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International Journal of Industrial

EngineeringOF
Research
and DevelopmentENGINEERING
(IJIERD), ISSN 0976 –
INTERNATIONAL
JOURNAL
INDUSTRIAL
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME
RESEARCH AND DEVELOPMENT (IJIERD)

ISSN 0976 – 6979 (Print)
ISSN 0976 – 6987 (Online)
Volume 3, Issue 1, January- June (2012), pp. 74-91
© IAEME: www.iaeme.com/ijierd.html
Journal Impact Factor (2011): 0.8927 (Calculated by GISI)
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IJIERD
©IAEME

OPTIMIZING THE UNEVENNESS IN PRODUCTION SCHEDULING
THROUGH MATHEMATICAL APPROACH: A CASE STUDY
S. K. Gupta1, Dr. V. K. Mahna2, Dr. R. V. Singh3, Rajender Kumar4
1

Research Scholar & Associate Professor, Department of Mechanical Engineering, FET, MRIU,
Faridabad, India-121003
2
Executive Director & Dean Academics, FET, MRIU, Faridabad, India-121003
3
Professor & Head, Department of Mechanical Engineering, FET, MRIU, Faridabad, India-121003
4
Asst. Prof., Department of Mechanical Engineering, FET, MRIU, Faridabad, India-121003
E-Mail: gupta.sarojkumar@gmail.com, rajender629@yahoo.com

ABSTRACT
World over manufacturing has received a great deal of attention in the recent few years for
efficient utilization of resources, because of the market becoming customer oriented. There is
still no consensus on how best to measure and manage production within manufacturing
industries as there are numerous variables which change from industry to industry. In real world,
the global competition is forcing entrepreneur’s to cut corners on customer deliveries and input
production cost. Under the circumstances production scheduling is an important matter
especially in the organizations wherein the product consists of no. of models of the same
product. This case reveals that the production is either in the form of overproduction or
underproduction as and when compared with planned production. The situation of
underproduction isn’t that serious as is the case of overproduction since overproduction is
generation of unnecessary inventories either in the form of WIP or finished goods. Therefore,
this is nothing except generating a form of waste which is fundamentally against the principles of
Lean Manufacturing. The situation of unnecessary and undesirable inventories results in lockup
of funds, which could be otherwise utilized effectively. Mathematical modeling may be an
answer to remove such waviness and unbalances through application of averages, variance and
deviation. The study was conducted and data collected for the purpose of optimization in XYZ
Company manufacturing Shock Absorbers with 203 different varieties catering to need of OE
suppliers and replacement market. The most advantageous manufacturing priorities for a given
competitive situation are also discussed in this paper.
Keywords: Quality, Overproduction, Underproduction, Lean Manufacturing, Inventory.

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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME

1.0 INTRODUCTION
Over the last two decades there has been enormous increase not only in demand but also in
production supply of variety of products. In most of the manufacturing industries, the main issue
of productivity is production planning. The materials play an important role so far as its
contribution towards the product and also the cost are concerned. Therefore, a systematic control
is essential so far as materials are concerned to avoid obsolescence, unnecessary storage and
material handling including the delayed deliveries. Figure 1 shows the various inputs to
production to make the system efficient and effective.

Figure 1 Resources that must be managed effectively
Twenty keys are discussed for workplace improvement in manufacturing industry as shown in
Figure 2 [8]. These keys must be considered in order to achieve continuous improvement. These
20 keys are arranged in a circle that shows the relations between the keys and their influence on
the three main factors: quality, cost, and lead time. The arrangement in the circle is not
categorical, and some keys offer benefits in more than one factor. There are four keys outside the
circle. Three of them (keys 1, 2, and 3) must be implemented before the rest, and key 20 is the
result of implementing the other 19 keys.

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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME

Figure 2 Twenty keys for workplace improvement
The lack of planning generates imbalance in the planned targets and subsequently deliveries. As
a result of this, the customer demand gets nullified resulting into loss of revenues. The uncertain
production plan and scheduling also leads to very heavy inventory of raw materials, WIP and
undesired movements of materials. This leads to unnecessary breakup of lots considered for
manufacturing. The result is loss of man-hours, machine-hours, material input and also increase
in the input cost. All these are a type of waste which does not add any value. "A more liberal and
extensive reciprocity in the production and sale of commodities is necessary, so that the
overproduction of the organizations can be satisfactorily disposed off to the market.”
The problem of unevenness in planning and scheduling can be addressed through process of
categorization of the demand factors pertaining to various models. This categorization shall
provide a whip to the planning and scheduling department to keep a close watch and amend the
actions where-so-ever required. Once, the objective of smoothening the production is achieved
80-85% then it becomes easy to meet the market requirements. This paper addressed the data
bifurcation in which the products are refers to three main categories such as Production at par,
overproduction, underproduction. This paper presents mathematical optimization with
application of methodology for finding Co-efficient of variation [5].

