This presentation describes an overview of practical applications of Probabilistic Decision Analysis and Monte Carlo Models. Examples are provided in the areas of sales forecasting, manufacturing production, and component design
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Brioneja Probabilistic Decision Analysis For Elastomeric Components Sep 16, 2010 Jose A Briones
1. Jose A. Briones, Ph.D. CSI Calendering Inc., Arlington, TX Energy Rubber Group Technical Meeting, September 16, 2010
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16. Line 1 Line 2 Line 3 Line 4 Product Family A Product Family B Product Family C Product Family D Post-Treatment Facility 350 Units/hr 125 Units/hr/line 87.5 Units/hr/line 62.5 Units/hr/line 37.5 Units/hr/line
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19. Typical Range Range Min Max Production Target of product C, Units/mo 15,000 10,000 20,000 Production Target of product D, Units/mo 10,000 5,000 15,000 Production Rate of Product A, lines 1 and 2, Units/hr 250 240 260 Production Rate of Product B, lines 1 and 2, Units/hr 175 165 200 Rate of Production product C, lines 3 and 4 Units/hr 125 90 140 Rate of Production product D, lines 3 and 4 Units/hr 75 60 80 Maximum Production Rate 4 lines running, Units/hr 350 330 370 Var Margin Product A US$/unit $2.50 $2.30 $2.70 Var Margin Product B US$/unit $2.75 $2.60 $3.00 Var Margin Product C US$/unit $4.00 $3.50 $4.50 Var Margin Product D US$/unit $5.00 $4.50 $5.50 Plant fixed cost Euros/month 500,000 € 450,000 € 550,000 € Selling & Admin costs Euros/month 50,000 € 45,000 € 55,000 € Projected fixed cost savings Euros/month 75,000 € 65,000 € 90,000 € US Dollar/ Euro Exchange Rate 0.8 0.7 0.95
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22. ~50% of time devoted to C & D A or B C D 5.0% 90.0% 5.0% 100.0% 0.0% 0.0% 0.448 0.575 0 . 0 0 . 1 0 . 2 0 . 3 0 . 4 0 . 5 0 . 6 0 . 7 0 10 20 30 40 50 60 % of treatment line time devoted to A/B, C & D Grades % of treatment line time devoted to A + B Grades / Column Minimum 0.3699 Maximum 0.6080 Mean 0.5203 Std Dev 0.0384 Values 5000 % of treatment line time devoted to Product D / Column Minimum 0.0849 Maximum 0.1304 Mean 0.1032 Std Dev 0.00770 Values 5000 % of treatment line time devoted to Product C / Column Minimum 0.2963 Maximum 0.5094 Mean 0.3766 Std Dev 0.0374 Values 5000
23. Production of B vs. A results in a more significant loss of capacity compared to Scenario 1 A B 5.0% 90.0% 5.0% 100.0% 0.0% 0.0% 2.700 2.906 1 . 8 2 . 0 2 . 2 2 . 4 2 . 6 2 . 8 3 . 0 3 . 2 Values in Millions 0 1 2 3 4 5 6 7 V a l u e s x 1 0 ^ - 6 Total theoretical capacity, Product A vs. B plus Products C & D, kg/yr Total theoretical capacity, Product A plus Products C & D, kg/yr Minimum 2596788.1735 Maximum 3001093.4875 Mean 2803246.3861 Std Dev 62557.3764 Values 5000 Total theoretical capacity, Product B plus products C & D, kg/yr Minimum 1942146.1959 Maximum 2697819.5994 Mean 2362657.7945 Std Dev 120704.1615 Values 5000
24. Production of A has less than 2% probability of losses, 48% probability of profit >1.5 MM $ A B 1.2% 51.1% 47.7% 13.2% 72.0% 14.8% 0.00 1.45 - 3 - 2 - 1 0 1 2 3 4 Values in Millions 0 1 2 3 4 5 6 7 V a l u e s x 1 0 ^ - 7 Profitability, Product A vs. B Case US$/yr Profitability, Product A Case US$/yr / Column Minimum -852160.3638 Maximum 3287264.9694 Mean 1405082.2802 Std Dev 608985.6034 Values 5000 Profitability, Product B Case US$/yr / Column Minimum -2021651.9911 Maximum 3250368.3280 Mean 735213.2672 Std Dev 665321.2558 Values 5000
