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Procedia Manufacturing 43 (2020) 247–254

17th Global Conference on Sustainable Manufacturing

17th Global Conference on Sustainable Manufacturing
A dynamic
AScreen
dynamic programming
programming model
model for
for Reconfigurable
Reconfigurable Vibrating
Vibrating
Screen machine
machine operations
operations planning
planning
environment
in
in a
a fluctuating
fluctuating market
market
environment
Olasumbo Makindea* , Boitumelo Ramatsetsea, Thomas Munyaia
Olasumbo Makindea*, Boitumelo Ramatsetsea, Thomas Munyaia
a
Tshwane University of Technology, Staatsartillerie Rd, Pretoria West, Pretoria, 0001
a
Tshwane University of Technology, Staatsartillerie Rd, Pretoria West, Pretoria, 0001

Abstract
Abstract
Fluctuation in mineral concentrates demand has resulted into the design of a Reconfigurable Vibrating Screen
Fluctuation
(RVS) machine. in mineral
However, concentrates demand
the question; “which hasconfiguration(s)
resulted into the design
should thisofmachine
a Reconfigurable
be configuredVibrating Screen
to, at different
(RVS) machine. However, the question; “which configuration(s) should this machine be configured
periods in order to minimize the total operating cost of utilizing this machine in meeting the fluctuating customer to, at different
periods
demands?”in order to minimize
still need the totalbyoperating
to be answered cost of
the designer ofthe
utilizing thisInmachine
machine. light ofinthis,
meeting the fluctuating
this paper proposes a customer
dynamic
demands?” still need to be answered by the designer of the machine. In light of
programming model that will ensure cost-effective configuration and utilization of the RVS machine this, this paper proposes in a dynamic
meeting
programming model that
fluctuating customers will ensure
demand. cost-effective
The dynamic configuration
programming model was andtested
utilization
using ofthethe RVS concentrates
mineral machine in meeting
demand
fluctuating customersXYZ.
of mining company demand.The The dynamic
results of theprogramming model was
dynamic computation fortested usingstudy
this case the mineral
revealedconcentrates demand
that RVS machine
of mining company XYZ. The results of the dynamic computation for this
must be operated using a configuration sequence of 4700mm × 2500mm, 3500mm × 2000mm and 4700mm ×case study revealed that RVS machine
must be operated
2500mm, usingof afirst
for a period configuration sequence
two (2) months, of 4700mm
second × 2500mm,
two (2) months and the 3500mm
last month× 2000mm and 4700mm
respectively, in order to×
2500mm, for a period of first two (2) months, second two (2) months and the last
meet the customer’s five-month period demand in mining company XYZ, at a minimum total machine operations month respectively, in order to
meet theR681966.21.
cost of customer’s five-month
The machine period demand
operations in mining
planning company
solution XYZ,
offered at a study
in this minimumservetotal
as a machine
knowledge operations
advisor
cost of R681966.21. The machine operations planning solution offered in this study serve
for RVS machine users towards ensuring just-in-time and exact screening of varying mineral concentrates demanded as a knowledge advisor
for RVS machine users towards ensuring just-in-time and exact screening
by the customers in a cost-effective manner using a reasonable power consumption. of varying mineral concentrates demanded
by the customers in a cost-effective manner using a reasonable power consumption.
© 2020 The Authors. Published by Elsevier B.V.
© 2019
This The
is an Authors,
open accessPublished by Elsevier
article under B.V.
the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
© 2019
Peer Theunder
review
review Authors,
underthe Published by of
theresponsibility
responsibility Elsevier
ofthe B.V. committee
thescientific
scientific committee of the
of the Global
Global Conference
Conference on Sustainable
on Sustainable Manufacturing
Manufacturing.
Peer review under the responsibility of the scientific committee of the Global Conference on Sustainable Manufacturing
Keywords: Reconfigurable Vibrating Screen; Dynamic Programming Model; Mineral Concentrates; Reconfiguration Time
Keywords: Reconfigurable Vibrating Screen; Dynamic Programming Model; Mineral Concentrates; Reconfiguration Time

1. Introduction
1. Introduction
Fluctuation and frequent changes in customers’ demand is one of the crucial problems that remain inevitable within
Fluctuation and frequent
the manufacturing, changes
service in customers’
and mining demand[1],
organisations is one
[2] of
andthe[3].
crucial problems
To this effect,that remain inevitable
ineffective management within
of
the manufacturing, service and mining organisations [1], [2] and [3]. To this effect, ineffective
customer’s changing and fluctuating demands could result into: (i) backordering of customers’ demand, (ii) management of
customer’s changing and fluctuating demands could result into: (i) backordering of customers’
customer dissatisfaction and disloyalty, (iii) inefficient process designs tailored towards meeting these changing demand, (ii)
customer
demands, dissatisfaction and value-added
and (iv) reduced disloyalty, (iii) inefficient
activities process
carried out indesigns tailored
meeting towardsdemand
customers’ meeting[4],
these
[5] changing
and [6].
demands, and (iv) reduced value-added activities carried out in meeting customers’ demand [4], [5] and [6].

