OPERATION SCHEDULING

ACTIVITIES INVOLVES IN OPERATION SCHEDULING

1. ASSIGNING JOB ORDERS TO DIFFERENT M/C (OR WORK CENTRES). 2. SEQUENCING ON PRIORITIZATION DECIDING THE SEQENCE OF PROCESSING OF DIFFERENT MACHINES ON BASIS OF SOME PRIORITY RULE. 3. ROUTING PLANING ROUTE OF MOVEMENT OF MATERIAL FROM ONE DEPARTMENT TO ANOTHER DURING PROCESSING. 4. DISPATCHING ISSUING DISPATCH LIST TO VARIOUS WORK CENTRES (WC) CONTAINING INFORMATION ABOUT WCs A CUSTOMER ORDER SHOULD BE PROCESSED AT. THE CUSTOMER ORDER TO BE PROCESSED FIRST. AMOUNT OF TIME PROCESSING SHOULD TAKE. 5. EXPEDITING TRACKING THE PROGRESS OF SCHEDULED JOBS AND IMPLEMENTATION OF SCHEDULES, REVISING SCHEDULES IN CASE OF DELAY AND EXPEDITING COMPLETION OF CERTAIN JOBS.

PROBLEMS DUE TO ABSENCE OF PROPER SCHEDULING

DELAYS IN MEETING THE DUE DATES OF CUSTOMER ORDERS HIGH WORK IN PROCESS INVENTORY LOW UTILISATION OF WORKERS AND MACHINES (HIGH IDLE TIME) ABSENCE OF PROPER SCHEDULING

HIGH AVERAGE COMPLETION TIME OF JOBS

NO ACCURATE INFORMATION AVAILABLE OF THE CURRENT STATUS OF A JOB

HIGHER COST OF PRODUCTION / OPERATIONS

HIGHER SETUP TIME (OVERALL) OF MACHINES

SEQUENCING OR PRIORITIZATION
SCHEDULING

SEQUENCING n JOBS

SEQUENCING TWO JOBS ON m MACHINES IN DIFFERENT ORDERS (AKERS METHOD)

ASSIGNING n JOBS TO m M/C MMMMMM ON m MACHINES

ON ONE MACHINE

ON TWO MACHINES

ON THREE MACHINES

FIRST COME, FIRST SERVED (FCFS) METHOD

LAST COME, FIRST SERVED (LCFS) METHOD

IN THE SAME JOB SEQUENCE

ASSIGNMENT MODEL

DUE DATE METHOD

RANDOM METHOD

JOHNSONS METHOD

SHORTEST PROCESSING TIME (SPT) METHOD

JOHNSONS METHOD SEQUENCING n JOBS ON m MACHINES

JOHNSONS METHOD CAN ONLY BE APPLIED IN SEQUENCING n JOBS ON m MACHINES M1, M2, Mm IN THE ORDER M1, M2, Mm ONLY IF ANY ONE OR BOTH OF THESE CONDITIONS ARE FULLFILLED. THESE CONDITIONS ARE: 1. MINIMUM PROCESSING TIME ON M/C M1 MAXIMUM PROCESSING TIME ON M/C M2 , M3 , . M(m-1). 2. MINIMUM PROCESSING TIME ON M/C Mm MAXIMUM PROCESSIN TIME ON M/C M2 , M3 , . M(m-1).

SEQUENCING n JOBS ON THREE MACHINES

JOHNSONS METHOD CAN BE APPLIED IN PROBLEMS OF SEQUENCING n JOBS ON THREE MACHINES ONLY WHEN CERTAIN CONDITIONS ARE FULLFILLED. THESE CONDITIONS ARE. 1. MINIMUM PROCESSING TIME ON M/C MAXIMUM PROCESSING TIME ON M/C M2 . 2. MINIMUM PROCESSING TIME ON M/C MAXIMUM PROCESSIN TIME ON M/C M2 . M1 M3

IF ANY ONE OR BOTH OF THE ABOVE TWO CONDITIONS ARE SATISFIED, JOHNSONS METHOD CAN BE APPLIED.

ASSUMPTIONS :
TWO HYPOTHETICAL MACHINES X AND Y ARE CONSIDERED.