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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME

2.0 LITERATURE REVIEW
Data filtering has become a key technology for modern production control systems. The goal of
data bifurcation or filtration is a route to the right decision of controlling and optimizing the
production. In order to deal with high variety of products, a very small variety of products
requires the attention for getting the maximum efficiency. The VED technique is the best
adopted as a routine practice for optimal use of resources and elimination of out of stock
situations in the production house. The VED analysis will facilitate planning department to
engage entire energy to limited area only leading to reducing overproduction to bare minimum
including best utilization of funds [2,11].
Optimization is about utilizing the resources in organized manner to achieve higher efficiency.
Optimization is thus, about achieving high utilization, high efficiency and high effectiveness at
bare minimum cost [4]. Mathematical Optimization refers to the selection of a best element
(with regard to some criteria) from some set of available alternatives. In the simplest case, an
optimization problem consists of maximizing or minimizing a real function by systematically
choosing input values from within an allowed set and computing the value of the function. The
generalization of optimization theory and techniques to other formulations comprises a large area
of applied mathematics. More generally, optimization includes finding "best available" values of
some objective function given a defined domain, including a variety of different types of
objective functions and different types of domains.
3.0 CASE STUDY
A study was undertaken in a company manufacturing shock absorbers and having a wide variety
of the product numbering 203. The period of this study was based on a data spread over the
period of last six month as per Annexure 1. Table 1 shows the performance of actual production
as compared with planned production targets. This variation has been graphically represented
through Bar Chart as given in Figure 3.
Table 1 Gross average monthly production

Months
Jan’12
Feb'12
March'12
April'12
May'12
June'12
Average

Planned Production
222521
250428
266333
248845
186317
176038
225080

77

Actual Production
151431
156504
152994
209559
149798
150009
161716

International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME

Variation in Actual & Planned
Production

Production Quantity

300000
250000
200000

Series1
Series2

150000

Series3

100000

Series4

50000

Ja
n’
12
Fe
b'
12
M
ar
ch
'1
2
Ap
ril
'1
2
M
ay
'1
2
Ju
ne
'1
2

0

Months Detail

Figure 3 Gross average monthly productions
3.1 Inferences
On analysis of data given in Annexure 1, it was found that on an average 13 % production was
inline with the plans ac in Annexure 2, 20% of the production on an average was overproduced
i.e. over and above the planned production as in Annexure 3, and in balance cases it was
observed that 67% of the production was in the category of underproduction as compared to
palmed production as in Annexure 4. The process of straightening the plans is a quite heavy task
therefore, the principles of VED analysis was followed for purpose of categorization so that
effective controls could be introduced. Table 2 shows the VED analysis of over production,
under production and production at par. The categorization establishes that production at par is
the lowest followed by overproduction and further followed by under production.
Table 2 Actual Performance
Production Data

Actual Model
Contribution
13%
20%
67%
100%

Production at Par
Over Production
Under Production
Total
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME

Model Contribution

Production at
Par, 13%
Over
Production,
20%

Production at Par
Over Production
Under Production

Under
Production,
67%

Figure 4 Pie chart for category bifurcation
The production data reveals over planning as compared to manufacturing capacity. This variation
is almost to the tune of 28% as given in the Figure 3. This over planning will result in
unnecessary pressure on material planning, unnecessary occupancy of space, lockup of funds,
obsolescence in spoilage of materials and frequent movement of the stocks. Table 3 provides
comparative analysis of underproduction; overproduction and production at par in terms of no. of
product produced in six months and the contribution of each category so-far-as volumes
manufactured are concerned.
Table 3 Comparative Analysis on Production Data
Production Detail
Production at Par
Over Production
Under Production
Total

Production Quantity
17268
353971
608547
979786

Percentage Contribution
02%
36%
62%
100%

It is concluded from Table 3 above that the Production Planning and Control Department of said
company is working with no exposure to the technological advancements. It is evident that the

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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME

production data doesn’t match with the planned production. In most of the categories, it is
underproduction followed with overproduction and further very small percentage matching with
the planned data.
The data was further analyzed and it was observed that there is a huge variation from the
standard deviation. This was further normalized with the help of mathematical modeling and the
details are as per enclosed table. This normalized solution can remove the waviness to a great
extent by introducing controls on categorized items only. Table 4 gives details regarding
category-wise breakup of VED analysis. This table establishes that a mere control of 35 items
out of 203 items (17%) will help in eliminating the imbalances in the production and improving
the overall performance.
Table 4 Results Summary Sheet
Sr.
No.

Items for Control
Description

Total No. of Items

Category Bifurcation
V

E

D

Total

1

Under Production

135

23

(17%)

4

7

12

23

2

Over Production

41

12

(30%)

3

4

5

12

3

Balanced

27

0

0

0

0

0

Total

203

35

7

11

17

35

Table 5 is based on optimized data including the percentage smoothness of both categories i.e.
over production and under production. The category of overproduction being serious in nature
has been smoothened to an extant of 92% with control on 12 items (0.6% of total varieties).
Table 5 Optimization Results
Production
Detail
Over
Production
Under
Production
Total