2351-9789 © 2019 The Authors, Published by Elsevier B.V.

2351-9789
Peer review©under
2019the
Theresponsibility
Authors, Published by Elsevier
of the scientific B.V. of the Global Conference on Sustainable Manufacturing
committee
Peer review under the responsibility of the scientific committee of the Global Conference on Sustainable Manufacturing

2351-9789 © 2020 The Authors. Published by Elsevier B.V.

This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer review under the responsibility of the scientific committee of the Global Conference on Sustainable Manufacturing.
10.1016/j.promfg.2020.02.149
248 Olasumbo Makinde et al. / Procedia Manufacturing 43 (2020) 247–254
2 Olasumbo/ Procedia Manufacturing 00 (2019) 000–000

However, meeting the predicted fluctuating and changing customers demand using the current conventional machine
solutions, on the one hand, increases the operational cost of an organisation. On the other hand, it reduces the
machine utilization rate (i.e. increases the machine downtime period) during the low customer demand peak periods
[7]. In light of this, Ramatsetse et al. [8] and [9] proposed a suitable machine design solution called Reconfigurable
Vibrating Screen (RVS) machine, premised on the application of Reconfigurable Manufacturing System (RMS)
principles introduced in the works of [10], [11] and [12]. According to these authors, the Reconfigurable Vibrating
Screen (RVS) machine is a screening machine designed at the outset to accommodate rapid adjustment of the
structural components of the machine in order to quickly adjust the machine mineral screening capacity and
functionality.
A detailed diagram that highlight the various components of the RVS machine is depicted in Figure 1a. Based on the
design mechanism for this RVS machine, it can be inferred that the RVS machine can be configured to different
machine configurations; 2500mm × 1500mm (C1), 3000mm × 1800mm (C2), 3500mm × 2000mm (C3), 4000mm ×
2000mm (C4), and 4700mm × 2500mm (C5) with a view to meeting varying mineral concentrates demand of the
customers at different time periods. Typical configurations of the RVS machine is depicted in Figure 1b.

(a)

(b)
Fig. 1: (a) Components of the RVS machine and (b) Feasible configurations of the RVS machine

The reconfiguration of the RVS machine from C1 to C2, C1 to C3, C2 to C4, C3 to C5, C1 to C4, C2 to C5 and C1
to C5 require a specific number of screen panel modules, which needs to be purchased at a particular cost. To this
effect, this paper seeks to establish the suitable machine configuration that the RVS machine must be positioned, at
different fluctuating demand periods with a view to: (i) minimize the Total Production Cost (TPC) of meeting these
demands, (ii) minimize the Opportunity Sales Loss (OSL) that could arise if the machine is not positioned at a
suitable machine configuration and (iii) minimize the Machine Utilization Loss (MUL) if the machine is positioned
at a particular machine configuration, using a dynamic programming procedure proposed by Wagner and Whitin
[13]. The remaining sections of the paper are highlighted as follows. Section 2 present the model formulation
utilized in establishing the suitable RVS machine operations planning in meeting fluctuating and turbulent market
demands. Section 3 present and discuss the results obtained from the dynamic programming computation. The last
section concludes based on the results obtained from the study.
 Olasumbo Makinde et al. / Procedia Manufacturing 43 (2020) 247–254 249
Olasumbo/ Procedia Manufacturing 00 (2019) 000–000 3

2. Research Methodology
2.1 Model Objective
The main objective of the model developed in this study is to establish a suitable operations plan that advises on the
suitable machine configuration that the RVS machine must be configured in order to minimize: (i) OSL, (ii) MUL
and (iii) TPC; in meeting fluctuating granite concentrates demand for a period of five (5) months.