PROCESSING TIME OF VARIOUS JOBS ON MACHINE X IS THE SUM OF PROCESSING TIME OF CORRESPONDING JOBS ON MACHINES M1 , M2 , . M(m1).

SIMILARLY, PROCESSING TIME OF VARIOUS JOBS ON MACHINE Y IS THE SUM OF PROCESSING TIMES OF THE CORRESPONDING JOBS ON MACHINES M2 , M3 , . Mm.

PROBLEM : THERE ARE TEN JOBS TO BE PROCESSED THROUGH TWO MACHINES M1 AND M2 IN THE ORDER M1, M2. THE PROCESSSING TIME REQUIRED BY EACH JOB (IN HOURS) IS GIVEN IN THE TABLE BELOW. FIND THE OPTIMAL SEQUENCE FOR THE PERFORMANCE OF THESE JOBS IN THE MINIMUM POSSIBLE TIME. JOB A B C D E F G H I M1 2 5 1 6 2 3 5 1 6 M2 7 3 4 7 8 9 10 2 1

J SOLUTION :

SEQUENCING USING JOHNSONS METHOD : TABLE I JOB A B C D E F G H I J TABLE II JOB A B C D E F G H I J M1 2 5 1 6 2 3 5 1 6 8 M2 7 3 4 7 8 9 10 2 1 5 M1 2 5 1 6 2 3 5 1 6 8 M2 7 3 4 7 8 9 10 2 1 5

TABLE III JOB A B C D E F G H I J M1 2 5 1 6 2 3 5 1 6 8 M2 7 3 4 7 8 9 10 2 1 5

TABLE IV JOB A B C D E F G H I J M1 2 5 1 6 2 3 5 1 6 8 M2 7 3 4 7 8 9 10 2 1 5

TABLE V JOB A B C D E F G H I J M1 2 5 1 6 2 3 5 1 6 8 M2 7 3 4 7 8 9 10 2 1 5

OPTIMAL SEQUENCE I H C A E F G D J B I

OPTIMAL SEQUENCE II C H E A F G D J B I

OPTIMAL SEQUENCE III H C E A F G D J B I

OPTIMAL SEQUENCE IV C H A E F G D J B I

TABLE VI JOB H C A E F G D J B I MACHINE 1 IN OUT 0 1 1 2 2 4 4 6 6 9 9 14 14 20 20 28 28 33 33 39 MACHINE 2 IN OUT 1 3 3 7 7 14 14 22 22 31 31 41 41 48 48 53 53 56 56 57 WAITING TIME OF JOBS 0 (3-2)=1 (7-4)=3 (14-6)=8 (22-9)=13 (31-14)=17 (41-20)=21 (48-28)=20 (53-33)=20 (56-39)=17

IDEAL TIME OF MACHINES MACHINE 1 MACHINE 2 = = (57 39) = (1 0) = 18 1

PROBLEM :
THE FOLLOWING TABLE GIVES THE PROCESSING TIMES (IN HOURS) OF SEVEN JOBS TO BE PROCESSED ON THREE MACHINES M1, M2, M3. SEQUENCE THESE JOBS USING JOHNSONS METHOD AND FIND THE OVERALL PROCESSING TIME. FIND ALSO THE WAITING TIMES OF THE JOBS AND THE IDLE TIMES OF THE THREE MACHINES.

JOB A B C D E F G

M1 1 3 7 9 4 5 2

M2 7 3 8 2 8 6 1

M3 8 10 9 11 9 14 12

SEQUENCING USING JOHHSONS METHOD (n JOBS ON 3 MACHINES)

TABLE - I

JOB A B C D E F G

M1 1 3 7 9 4 5 2

M2 7 3 8 2 8 6 1

M3 8 10 9 11 9 14 12

MIN OF M1 = MAX OF M2 = MIN OF M3 =

1 8 8

THUS, MAX OF M2 = MIN OF M3. THEREFORE, THE METHOD CAN BE APPLIED.