Total Produced Quantity
No. of
Quantity
Products
41
353971

Optimized Quantity
No. of
Quantity
Products
12
326937

Percentage
Contribution
92%

135

608547

23

277961

28%

176

962518

35

704898

73%

4.0 CONCLUSION
In this competitive globalization, almost all the manufacturing organizations realize the value of
on time delivery of their products to market or stockholders. The amount of product varieties was
found under production to be tune of 67%, over production 20% and remaining 13% production
just matching with the actual plans giving rise to huge build up of inventories all around. This
also results in non compliance of deliveries and thereby an unsatisfied customer. Under
production is the confirmation of living in dreams while it is quiet evident that the planned data
is much beyond capacities and therefore away from realm. This statement is further confirmed
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME

by the fact that the data depicts 62% of quantities produced are underproduction as compared
with planned production. The situation is not so serious except that there is extra amount of
burden for procurement to cater the needs of the planned production. Similarly, the fate of over
production is also bad as it results in build up of unnecessary inventories either in the form of
WIP or finished goods. This is contrary to fundamental principles of Lean Manufacturing. The
amount of over production is to the tune of 36% of the item produced. The co-efficient of
variation when applied to this situation optimizes the given data in a fashion that mere strict
control of 9 % of the items produced can provide smoothness up to 38% and further control of
8% of items can remove waviness up to 35%. Therefore, the overall results can be improved up
to 73% by controlling 35 items as given in the table above.
REFERENCES
1. Dilworth, J. B., (1993). “Production and Operations Management: Manufacturing and
Services”. Mc-Graw Hill Publication, 4th Edition.
2. Grewal C.S. and Sareen K.K. (2006). “Development of model for lean improvement: A
case study of automobile industry”. Industrial Engineering Journal, Vol. 35(5), pp. 2427.
3. Hines, P., Rich, N. & Esain, A. (1997). "Creating a Lean Supplier Network: A
Distribution Industry Case". Proceedings of the Logistics Research Network Conference,
Huddersfield, U.K.: University of Huddersfield, pp. 60-77.
4. Khare, S. (2006). “Optimizing the Organization: Unleashing the potential of practices,
processes and people”. Tata Mc-Graw Hill Publishing Company Limited, New Delhi, pp.
2-10.
5. Kobayashi, I. (1998). “20 Keys to Workplace Improvement”. Productivity Press,
Cambridge, revised edition, MA.
6. Ohno, T. (1988). "Toyota Production system: Beyond Large Scale Production".
Productivity Press, Cambridge, MA.
7. Pavnaskar, S.J., Gershenso, J.K and Jambekar, A.B. (2003). "Classification scheme for
lean manufacturing tools”, International Journal of Production Research, Vol. 41, pp.
3075-3090.
8. Sardana, S., Kumar, R., Bajwa, M. and Gulati, P. (2011). “Application of SPC tool for
finding variation in the Process Output (A Case Study)”. International Journal of
Industrial Engineering Research and Development, ISSN: 0976-6987, Vol. 2, Iss. 1,
May-Oct., 2011, pp. 46-58.
9. Schroeder, R. G., (1993). “Operations Management: Decision making in the Operations
Function”, Mc-Graw Hill Publication, 4th Edition.
10. Stevenson, W.J. (1996). “Production and Operations Management”, Irwin McGraw-Hill,
5th ed., New York.
11. Womack, J.P., and D.T. Jones, “From Lean production to the Lean Enterprise”, Harvard
Business Review, pp. 93-103(1994).

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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME
Annexure 1: Planned Production V/S Actual Performance from time period of January to June, 2012
Sr. No. Part No.

