Optimized balancing of production with demand in shipyards: methodology applied to a real case

Purpose: The aim of this study is to propose a methodology for optimizing the aggregate planning problem in shipyards and illustrate its application in a real case. The methodology should be generic and flexible so that it can serve as a reference for application in any small-scale shipyard. Theoretical framework: Aggregate planning is the process of balancing production with demand, typically projected over time horizons of six to twelve months. This balancing act involves adjusting productive resources, aiming to simultaneously meet demand while minimizing costs. Methodology/Approach: The study introduces a generic methodology applicable to aggregate planning in small nautical shipyards. It comprises the following steps: measuring capacity, forecasting demand, selecting the appropriate capacity policy for production management, and finally proposing an optimal aggregate planning alternative. Findings: The methodology used proved to be viable for application in a real-life case, demonstrating its suitability for the specific industry. The time required to apply this methodology in a small shipyard (with fewer than 20 employees) can be estimated at 1 to 2 weeks. This methodology could even be implemented as consultancy for industries in the sector due to its numerous benefits. Research, practical & social implications: The study presents a new technology for planning and controlling production in the Brazilian nautical market, fostering its growth and international competitiveness. As a consequence, the development of the national industry leads to the creation of new jobs. Originality/ Value: The value of the study lies in its direct contribution to professional practice, providing a valuable reference for production planning in similar industries. The paper presents an original Aggregate Planning methodology, demonstrated through a case study in nautical shipyards. The results obtained demonstrate the effectiveness of the approach in minimizing production costs. Keywords: Nautical industry, nautical shipyard, aggregate planning, linear programming, capacity planning.