TABLE II

JOB A B C D E F G
TABLE III

X 8 6 15 11 12 11 3

Y 15 13 17 13 17 20 13

JOB A B C D E F G

X 8 6 15 11 12 11 3

Y 15 13 17 13 17 20 13

TABLE - IV

JOB A B C D E F G
TABLE - V

X 8 6 15 11 12 11 3

Y 15 13 17 13 17 20 13

JOB A B C D E F G
TABLE - VI

X 8 6 15 11 12 11 3

Y 15 13 17 13 17 20 13

JOB A B C D E F G

X 8 6 15 11 12 11 3

Y 15 13 17 13 17 20 13

OPTIMAL SEQUENCE I G B A D F E C

OPTIMAL SEQUENCE II G B A F D E C

TABLE VII JOB G B A D F E C MACHINE I MACHINE II MACHINE III WAITING TIME OF JOB IN OUT IN OUT IN OUT 0 2 2 3 3 15 0 2 5 5 8 15 25 (15-8)=7 5 6 8 15 25 33 (8-6)+(25-15)=12 6 15 15 17 33 44 (33-17)=16 15 20 20 26 44 58 (44-26)=18 20 24 26 34 58 67 (26-24)+(58-34)=26 24 31 34 42 67 76 (34-31)+(67-42)=28

IDEAL TIME OF MACHINES MACHINE I MACHINE II MACHINE III = = = (76-31) (2-0)+(5-3)+(20-17)+(76-42) (3-0) = = 45 41 =

PROBLEM :
THE FOLLOWING TABLE GIVES THE PROCESSING TIMES (IN HOURS) OF SEVEN JOBS TO BE PROCESSED ON FOUR MACHINES M1, M2, M3 AND M4 IN THE ORDER M1, M2, M3, M4. SEQUENCE THE GIVEN JOBS USING JOHNSONS METHOD AND FIND THE OVERALL PROCESSING TIME.

JOB A B C D E F G

M1 3 8 11 4 5 10 2

M2 1 0 3 7 5 2 5

M3 4 5 8 3 1 0 6

M4 12 15 10 8 10 13 9

SOLUTION :
SEQUENCING USING JOHHSONS METHOD (n JOBS ON m MACHINES)
TABLE I

JOB A B C D E F

M1 3 8 11 4 5 10

M2 1 0 3 7 5 2

M3 4 5 8 3 1 0

M4 12 15 10 8 10 13

G
TABLE II

JOB A B C D E F G
TABLE III

X 8 13 22 14 11 12 13

Y 17 20 21 18 16 15 20

JOB A B C D E F G
TABLE IV

X 8 13 22 14 11 12 13

Y 17 20 21 18 16 15 20

JOB A B C D E F

X 8 13 22 14 11 12

Y 17 20 21 18 16 15

G
TABLE V

13

20

JOB A B C D E F G
TABLE VI

X 8 13 22 14 11 12 13

Y 17 20 21 18 16 15 20

JOB A B C D E F G

X 8 13 22 14 11 12 13
= = = = 2 7 8 8

Y 17 20 21 18 16 15 20

MIN. OF M1 MAX. OF M2 MAX. OF M3 MIN. OF M4 THUS,

MIN. OF M4 = MAX. OF M3 AND MIN. OF M4 > MAX. OF M2.

THEREFORE, THE METHOD CAN BE APPLIED.

OPTIMAL SEQUENCE I A E F B G D C

OPTIMAL SEQUENCE II A TABLE VII MACHINE I MACHINE II MACHINE III MACHINE IV IN OUT IN OUT IN OUT IN OUT 0 3 3 4 4 8 8 20 3 8 8 13 13 14 20 30 8 18 18 20 20 20 30 43 18 26 26 26 26 31 43 58 26 28 28 33 33 39 58 67 28 32 33 40 40 43 67 75 32 43 43 46 46 54 75 85 E F G B D C

JOB A E F B G D C

THE ASSIGNMENT MODEL FOR SCHEDULING

PROBLEM :
IN THE MACHINE SHOP OF XML MOTORS LTD, THERE ARE FIVE JOBS (J1 J5) TO BE ASSIGNED TO FIVE LATHE MACHINES A, B, C, D AND E. THE PROCESSING TIMES (IN MINUTES) OF VARIOUS JOBS ON THE MACHINES, FROM PAST EXPERIENCE, ARE GIVEN IN THE TABLE GIVEN BELOW. JOB J5 CANNOT BE ASSIGNED TO MACHINE E, AS THIS MACHINE DOES NOT HAVE PROPER AUTOMATION TO HANDLE THIS JOB. ASSIGN THE JOBS TO THE MACHINES SUCH THAT THE TOTAL PROCESSING TIME IS MINIMUM. FIND ALSO THE MINIMUM TOTAL PROCESSING TIME OF THE JOBS. TABLE J1 J2 J3 J4 J5 A 74 52 59 22 29 B 34 67 73 50 93 C 15 92 87 28 82 D 66 84 70 37 55 E 38 41 18 24 M

SOLUTION :
THE ASSIGNMENT HEURISTIC CAN BE APPLIED IN THE FOLLOWING STEPS.