January

February

March

April

May

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

June

Actual

Plan

Actual

1

3558

7304

1458

10708

1260

15448

3144

7000

2485

7582

3726

6956

2828

2

3504

4848

2574

9078

5286

12292

4000

8000

3594

11956

4650

12256

7240

3

3543

4020

1074

7946

984

10962

2334

5000

2946

4554

2340

4364

2742

4

3712

12964

10124

17846

12799

22547

13024

18023

20688

18835

16700

8385

9538

5

6222

2770

1280

6290

2450

7340

3340

5000

2650

4380

1980

4100

3076

6

3542

5350

2820

5732

672

9560

2568

4000

5134

1986

1992

1644

1506

7

3510

852

84

2070

0

4870

1132

2000

780

2770

1218

3562

0

8

3549

4758

2244

6214

1218

11496

4170

4000

4482

2522

3384

2138

2882

9

3371

3840

0

0

0

4100

1188

5412

612

100

247

100

156

10

6201

0

0

2000

0

4000

0

1500

0

1500

0

1500

0

11

3407

400

0

1400

0

1400

0

1900

0

2350

0

2900

0

12

4119

600

0

1100

68

1032

0

1332

0

1732

50

1982

152

13

3519

606

0

906

396

510

0

2910

828

4682

1866

2816

2814

14

4134

800

0

1300

0

1300

0

1300

0

1550

324

1376

860

15

3329

400

0

900

0

900

0

1100

0

1500

84

1816

686

16

6203

3000

1919

5439

2318

2382

1338

1644

1296

948

719

229

299

17

3727

6290

2164

8224

4730

8494

6810

3500

6564

2430

2388

5158

5798

18

4123

400

0

900

0

900

0

1100

0

1340

100

1440

392

19

4122

600

0

1100

0

1100

100

1000

0

1120

128

1192

404

20

3720

5220

3400

6850

4130

6830

3440

9090

8610

3000

5121

3279

4090

21

6225

0

188

2000

0

500

0

2000

936

1764

0

1764

1431

22

3380

1800

0

0

0

700

0

2200

0

800

420

780

684

23

6202

3000

1758

6116

2981

2426

1440

1886

1942

600

542

58

450

24

4136

600

0

1100

0

1100

0

1100

0

1600

876

1024

811

25

4127

600

0

1100

0

1100

0

1500

494

1206

492

714

582

26

3528

1000

0

3050

717

933

0

1000

813

187

0

0

0

27

3366

1520

1144

1880

192

2688

1280

1000

456

1344

1512

532

292

28

3367

1090

330

2260

800

2460

730

1000

1262

538

450

788

650

29

3526

1500

0

3000

1177

323

113

350

200

150

18

0

0

30

6151

4000

3731

5586

2994

0

1892

358

511

2647

0

2647

2302

31

3435

728

240

0

0

1000

0

2500

444

0

0

600

354

32

4126

600

0

1100

100

1000

244

956

388

768

332

436

204

33

3344

880

278

0

0

1032

0

2032

0

750

960

990

876

34

3379

1300

0

0

0

600

0

1100

0

750

480

470

264

35

3457

0

0

400

0

800

0

400

0

800

0

1200

144

36

3455

0

0

400

0

800

0

400

0

800

0

1200

156

37

3473

0

0

400

0

800

0

400

0

800

0

1200

186

38

3598

500

258

742

180

1062

474

500

0

1000

0

1500

1146

39

3527

700

0

2250

413

637

332

500

409

91

0

0

0

40

3513

1000

0

2000

1280

720

88

0

0

0

0

2000

1368

41

3512

730

0

1730

924

806

0

0

0

0

0

2000

1449

42

3569

1310

90

0

0

150

0

650

0

450

0

550

174

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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME
43