2.2 Model Notations

The notations used in the model are highlighted in Table 1.
Table 1: Model Notations
Notations Description
, , Cost of renting a space for the mineral screening operation, labour cost of the machine
and FMC operator, cost of powering the screening operations at different configuration of the RVS
machine and feasible machine configuration.
, and Wage cost and time to reconfigure the machine from configuration i to another in month j
as well as cost of a standard module (i.e. a screen panel of size 500mm × 500mm) utilised
to reconfigure the machine from configuration i to another in month j.
, Cost of a customized module ((i.e. either screen panel of size 500mm × 300mm or 500mm
and FRM × 200mm) utilised to reconfigure the machine from configuration i to another in month j,
number of standard and customized modules utilised to reconfigure the machine from
configuration i to another in month j and feasible reconfiguration mechanism.
, Cost of space to hold granite concentrates inventory, salary cost of the security worker
, NOM monitoring the granite concentrates inventory, maximum quantity of granite concentrates
that could be held in month j, number of modules and maximum full production capacity.
and MFC
, and Amount of granite concentrate inventory generated by the RVS machine positioned at
configuration i in month j, quantity of granite concentrates produced by the RVS machine
positioned at configuration i in month j and maximum quantity of granite concentrates that
could be produced by the RVS machine, when positioned at configuration i in month j.

2.3 Model Assumptions

The assumptions considered during the modelling of the RVS machine operations configuration planning are
highlighted as follows.
(a) The granite concentrates demanded by the customers fluctuate every month.
(b) The screen panel modules and holding pins required to reconfigure the RVS machine from one machine
configuration to another is readily available from the supplier.
(c) The RVS machine will operate effectively without breaking down during the period of meeting the five months
fluctuating granite concentrate demand.
(d) The rate of granite concentrate screening on the RVS machine and the amount of excess mineral concentrates
held during the five month period are simultaneously controlled in the model.
(e) Multiple objectives tailored towards minimizing the TPC, MUL and OSL were considered in this model.
(f) The fluctuating granite concentrate demand is deterministic
(g) Backordering of the granite concentrate demand is not allowed.

2.4 Model Formulation

The RVS machine operations planning model unveils five (5) cost functions; namely, the production cost function,
opportunity sales loss function, the machine utilization loss function, set up cost function and inventory cost
function.
The production cost ( for the RVS machine operating at a machine configuration i in meeting month j demand
( ) is given as equation (1).
250 Olasumbo Makinde et al. / Procedia Manufacturing 43 (2020) 247–254
4 Olasumbo/ Procedia Manufacturing 00 (2019) 000–000

= + + (1)
The setup cost function ( ) for positioning the RVS machine at machine configuration i in month j is given as
equation (2).
= × ) + {( × )+( × )} (2)
The cost of holding and carrying excess granite concentrates ( ; produced from the RVS machine positioned at
configuration i, from month j to month j + 1 is given by as equation (3).
= × (3)
The opportunity sales loss function incurred for positioning the RVS machine at machine configuration i in meeting
granite concentrates demand ( ) is given as equation (4).
(4)
The machine utilisation loss function incurred for operating the RVS machine at machine configuration i in month j
is given as equation (5).

(5)

In light of this, total production cost function that need to be minimized in order to achieve the aforementioned
objective is given as equation (6).
= + + ) (6)
Therefore, the RVS machine operations planning model required to achieve the aforementioned objective in section
2.1 is stated as:
Minimize = + + ), Minimize = and Minimize