JOBS

J1 J2 J3 J4 J5

MACHINES A B 74 34 52 67 59 73 22 50 29 93

C 15 92 87 28 82

D 66 84 70 37 55

E 38 41 18 24 M

STEP 1 FIND THE SMALLEST VALUE IN EVERY ROW AND SUBTRACT IT FROM EACH CELL VALUE IN THE CORRESPONDING ROW AS SHOWN IN THE FOLLOWING TABLE. FOR EXAMPLE, IN THE FIRST ROW THE SMALLEST VALUE IS 15; SUBTRACT 15 FROM EACH CELL VALUE OF THE FIRST ROW. THUS THE REVISED TABLE IS OBTAINED. MACHINES A B 59 19 11 26 41 55 0 28 0 64

JOBS

J1 J2 J3 J4 J5

C 0 51 69 6 53

D 51 43 52 15 26

E 23 0 0 2 M

STEP 2 FIND THE SMALLEST VALUE IN EVERY COLUMN AND SUBTRACT IT FROM EACH CELL VALUE IN THE CORRESPONDING COLUMN. FOR EXAMPLE, IN THE FIRST COLUMN THE SMALLEST VALUE IS 0; SUBTRACT 0 FROM EACH VALUE OF THE FIRST COLUMN. THUS THE REVISED TABLE IS OBTAINED. MACHINES A B 59 0 11 7 41 36 0 9 0 45

JOBS

J1 J2 J3 J4 J5

C 0 51 69 6 53

D 36 28 37 0 11

E 23 0 0 2 M

STEP 3 MAKE HORIZONTAL AND VERTICAL LINES TO COVER ALL THE ZEROS IN THE TABLE (SHOWN BY GREY SHADED RECTANGLES IN THE FOLLOWING TABLE). THE LINES DRAWN CAN BE ALL HORIZONTAL, ALL VERTICAL,

OR A COMBINATION OF VERITICAL AND HORIZONTAL LINES. IF THE NUMBER OF LINES REQUIRED TO COVER ALL THE ZEROS IN THE TABLE IS EQUAL TO THE NUMBER OF MACHINES (AS THE NUMBER OF JOBS, AS BOTH EQUAL), THE OPTIMAL SOLUTION IS OBTAINED AND WE CAN SKIP STEP 4 AND DIRECTLY GO TO STEP 5. IN OUR EXAMPLE, THE NUMBER OF LINES REQUIRED TO COVER ALL ZEROS IS FOUR i.e., LESS THAN THE NUMBER OF MACHINES, THEREFORE, WE FOLLOW STEP 4. MACHINES A B 59 0 11 7 41 36 0 9 0 45

JOBS

J1 J2 J3 J4 J5

C 0 51 69 6 53

D 36 28 37 0 11

E 23 0 0 2 M

STEP 4 SELECT THE SMALLEST VALUE OUT OF THOSE NOT COVERED BY ANY OF THE LINES. IN OUR EXAMPLE, IT IS 7. SUBTRACT THIS VALUE FROM ALL THE VALUES NOT COVERED BY ANY OF THE LINES (i.e., 7, 51, 28, 36, 69, 37, 45, 53 AND 11) AND ADD IT TO THOSE AT THE INTERSECTION OF ANY TWO LINES (i.e., 59, 23, 0 AND 2). AGAIN MAKE HORIZONTAL AND VERTICAL LINES TO COVER ALL THE ZEROS IN THE TABLE. IF THE NUMBER OF LINES REQUIRED TO COVER ALL THE ZEROS IN THE