3358

1480

280

0

0

220

0

1020

0

800

384

816

828

44

6284

5716

5588

5132

3612

3120

3072

3048

1946

0

0

0

0

45

3423

2200

880

0

0

1000

60

940

408

0

0

0

0

46

6282

400

0

3600

2872

1198

841

957

597

1560

640

1520

1507

47

6145

6718

4604

3215

2038

0

98

352

856

1000

816

684

786

48

6278

500

0

1000

0

1500

800

300

0

300

110

190

170

49

6160

0

0

300

0

600

0

600

0

600

0

600

0

50

3472

0

0

400

0

800

0

400

192

608

0

1008

372

51

6171

1634

1180

0

0

780

396

1234

72

0

0

1000

456

52

4120

400

0

400

68

332

0

332

0

582

72

810

192

53

3599

500

306

696

306

890

306

500

294

706

0

1206

836

54

3715

1040

590

820

270

550

0

800

920

1680

1290

2740

2166

55

6170

1980

1100

0

0

2320

360

4460

3980

0

984

0

0

56

3751

860

540

1570

910

1760

700

500

610

900

790

1110

950

57

3453

0

0

400

0

800

0

400

0

800

390

810

654

58

3221

700

0

1200

575

1125

0

625

900

725

875

350

275

59

3570

800

354

0

0

500

0

1000

348

200

36

264

0

60

3520

0

0

0

0

0

0

2000

0

0

0

0

0

61

3536

0

0

0

0

0

0

0

0

0

0

2000

0

62

4135

400

0

900

116

784

220

564

464

300

180

220

260

63

3383

1000

429

2400

937

63

0

550

721

0

0

0

0

64

6236

0

0

0

0

0

0

600

0

600

0

1200

486

65

3337

400

0

0

0

500

0

1000

0

0

0

0

0

66

3748

0

0

500

0

1500

324

1676

1602

122

108

600

522

67

6228

775

905

0

0

2000

300

1700

1477

223

0

223

409

68

3357

730

280

0

0

500

0

1000

300

0

0

0

0

69

6198

1200

258

950

290

652

654

0

0

0

0

0

0

70

3726

620

610

700

460

1440

190

900

750

800

830

570

620

71

6169

2700

1780

0

0

2560

1652

1408

1500

0

180

0

0

72

6215

1383

297

2586

2509

359

841

0

0

431

0

431

0

73

3280

4920

4920

6810

6180

6630

4490

8640

8464

8276

8576

6200

7338

74

6237

100

0

0

0

380

0

980

600

380

0

1280

1153

75

3227

700

600

0

0

380

0

780

792

500

216

884

288

76

6135

0

0

200

0

500

0

500

336

164

0

164

0

77

6235

359

0

0

0

680

0

680

536

144

143

0

0

78

3732

400

0

0

0

500

0

500

228

0

0

0

0

79

3103

620

250

0

0

550

252

1098

684

300

264

0

0

80

6157

2400

2129

270

160

750

589

161

80

981

758

523

255

81

3107

0

0

500

0

500

0

500

420

0

0

0

0

82

6269

200

0

176

504

183

0

183

243

410

291

909

0

83

6259

0

0

0

0

0

0

0

0

500

0

800

288

84

3232

0

0

300

0

300

0

2800

2400

0

0

0

0

85

6161

0

0

200

200

200

200

200

200

200

200

200

200

86

3101

500

0

200

0

1200

996

1050

984

0

0

0

0

87

6289

0

0

0

0

0

0

0

0

2502

1631

871

804

88

3252

600

610

200

0

700

0

1100

1064

200

192

0

0

83

International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME
89

3208

930

250

0

0

500

288

612

600

0

0

0

0

90

6156

0

0

100

0

250

75

525

520

530

0

530

442

91

3354

1250

370

0

0

0

0

0

0

0

0

0

0

92

3562

400

0

500

378

1522

954

736

930

100

0

0

120

93

3730

0

0

800

800

0

0

0

0

0

0

0

0

94

3267

500

480

0

0

500

0

900

624

0

0

0

0

95

3733

140

0

140

0

140

117

23

0

0

0

460

0

96

6227

0

0

0

0

122

0

1922

1630

292

0

3292

3231

97

3240

5064

4800

7264

4840

7424

8020

2404

2690

2300

3220

1080

1220

98

3417

10

0

0

0

0

0

700

130

570

470

0

0

99

6211

0

0

300

0

300

0

300

0

300

528

0

0

100

3343

2080

1712

0

0

100

0

100

0

100

0

100

102

101

6175

1389

799

590

463

727

662

322

591

0

0

150

0

102

3735

140

0

140

0

140

67

73

66

0

0

300

0

103

3364

0

0

0

0

0

0

0

0

500

136

864

600

104

6194

0

0

5000

4572

428

229

199

0

5500

5379

0

386

105

3418

68

0

0

0

0

0

500

0

500

492

0

42

106

4129

0

0

0

0

0

0

0

0

200

16

334

0

107

3262

1000

770

1230

1080

1150

1030

0

0

0

0

0

0

108

3263

500

500

0

0

0

0

0

0

0

0

0

0

109

3456

500

500

0

0

0

0

0

0

0

0

0

0

110

3345

800

720

0

0

0

0

500

0

0

0

0

84

111

3729

0

0

0

0

0

0

0

0

0

0

600

132

112

4314

1096

996

3000

2880

12

288

3324

2976

1084

945

3139

3108

113

3365

0

0

0

0

0

0

500

376

624

310

114

6127

0

0

100

0

100

0

500

576

600

324

676

646

115

3382

0

0

0

0

0

0

750

425

325

175

0

59

116

3511

4906

3906

5710

5562

5798

4080

1000

3966

648

1086

3412

2466

117

3226

400

400

0

0

0

0

0

0

0

0

0

0

118

3360

400

400

0

0

0

0

0

0

0

0

0

0

119

3361

400

400

0

0

0

0

0

0

0

0

0

0

120

3736

0

0

0

0

0

0

0

0

200

200

200

200

121

3128

1000

600

0

0

0

0

500

504

0

0

0

0

122

6186

170

100

170

180

0

0

0

0

260

0

260

204

123

3419

32

0

0

0

0

0

300

0

300

240

0

36

124

6178

0

0

0

0

0

0

0

0

300

300

50

50

125

3725

860

520

0

0

0

10

0

0

0

0

0

0

126

6162

0

0

1810

1218

592

806

0

0

150

203

0

0

127

3260

120

0

0

0

500

488

512

324

0

0

0

0

128

3749

0

0

1000

950

1550

1470

1080

990

880

680

1200

1310

129

6154

3289

2616

673

710

0

339

0

0

0

0

0

0

130

3317

700

444

0

0

