of uncertain demand. One option is to simply produce the mean demand; depending on the actual demand, this could result in a shortage (lost sales) or excess inventory. Two other options are to produce at a level equal to either 75% or 90% of the demand (i.e., find the value so that 75% or 90% of the area under the normal distribution is to the left). Using Monte Carlo simulation, evaluate and compare these three policies and write a report to the operations manager summarizing your finding.
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