TABLE IS EQUAL TO THE NUMBER OF MACHINES (OR THE NUMBER OF JOBS), THE OPTIMAL SOLUTION IS OBTAINED. MACHINES A B 66 0 11 0 41 29 7 9 0 38

JOBS

J1 J2 J3 J4 J5

C 0 44 62 6 46

D 36 21 30 0 4

E 30 0 0 9 M

STEP 5 A SINGLE ZERO IN ANY ROW OR COLUMN IS ASSIGNED FIRST. FOR EXAMPLE, THE FIFTH ROW CONTAINS A SINGLE ZERO, WHICH IS ASSIGNED, i.e., JOB J5 HAS BEEN ASSIGNED TO MACHINE A. SIMILARLY J3 AND J4 ARE ASSIGNED TO E AND D RESPECTIVELY. THE FIRST ROW CONTAINS TWO ZEROS THEN WE WILL CHECK FOR COLUMNS WHICH CONTAINS SINGLE ZERO AND HENCE J1 IS ASSIGNED TO C. NOW SHADE THE OTHER ZERO IN THE FIRST ROW WITH DARK GREY, NOW EXCLUDING THIS ONE SINGLE ZERO IN SECOND COLUMN AND IT IS ASSIGNED AND HENCE J2 TO B. SHADE THE OTHER ZERO IN SECOND ROW DARK GREY. HENCE, ALL THE JOBS HAVE BEEN ASSIGNED TO THE GIVEN MACHINES, J1 TO C, J2 TO B, J3 TO E, J4 TO D AND J5 TO A. THUS, THE MINIMUM TOTAL PROCESSING TIME IS 15 + 67+ 18 + 37 + 29 = 166 MIN.

JOBS

J1 J2 J3 J4 J5

MACHINES A B 66 0 11 0 41 29 7 9 0 38

C 0 44 62 6 46

D 36 21 30 0 4

E 30 0 0 9 M

LINEAR PROGRAMMING I FORMULATION AND GRAPHIC SOLUTION

LINEAR PROGRAMMING

TECHNIQUE CHOOSING THE BEST ALTERNATIVE FROM A SET OF FEASIBLE ALTERNATIVES. AS LINEAR

CONSTRAINTS CAN BE EXPRESSED MATHEMATICAL FUNCTIONS.

THE REQUIREMENTS FOR FORMULATION ARE :

OBJECTIVE SHOULD BE CLEARLY IDENTIFIABLE AND MEASURABLE IN QUANTITATIVE TERMS. FOR EX. MAXIMISATION OF SALES, OF PROFIT, MINIMISATION OF COST AND SO ON.

ACTIVITIES TO BE DISTINCTLY IDENTIFIABLE AND MEASURABLE IN QUANTITATIVE TERMS. FOR INSTANCE, THE PRODUCTS INCLUDED IN A PRODUCTION PLANNING PROBLEM. GOAL SHOULD BE IDENTIFIABLE AND MEASURABLE QUANTITATIVELY. RELATIONSHIPS REPRESENTING THE OBJECTIVE AS ALSO THE RESOURCE LIMITATION CONSIDERATIONS, REPRESENTED BY THE OBJECTIVE FUNCTION AND THE CONSTRAINT FUNCTION AND THE CONSTRAINT EQUATIONS OR INEQUALITIES, RESPECTIVELY MUST BE LINEAR IN NATURE. THERE SHOULD BE SERIES OF ALTERNATIVE COURSES OF ACTION AVAILABLE TO THE DECISION MAKER. WHEN THESE CONDITIONS ARE FULLFILLED, THE PROBLEM CAN BE EXPRESSED IN ALGEBRAIC FORM, CALLED THE LINEAR PROGRAMMING PROBLEM (LPP) AND THEN SOLVED FOR OPTIMAL DECISION.