25. Values in $ 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 Fixed cost US$/kg Products A, B, C & D Fixed cost US$/kg Product D / Column Minimum $4.6730 Maximum $8.7315 Mean $6.3410 Std Dev $0.6228 Values 5000 Fixed cost US$/kg Product C / Column Minimum $2.6522 Maximum $5.8660 Mean $3.8579 Std Dev $0.4645 Values 5000 Fixed cost US$/kg Product A / Column Minimum $1.2306 Maximum $2.6219 Mean $1.9559 Std Dev $0.2068 Values 5000 Fixed cost US$/kg Product B. / Column Minimum $1.8782 Maximum $3.2967 Mean $2.5241 Std Dev $0.2136 Values 5000 Fixed Cost of Product A drops in this scenario A B D C 5.0% 90.0% 5.0% 99.8% 0.2% 0.0% 5.40 7.43 1 2 3 4 5 6 7 8 9
26. Values in $ 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 Profit Products A, B C & D US$/Kg Profit Product A US$/Kg / Column Minimum -$0.1944 Maximum $1.2512 Mean $0.5441 Std Dev $0.2233 Values 5000 Profit Product B US$/Kg / Column Minimum -$0.6366 Maximum $1.0344 Mean $0.2593 Std Dev $0.2276 Values 5000 Profit Product C US$/Kg / Column Minimum -$2.0249 Maximum $1.5637 Mean $0.1421 Std Dev $0.5091 Values 5000 Profit Product D US$/Kg / Column Minimum -$4.8411 Maximum -$0.3715 Mean -$2.3410 Std Dev $0.6569 Values 5000 Profit of Product A increases in this scenario A B D C 0.7% 94.3% 5.0% 13.2% 86.7% 0.1% 0.00 0.91 - 5 - 4 - 3 - 2 - 1 0 1 2
27. Product A has much higher gross profit than Product B Product D has negative gross profit Fixed Cost/Kg Gross Profit/Kg Product A $1.96 $0.54 Product B $2.52 $0.26 Product C $3.85 $0.14 Product D $6.34 -$2.34
28. Emphasizing sales of Product A has the best probability for higher profits Scenario 2 - A Scenario 2 - B % time devoted to C & D 48% 48% Production of C 0.7 MM kg/yr 0.7 MM kg/yr Total Plant Capacity 2.8 MM kg/yr 2.4 MM kg/yr Profitability 1.4 MM $/yr 0.7 MM $/yr Probability of Losses 1% 13%
29. 0.73 -0.51 0.34 0.22 0.13 0.10 0.07 0.06 0.06 -0.05 0.05 0.04 0.03 0.02 0.01 - 0 . 6 - 0 . 4 - 0 . 2 0 . 0 0 . 2 0 . 4 0 . 6 0 . 8 Coefficient Value Production of product D, Kg/mo Hours/day operating Production Rate of Product A, lines 1 and 2, kg/hr Var Margin Product D US$/kg Rate of Production product D, Kg/mo Selling & Admin costs Euros/month Var Margin Product C US$/kg Production of product C, Kg/mo Days of the week operating Operational Efficiency Projected fixed cost savings Euros/month Maximum Production Rate 4 lines running, kg/hr Var Margin Product A US$/kg Plant fixed cost Euros/month US Dollar/ Euro Exchange Rate Profitability, Product A Case US$/yr / Column Regression Coefficients Maximum Production Rate for the 4 lines is a critical factor for profitability of A
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36. 5.0% 90.0% 5.0% 100.0% 0.0% 0.0% 154.4 172.8 8 0 9 0 1 0 0 1 1 0 1 2 0 1 3 0 1 4 0 1 5 0 1 6 0 1 7 0 1 8 0 1 9 0 Values in Thousands 0 1 2 3 4 5 6 7 8 V a l u e s x 1 0 ^ - 5 Theoretical capacity Products A & B Kg/mo Theoretical capacity Product A Kg/mo / Column Minimum 143825.4377 Maximum 182165.7345 Mean 163603.8872 Std Dev 5589.9594 Values 5000 Theoretical capacity Product B kg/mo / Column Minimum 89846.9886 Maximum 157539.8296 Mean 126888.1712 Std Dev 10465.5035 Values 5000