0

0

0

0

0

0

0

0

131

3721

950

1090

800

710

890

870

720

720

700

500

1200

1130

132

6261

0

0

0

0

0

0

0

0

200

0

200

163

133

3228

130

0

0

0

0

0

500

396

0

0

0

0

134

3229

300

0

0

0

0

0

0

0

0

0

0

72

84

International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME
135

4133

600

0

1100

756

444

270

174

635

0

442

0

0

136

3427

0

0

0

0

200

200

0

0

0

0

0

0

137

6184

0

0

0

0

0

0

0

0

100

0

500

400

138

6240

0

0

0

0

0

0

0

0

0

0

500

300

139

3424

1400

1206

0

0

0

0

0

0

0

0

0

0

140

3234

760

830

500

200

300

70

1730

2060

820

780

1050

1036

141

3246

500

485

200

144

56

0

56

0

0

0

0

0

142

6131

150

160

300

240

60

0

60

0

0

0

119

120

143

6283

7652

5568

6084

7310

2880

3516

5764

5685

0

132

0

0

144

3452

500

340

0

0

0

0

0

0

0

0

0

0

145

3438

0

0

0

0

150

0

150

180

0

0

300

288

146

4117

0

0

0

0

50

50

50

50

50

50

0

0

147

3484

0

0

0

0

0

0

0

0

0

0

100

100

148

3416

70

70

0

0

0

0

0

0

0

0

0

0

149

6193

0

0

0

0

0

0

0

0

0

0

2000

2000

150

3102

0

0

0

0

0

0

0

0

500

500

0

0

151

6144

1100

900

350

550

0

0

0

0

0

0

300

300

152

3476

260

260

0

0

0

0

0

0

0

0

0

0

153

3175

200

200

0

0

0

0

0

0

0

0

0

0

154

3353

180

180

0

0

0

0

0

0

0

0

0

0

155

3475

1600

1836

0

0

224

0

224

212

0

0

0

0

156

6260

0

0

0

0

0

0

0

0

500

500

0

0

157

3251

0

0

0

0

150

150

0

0

0

0

0

0

158

3350

0

0

0

0

0

0

0

0

400

400

0

0

159

3351

0

0

0

0

0

0

0

0

600

600

0

0

160

3737

0

0

0

0

0

0

0

0

150

150

0

0

161

6204

300

300

220

80

0

80

0

0

0

0

240

300

162

6212

0

0

1500

1500

1000

1000

0

0

0

0

0

0

163

3241

0

0

0

0

0

0

0

0

0

0

50

60

164

6138

180

220

200

0

200

192

8

192

0

0

0

0

165

6268

500

248

270

543

0

0

0

0

0

0

0

0

166

4115

0

0

0

0

0

0

0

52

0

0

0

0

167

6190

0

0

0

0

0

0

0

91

150

0

150

265

168

4309

0

0

0

0

0

0

0

100

0

0

0

0

169

3714

0

0

0

0

0

0

0

0

25

0

0

140

170

4321

1000

920

2000

1950

0

0

600

0

0

0

500

1368

171

6257

0

25

0

60

0

0

0

0

0

50

0

20

172

4128

0

0

0

0

0

0

0

0

0

156

0

0

173

4113

0

0

0

0

100

0

100

100

100

210

0

156

174

6124

0

0

200

144

56

0

56

192

0

0

48

192

175

6136

0

0

200

180

20

0

20

120

0

0

80

192

176

3129

0

0

0

0

0

0

0

0

0

0

0

180

177

3244

0

0

300

300

0

0

0

0

0

0

730

918

178

6279

0

0

0

100

0

0

0

0

0

0

0

93

179

4118

0

0

0

0

0

0

0

200

0

0

0

0

180

6216

0

0

300

430

0

75

0

0

0

0

0

0

85

International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME
181

6229

959

1077

0

220

0

0

0

0

0

0

1200

182

3316

1100

680

0

0

150

0

650

528

6

0

0

948

183

6132

0

0

300

216

84

60

24

0

0

0

84

476

184

3700

0

0

0

0

0

0

0

168

932

960

0

72

185

3176

0

0

0

0

0

0

0

0

0

0

0

276

186

6158

0

0

0

291

0

0

0

0

0

0

0

0

187

3245

0

0

200

204

0

0

0

0

0

0

539

828

188

6143

2300

2380

920

1055

565

619

546

635

1200

1055

745

857

189

3713

0

0

0

0

0

0

0

0

0

354

0

0

190

3224

300

810

0

0

0

0

0

0

0

0

0

0

191

3247

150

150

0

0

0

0

0

0

0

0

0

648

192

3900

4522

4160

5000

4416

7234

5328

9306

11481

4325

4848

2627

4018

193

3220

0

1560

1740

1296

84

0

84

236

0

0

3050

3360

194

6133

1000

1830

2040

2796

8

0

8

0

0

0

0

0

195

3711

6124

6286

7428

7650

8278

5198

9000

11402

8598

9740

1858

2824

196

6288

0

0

0

0

0

0

0

0

2080

4704

0

648

197

3289

4192

4872

2000

2769

4520

6334

0

0

0

0

1000

1152

198

3728

8820

7554

13266

14511

8795

9120

6675

7840

5680

7416

4714

5414

199

4315

270

3780

1600

1331

270

420

0

0

0

0

0

552

200

6241

3140

4470

8170

8210

7460

7780

5080

8280

1850

3206

3244

3636

201

6213

5000

4770

0

1798

0

0

12300

13099

0

0

7200

11668

202

3601

0

4050

200

975

0

3750

6250

7512

5800

5600

4200

4055

203

6226

Total

1093

5000

3921

0

2220

11114

20147

16167

16595

15500

21560

2200

2789

222168

154119

252657

158864

267603

154674

248765

209795

187781

151738

175828

150656

Annexure 2 Planned V/s Actual Production: Production at Par Optimization

Sr.
No.

Product Code

Plan Production

Actual Production

1.

6204

760

760

2.

6161

1000

1000

3.

3730

800

800

4.

3263

500

500

5.

3456

500

500

6.

3226

400

400

7.

3360

400

400

8.

3361

400

400

9.

3736

400

400

10

3427

200

200

11.

3484

100

100

12.

3416

70

70

13.

3251

150

150

14.

3350

400

400

15.

3351

600

600

86

International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME
16.

3737

150

150

17.

6212

2500

2500

18.

6178

350

350

19.

4117

150

150

20.

6193

2000

2000

21.

3102

500

500

22.

6144

1750

1750

23.

3476

260

260

24.

3175

200

200

25.

3353

180

180

26.

3475

2048

2048

27.

6260

500

500

Total

17268

17268

Annexure 3: Analysis of Planned V/s Actual Production: Underproduction Optimization
Sr. No.