FORMULATION OF LINEAR PROGRAMMING PROBLEMS 1. THE MAXIMISATION CASE

EXAMPLE : A FIRM IS ENGAGED IN PRODUCIN TWO PRODUCTS, A AND B. EACH UNIT OF PRODUCT A REQUIRES 2 KG OF RAW MATERIAL AND 4 LABOUR HOURS FOR PROCESSING, WHEREAS EACH UNIT OF PRODUCT B REQUIRES 3 KG OF RAW MATERIAL AND 3 HOURS OF LABOUR, OF THE SAME TYPE. EVERY WEEK, THE FIRM HAS AN AVAILABILITY OF 60 KG OF RAW MATERIAL AND 96 LABOUR HOURS. ONE UNIT OF PRODUCT A SOLD YIELDS Rs.40 AND ONE UNIT OF PRODUCT B SOLD GIVES Rs.35 AS PROFIT. FORMULATE THIS PROBLEM AS A LINEAR PROGRAMMING PROBLEM ; ALSO DETERMINE AS TO HOW MANY UNITS OF EACH OF THE PRODUCTS SHOULD

BE PRODUCED PER WEEK SO THAT THE FIRM CAN EARN MAXIMUM PROFIT. ASSUME THAT THERE IS NO MAEKETING CONSTRAINT SO THAT ALL THAT IS PRODUCED CAN BE SOLD. THE OBJECTIVE FUNCITON : IDENTIFY THE GOAL IN TERMS OF THE OBJECTIVE FUNCTION. GOAL IS THE MAXIMISATION OF PROFIT, OBTAINED BY PRODUCING AND SELLING PRODUCTS A AND B. x1 AND x2 REPRESENT THE NUMBER OF UNITS PRODUCED PER WEEK OF THE PRODUCTS OF A AND B RESPECTIVELY. TOTAL PROFIT, Z = 40x1 + 35x2, AS THE UNIT PROFIT ON THE TWO PRODUCTS IS Rs.40 AND Rs.35 RESPECTIVELY. THE CONSTRAINTS : RESOURCES MUST BE IN LIMITED SUPPLY.

MATEMATICAL RELATIONSHIP USED TO EXPLAIN THIS LIMITATION IS INEQUALITY. THIS LIMITATION ITSELF IS KNOWN AS CONSTRAINT. AS A REQUIRES 2 Kg AND B REQUIRES 3 Kg OF RAW MATERIALS, THE TOTAL CONSUMPTION WOULD BE 2x1 + 3x2 WHICH CANNOT EXCEED THE TOTAL AVAILABILITY OF 60 Kg EVERY WEEK. WE CAN EXPLAIN THIS CONSTRAINT AS 2x1 + 3x2 60. SIMILARLY ONE UNIT OF A AND B REQUIRES 4 AND 3 LABOUR HOURS FOR PRODUCTION RESPECTIVELY. WITH THE AVAILABILITY OF 96 HOURS A WEEK, WE HAVE 4x1 + 3x2 96 AS THE LABOUR HOURS CONSTRAINT.

NON LINEARITY CONDITION : QUITE OBVIOUSLY, x1 AND x2, BEING THE NUMBER OF UNITS PRODUCED, CANNOT HAVE NEGATIVE VALUES. THUS, BOTH OF THEM CAN ASSUME VALUES ONLY GREATER THAN OR EQUAL TO ZERO. THIS IS NONNEGATIVITY CONDITION. THIS CAN SYMBOLICALLY EXPRESSED AS x1 0 AND x2 0. NOW WE CAN WRITE THE PROBLEM AS FOLLOWS : MAXIMISE Z = 40x1 + 35x2 PROFIT SUBJECT TO 2x1 + 3x2 60 4x1 + 3x2 96 x2, x2 0 RAW MATERIAL CONSTRAINT LABOUR HOURS CONSTRAINT NON-NEGATIVITY RESTRICTION

2. THE MINIMISATION CASE :

EXAMPLE : THE AGRICULURAL RESEARCH INSTITUTE SUGGESTED TO A FARMER TO SPREAD OUT AT LEAST 4800 Kg OF A SPECIAL PHOSPHATE FERTILISER AND NOT LESS THAN 7200 Kg OF A SPECIAL NITROGEN FERTILISER TO RAISE PRODUCTIVITY OF CROPS IN HIS FIELDS. THERE ARE TWO SOURCES FOR OBTAINING THESE MIXTURES A AND B. BOTH OF THESE ARE AVAILABLE IN BAGS WEIGHING 100 Kg EACH AND THEY COST Rs.40 AND Rs.24 RESPECTIVELY. MIXTURE A CONTAINS PHOSPHATE AND NITROGEN EQUUIVALENT OF 20 Kg AND 80 Kg RESPECTIVELY, WHILE MIXTURE B CONTAINS THESE INGREDIENTS EQUIVALENT OF 50 Kg EACH.

WRITE THIS AS A LINEAR PROGRAMMING PROBLEM AND DETERMINE HOW MANY BAGS OF EACH TYPE SHOULD THE FARMER BUY IN ORDER TO OBTAIN THE REQUIRED FERTILISER AT MINIMUM COST. THE OBJECTIVE FUNCTION : IF x2 AND x2 ARE TAKEN TO REPRESENT THE NUMBER OF BAGS OF MIXTURES A AND B RESPECTIVELY, THE OBJECTIVE FUNCTION CAN BE EXPRESSED AS FOLLOWS :

MINIMISE

Z = 40x1 + 24x2

COST

CONSTRAINTS : IN THIS PROBLEM THERE ARE TWO CONSTRAINTS, NAMELY, A MINIMUM OF 4800 Kg OF PHOSPHATE AND 7200 Kg OF NITROGEN INGREDIENTS ARE REQUIRED. IT IS KNOWN THAT EACH BAG OF MIXTURE A CONTAINS 20 Kg OF EACH BAG OF MIXTURE B CONTAINS 50 Kg OF PHOSPHATE. THE PHOSPHATE REQUIREMENT CAN BE EXPRESED AS 20x1 + 50x2 4800. SIMILARLY THE NITROGEN REUIREMENT WOULD BE 80x1 + 50x2 7200. NON NEGATIVE CONDITION : AS BEFORE, IT LAYS THAT THE DECISION VARIABLES, REPRESENTING THE NUMBER OF BAGS OF

MIXTURES A AND B, WOULD BE NON-NEGATIVE. THUS, x1 0 AND x2 0. THE LINEAR PROGRAMMING PROBLEM CAN NOW BE EXPRESSED AS FOLLOWS : MINIMISE Z = 40x1 + 24x2 SUBJECT TO 20x1 + 50x2 4800 80x1 + 50x2 7200 x2, x2 0 PHOSPHATE REQUIREMENT NITROGEN REQUIREMENT NON-NEGATIVITY RESTRICTION COST

THE SOLUTION TO LINEAR PROGRAMMING PROBLEMS

GRAPHIC METHOD : TO USE THE GRAPHIC METHOD FOR SOLVING LINEAR PROGRAMMING PROBLEMS, THE FOLLOWING STEPS ARE REQUIRED : IDENTIFY THE PROBLEMS THE DECISION VARIABLES, THE OBJECTIVE FUNCTION AND THE CONSTRAINT RESTRICTIONS. DRAW A GRAPH THAT INCLUDES ALL THE CONSTRAINTS / RESTRICTIONS AND IDENTIFY THE FEASIBLE REGION.

 OBTAIN THE POINT ON THE FEASIBLE REGION THAT OPTIMISES THE OBJECTIVE FUNCTION THE OPTIMAL SOLUTION. INTERPRET THE RESULTS. THE MAXIMISATION CASE : WE CONSIDER THE SAME EXAMPLE AGAIN. FOR THIS PROBLEM, THE DECISION VARIABLES ARE x2 AND x2, THE NUMBER OF UNITS OF THE PRODUCTS A AND B RESPECTIVELY. THE OBJECTIVE FUNCTION AND THE CONSTRAINTS ARE REPRODUCED AS MAXIMISE Z = 40x1 + 35x2 PROFIT SUBJECT TO OF 30 2x1 + 3x2 60 4x1 + 3x2 96 UNIT 28 x2, x2 0 OF 26
PRO 24 DUCT 22 B 20 18 16 14
12 10 8 6 4 2

No

32

RAW MATERIAL CONSTRAINT LABOUR HOURS CONSTRAINT

GRAPHIC PLOT OF CONSTRAINTS x2

LABOUR HOURS CONSTRAINT

10

12 14

16

18 20

22

24

No. OF UNITS OF PRODUCT A

RAW MATERIALS CONSTRAINT x1

26

28 30

32

No OF

32 30

UNIT 28 OF PRO DUCT B 26 24

DETERMINATION OF OPTIMAL SOLUTION USING ISO PROFIT LINE 22 x2

20 18 16 14
12 10 8 6 4 2

LABOUR HOURS CONSTRAINT

ISO-PROFIT LINES 2ISO4PROFIT 10 12 14 16 18 20 22 24 26 28 30 32 6 FEASIBLE 8 RAW REGION LINE PROFIT = MATERIALS No. OF UNITS OF PRODUCT A Rs.280 CONSTRAINT x1