Code

Total
Plan

Actual

Deviation

Average
Prod

Deviation
in days

%age
Contribution

Cumulative
%age

1

3558

54998

14901

40097

2484

-484

9.08

9.08

2

3504

58430

27344

31086

4557

-205

7.04

16.12

3

3543

36846

12420

24426

2070

-354

5.53

21.65

4

3712

98600

82873

15727

13812

-34

3.56

25.21

5

6222

29880

14776

15104

2463

-184

3.49

28.7

6

3542

28272

14692

13580

2449

-166

3.07

31.77

7

3510

16124

3214

12910

536

-723

2.94

34.71

8

3549

31128

18380

12748

3063

-125

2.89

37.6

9

3371

13552

2203

11349

367

-927

2.56

40.16

10

6201

10500

0

10500

0

0

2.39

42.55

11

3407

10350

0

10350

0

0

2.34

44.89

12

4119

7778

270

7508

45

-5005

1.69

46.58

13

3519

12430

5904

6526

984

-199

1.52

48.1

14

4134

7626

1184

6442

197

-979

1.45

49.55

15

3329

6616

770

5846

128

-1367

1.36

50.91

16

6203

13642

7889

5753

1315

-131

1.30

52.21

17

3727

34096

28454

5642

4742

-36

1.27

53.48

18

4123

6080

492

5588

82

-2044

1.26

54.74

19

4122

6112

632

5480

105

-1561

1.24

55.98

20

3720

34269

28791

5478

4799

-34

1.23

57.21

21

6225

8028

2555

5473

426

-386

1.23

58.44

22

3380

6280

1104

5176

184

-844

1.17

59.61

23

6202

14086

9113

4973

1519

-98

1.12

60.73

24

4136

6524

1687

4837

281

-516

1.09

61.82

87

International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME
25

4127

6220

1568

4652

261

-534

1.07

62.89

26

3528

6170

1530

4640

255

-546

1.05

63.94

27

3366

8964

4876

4088

813

-151

0.95

64.89

28

3367

8136

4222

3914

704

-167

0.92

65.81

29

3526

5323

1508

3815

251

-455

0.88

66.69

30

6151

15238

11430

3808

1905

-60

0.86

67.55

31

3435

4828

1038

3790

173

-657

0.85

68.4

32

4126

4860

1268

3592

211

-510

0.82

69.22

33

3344

5684

2114

3570

352

-304

0.80

70.02

34

3379

4220

744

3476

124

-841

0.79

70.81

35

3457

3600

144

3456

24

-4320

0.78

71.59

36

3455

3600

156

3444

26

-3974

0.78

72.37

37

3473

3600

186

3414

31

-3304

0.77

73.14

38

3598

5304

2058

3246

343

-284

0.74

73.88

39

3527

4178

1154

3024

192

-472

0.69

74.57

40

3513

5720

2736

2984

456

-196

0.68

75.25

41

3512

5266

2373

2893

396

-219

0.66

75.91

42

3569

3110

264

2846

44

-1940

0.64

76.55

43

3358

4336

1492

2844

249

-343

0.64

77.19

44

6284

17016

14218

2798

2370

-35

0.63

77.82

45

3423

4140

1348

2792

225

-373

0.63

78.45

46

6282

9235

6457

2778

1076

-77

0.62

79.07

47

6145

11969

9198

2771

1533

-54

0.62

79.69

48

6278

3790

1080

2710

180

-452

0.61

80.3

49

6160

2700

0

2700

0

0

0.61

80.91

50

3472

3216

564

2652

94

-846

0.60

81.51

51

6171

4648

2104

2544

351

-218

0.59

82.1

52

4120

2856

332

2524

55

-1368

0.57

82.67

53

3599

4498

2048

2450

341

-215

0.55

83.22

54

3715

7630

5236

2394

873

-82

0.54

83.76

55

6170

8760

6424

2336

1071

-65

0.52

84.28

56

3751

6700

4500

2200

750

-88

0.49

84.77

57

3453

3210

1044

2166

174

-373

0.49

85.26

58

3221

4725

2625

2100

438

-144

0.47

85.73

59

3570

2764

738

2026

123

-494

0.45

86.18

60

3520

2000

0

2000

0

0

0.45

86.63

61

3536

2000

0

2000

0

0

0.45

87.08

62

4135

3168

1240

1928

207

-280

0.43

87.51

63

3383

4013

2087

1926

348

-166

0.43

87.94

64

6236

2400

486

1914

81

-709

0.43

88.37

65

3337

1900

0

1900

0

0

0.43

88.8

66

3748

4398

2556

1842

426

-130

0.41

89.21

67

6228

4921

3091

1830

515

-107

0.41

89.62

88

International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME
68

3357

2230

580

1650

97

-512

0.37

89.99

69

6198

2802

1202

1600

200

-240

0.36

90.35

70

3726

5030

3460

1570

577

-82

0.35

90.7

71

6169

6668

5112

1556

852

-55

0.35

91.05

72

6215

5190

3647

1543

608

-76

0.34

91.39

73

3280

41476

39968

1508

6661

-7

0.35

91.74

74

6237

3120

1753

1367

292

-140

0.33

92.07

75

3227

3244

1896

1348

316

-128

0.30

92.37

76

6135

1528

336

1192

56

-639

0.27

92.64

77

6235

1863

679

1184

113

-314

0.27

92.91

78

3732

1400

228

1172

38

-925

0.26

93.17

79

3103

2568

1450

1118

242

-139

0.25

93.42

80

6157

5085

3971

1114

662

-50

0.25

93.67

81

3107

1500

420

1080

70

-463

0.24

93.91

82

6269

2061

1038

1023

173

-177

0.23

94.14

83

6259

1300

288

1012

48

-633

0.22

94.36

84

3232

3400

2400

1000

400

-75

0.22

94.58

85

3101

2950

1980

970

330

-88

0.22

94.8

86

6289

3373

2435

938

406

-69

0.21

95.01

87

3252

2800

1866

934

311

-90

0.21

95.22

88

3208