THE MINIMISATION CASE : WE SHALL CONSIDER THE GRAPHICAL SOLUTION OF TO THEIR LINEAR PROGRAMMING PROBLEMS OF THE MINIMISATION NATURE. THE SAME EXAMPLE IS BAGS 168 RECONSIDERED.
OF 156 MIX 144 No

MINIMISE TURE 132

A 120

Z = 40x1 + 24x2

COST PHOSPHATE REQUIREMENT NITROGEN REQUIREMENT

SUBJECT TO 108 20x1 + 50x2 4800 80x1 + 50x2 7200 96 x2, x2 0

84
72 60 48 36 24 12

GRAPHIC SOLUTION TO THE LPP x2

FEASIBLE REGION
NITROGEN RAW REQUIREMENT MATERIALS CONSTRAINT

ISOCOST LINE

20

40

60 80 100 120 140 160 180 200 220 240 260 280 300 No. OF BAGS OF MIXTURE A

CASE STUDY :
AN ELECTRONIC GOODS COMPANY HAS DISTRIBUTORS WHO WILL ACCEPT SHIPMENTS OF TRANSISTORS, RADIOS OR ELECTRONIC CALCULATORS TO STOCK FOR DIWALI INVENTORY. WHEREAS THE RADIOS CONTRIBUTE Rs.10 PER UNIT AND CALCULATORS Rs.15 PER UNIT OF PROFIT. EACH RADIO REQUIRES FOUR DIODES AND FOUR RESITORS, WHILE EACH CALCULATOR REUIRES TEN DIODES AND TWO RESISTORS. THE RADIO TAKES 12 MINUTES AND CALCULATORS TAKE 9.6 MINUTES ON THE COMPANYS ELECTRONIC TESTING MACHINE.

REQUIREMEN T PHOSPHATE

x1

THE PRODUCTION MANAGER ESTIMATES THAT 160 HOURS OF THE TEST TIME ARE AVAILABLE. THE FIRM HAS 8000 DIODES AND 3000 RESISTORS IN THE INVENTORY. DETERMINE THROUGH GRAPHICAL SOLUTION OF LINEAR PROGRAMMING, THE PRODUCT MIX TO MAXIMISE PROFIT. FORMULATE THE OBJECTIVE AND CONSTRAINT FUNCTIONS AND NON-NEGATIVITY RELATIONSHIP.

(A)

(B) DRAW THE GRAPH AND INDICATE THE FEASIBLE REGION AND FEASIBLE POINT SOLUTION. (C) DETERMINE THE OPTIMUM MIX AND PROFIT. (D) SUMMARISE THE GRAPHICAL SOLUTION PROCEDURE FOR MAXIMISATION PROBLEMS AND EXPLAIN THE MEANING OF ISO-PROFIT LINES.

SOLUTION : DECISION VARIABLES x1 AND x2 REPRESENTS THE NUMBER OF UNITS CONTRIBUTED PER UNIT OF THE PRODUCTS A (RADIO) AND B (CALCULATOR). THE OBJECTIVE FUNCTION THE TOTAL PROFIT

Z = 10x1 + 15x2 GOAL MAXIMISATION OF PROFIT CONSTRAINTS 4x1 + 10x2 8000 4x1 + 2x2 3000 DIODE CONSTRAINT RESISTOR CONSTRAINT

12x1 + 9.6x2 9600TIME CONSTRAINT x1, x2 0 NON-NEGATIVE RESTRICTION

1600 x1 1500 1400 No. OF 1300 UNITS 1200 1100 OF 1000 CALCULATOR 900 800 700 600 500 400 300 200 100 0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 No. OF UNITS OF RADIO

FEASIBLE REGION

x2

1600 1500 1400 No. OF 1300 UNITS 1200 1100 OF 1000 CALCULATOR 900 800 700 600 500 400 300 200 100 0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 No. OF UNITS OF RADIO

FEASIBLE REGION

x2