2042

1138

904

190

-143

0.21

95.43

89

6156

1935

1037

898

173

-156

0.20

95.63

90

3354

1250

370

880

62

-428

0.19

95.82

91

3562

3258

2382

876

397

-66

0.19

96.01

92

3267

1900

1104

796

184

-130

0.18

96.19

93

3733

903

117

786

20

-1209

0.18

96.37

94

6227

5628

4861

767

810

-28

0.17

96.54

95

3240

25536

24790

746

4132

-5

0.16

96.7

96

3417

1280

600

680

100

-204

0.16

96.86

97

6211

1200

528

672

88

-229

0.16

97.02

98

3343

2480

1814

666

302

-66

0.15

97.17

99

6175

3178

2515

663

419

-47

0.15

97.32

100

3735

793

133

660

22

-893

0.14

97.46

101

3364

1364

736

628

123

-154

0.14

97.6

102

6194

11127

10566

561

1761

-10

0.13

97.73

103

3418

1068

534

534

89

-180

0.13

97.86

104

4129

534

16

518

3

-5828

0.12

97.98

105

3262

3380

2880

500

480

-31

0.12

98.1

106

3345

1300

804

496

134

-111

0.11

98.21

107

3729

600

132

468

22

-638

0.11

98.32

108

4314

11655

11193

462

1866

-7

0.10

98.42

109

3365

1124

686

438

114

-115

0.10

98.52

110

6127

1976

1546

430

258

-50

0.09

98.61

89

International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME
111

3382

1075

659

416

110

-114

0.09

98.7

112

3511

21474

21066

408

113

3128

1500

1104

396

3511

-3

0.09

98.79

184

-65

0.08

98.87

114

6186

860

484

115

3419

632

276

376

81

-140

0.08

98.95

356

46

-232

0.08

99.03

116

3725

860

530

330

88

-112

0.08

99.11

117

6162

118

3260

2552

2227

325

371

-26

0.07

99.18

1132

812

320

135

-71

0.07

99.25

119

3749

5710

5400

310

900

-10

0.07

99.32

120

6154

3962

3665

297

611

-15

0.06

99.38

121

3317

700

444

256

74

-104

0.06

99.44

122

3721

5260

5020

240

837

-9

0.06

99.5

123

6261

400

163

237

27

-262

0.05

99.55

124

3228

630

396

234

66

-106

0.05

99.6

125

3229

300

72

228

12

-570

0.05

99.65

126

4133

2318

2103

215

351

-18

0.04

99.69

127

6184

600

400

200

67

-90

0.04

99.73

128

6240

500

300

200

50

-120

0.04

99.77

129

3424

1400

1206

194

201

-29

0.04

99.81

130

3234

5160

4976

184

829

-7

0.04

99.85

131

3246

812

629

183

105

-52

0.04

99.89

132

6131

689

520

169

87

-59

0.03

99.92

133

6283

22380

22211

169

3702

-1

0.03

99.95

134

3452

500

340

160

57

-85

0.03

99.98

135

3438

600

468

132

78

-51

0.02

100

1050366

608547

441819

Total

Annexure 4: Analysis of Planned V/s Actual Production: Overproduction Optimization
Total
Sr. No.

Code

Deviation

Average
Prod

Deviation in
%age
days
Contributio
n
10
30

1

3241

50

60

10

0.01

0.01

2

6138

588

604

16

101

5

0.02

0.04

3

6268

770

791

21

132

5

0.03

0.07

4

4115

0

52

52

9

180

0.08

0.15

5

6190

300

356

56

59

28

0.08

0.23

6

4309

0

100

100

17

180

0.15

0.38

7

3714

25

140

115

23

148

0.17

0.55

8

4321

4100

4238

138

706

6

0.21

0.76

9

6257

0

155

155

26

180

0.23

0.99

10

4128

0

156

156

26

180

0.23

1.22

11

4113

300

466

166

78

64

0.25

1.47

12

6124

360

528

168

88

57

0.25

1.72

90

Cumulative
%age

Sr. No.

International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 1, January - June (2012), © IAEME
13

6136

320

492

172

82

63

0.26

1.98

14

3129

0

180

180

30

180

0.27

2.25

15

3244

1030

1218

188

203

28

0.28

2.53

16

6279

0

193

193

32

180

0.29

2.82

17

4118

0

200

200

33

180

0.3

3.12

18

6216

300

505

205

84

73

0.31

3.43

19

6229

2159

2390

231

398

17

0.35

3.77

20

3316

1906

2156

250

359

21

0.37

4.15

21

6132

492

752

260

125

62

0.39

4.53

22

3700

932

1200

268

200

40

0.4

4.94

23

3176

0

276

276

46

180

0.41

5.35

24

6158

0

291

291

49

180

0.44

5.78

25

3245

739

1032

293

172

51

0.44

6.22

26

6143

6276

6601

325

1100

9

0.49

6.71

27

3713

0

354

354

59

180

0.53

7.24

28

3224

300

810

510

135

113

0.76

8

29

3247

150

798

648

133

146

0.97

8.97

30

3900

33014

34251

1237

5709

7

1.85

10.82

31

3220

4958

6452

1494

1075

42

2.23

13.05

32

6133

3056

4626

1570

771

61

2.35

15.4

33

3711

41286

43100

1814

7183

8

2.71

18.11

34

6288

2080

5352

3272

892

110

4.89

23.01

35

3289

11712

15127

3415

2521

41

5.11

28.12

36

3728

47950

51855

3905

8643

14

5.84

33.96

37

4315

2140

6083

3943

1014

117

5.9

39.85

38

6241

28944

35582

6638

5930

34

9.93

49.78

39

6213

24500

31335

6835

5223

39

10.22

60

40

3601

16450

25942

9492

4324

66

14.2

74.2

41

6226

49981

67232

17251

11205

46

25.8

100

287118

353971

Total

91