Subject to:
= + -

For all i = 1, 2, 3, 4,……., I and j = 1, 2, 3, 4,……., J

, and ≥ 0 for all i,j

2.5 RVS Machine Operations Planning Model Solution Procedure

This aforementioned multi-objective optimisation model was solved using a modified Wagner and Whitin solution
procedure. The modified solution procedure adopted in solving this model was premised on the following
conditions.
a) If the initial inventory at the beginning of the first month and the inventory at the end of each month j ( ) is zero
or less than the quantity of granite concentrates demanded by the customers ( , then the RVS machine should be
configured to any machine configuration that has the capacity of meeting at least the granite concentrates demanded
by a customer at a particular month j.
b) If the beginning inventory ( ) at the end of each month j-1 is greater than or equal to the quantity of granite
concentrates demanded by the customers ( in month j, then we should not operate the RVS machine to screen
granite concentrates in month j.
c) The optimal machine configuration of the RVS machine selected to screen granite concentrates in order to meet
customers’ granite concentrates demand in each month j is the machine configuration that will be operated with: (i)
minimum TPC, (ii) minimum MUL and (iii) minimum OSL.
The dynamic computation of the feasible solutions to this aforementioned multi-objective optimisation model is
sequentially executed by finding various machine configuration options (i.e. states) at which the RVS machine must
be positioned and operated in each month j (i.e. stage) in order to meet granite concentrates demand for these
 Olasumbo/ Procedia Manufacturing 00 (2019) 000–000 5
Olasumbo Makinde et al. / Procedia Manufacturing 43 (2020) 247–254 251
Olasumbo/ Procedia Manufacturing 00 (2019) 000–000 5
months. The RVS machine configuration option that minimizes the TPC, MUL and OSL in meeting the demand of
each month
months. The jRVS
is themachine
optimalconfiguration
machine configuration
option thatatminimizes
Olasumbo/ Procedia which thethe
Manufacturing machine must and
00 (2019) 000–000
TPC, MUL be operated. The optimal
OSL in meeting machine
the demand
5
of
configuration
eachmonths.
month Thepolicy
j is RVS for the
the optimal month
machinei serve as the
configurationbasis
at of establishing
which the suitable
machine mustmachine
be operating
operated. The configurations
optimal for
machine
other subsequent machine
months, configuration option thatrecursive
minimizesrelationship
the TPC, MUL thatand OSL in the
meeting
link the demandoptimal
of
configuration
each monthpolicy
j is the thej+1,
foroptimal
monthj+2,i serve
machine
……,as J.the
The
basis
configuration at of establishing
which the suitable
machine must
pinpoint
machine
be operating
operated. The
between
configurations
optimal machine for
machine configuration
other subsequent solution
months, j+1, for month
j+2, ……,j and otherrecursive
J. The subsequent months arethat
relationship depicted in equations
pinpoint the link (7) to (9). optimal
between
configuration policy for the month i serve as the basis of establishing suitable machine operating configurations for
machine
otherconfiguration solutionj+1,
subsequent months, for j+2,
month j and
……, J. other subsequent
The recursive months are
relationship thatdepicted
pinpointinthe
equations (7) to (9).
link between optimal (7)
machine configuration solution for month j and other subsequent months are depicted in equations (7) to (9).
(7)
(8)
(7)
(9)
(8)
(8) (9)
The step by step procedure of how the aforementioned modified Wagner and Whitin solution procedure was(9)
applied
to dynamically solve the RVS machine operations configuration planning is depicted in Figure 2.
The step by step procedure of how the aforementioned modified Wagner and Whitin solution procedure was applied
The step by step procedure of how the aforementioned modified Wagner and Whitin solution procedure was applied
to dynamically solve the RVS machine operations configuration planning is depicted in Figure 2.
to dynamicallyStart
solve the RVS machine operations configuration planning is depicted in Figure 2.
Start
Start
Identify the most suitable machine configuration
option that minimizes that minimizes TPC, MUL
Identify the mostmost
Identify suitable machine configuration
and OSL,the suitable
in meeting machine
demand configuration
of month i
option that that
option minimizes thatthat
minimizes minimizes TPC,
minimizes TPC,MUL
MUL
and OSL, in meeting
and OSL, demand
in meeting demandof of
month
monthi i

Is the optimal machine Do not screen granite

configurationthe solution
Is optimal
optimal in month i
machine concentrates
Do on the RVS Stop
Is the machine Do not
notscreen
screengranite
granite
capable of meeting the demand machine on
forthe
these
configuration solution in in
configuration solution month i
month i Yes
concentrates RVS
concentrates on the RVS Stop
Stop
of other
capable months?
of meeting the demand subsequent
machine for months
these
capable of meeting the demand Yes machine for these
of other months? Yes subsequent months
of other months? subsequent months
No Determine the optimal RVS machine
No Determine operations
configuration the optimal RVS
plan machine
that minimise the
Is the optimalNo machine Determine
configuration the optimal
operations RVS
plan that machine
minimise the
Yes summation of TPC, MUL and OSL
Is the solution
configuration optimal machine
in month i Yes
configuration
summationoperations
of TPC, MUL plan
andthat
OSLminimise the
Is the optimal
configuration machine
solution in month i summation
Determine of TPC, RVS
the optimal MULmachine
and OSL
capable of meeting the demand Yes Determine the optimal RVS machine
configuration
capable ofsolution
meeting inthemonth
demandi configuration operations plan that minimise the
of some of the subsequent configuration operations
Determine plan that
the optimal RVSminimise the
machine
capableofofsome of thethe
meeting subsequent
demand summation of TPC, MUL and OSL
months?
months? summation of TPC, MUL and OSL
configuration operations plan that minimise the
of some of the subsequent
months? NoNo summation of TPC, MUL and OSL
Identify the most
Identify suitable
the most machine configuration
Nomachine
suitable configuration
option that minimizes
option TPC,
that minimizes MUL
TPC, MULand
andOSL, capable
OSL, capableofof Compute
Compute thethe summation
summation of TPC,
of TPC, MULMUL
and and
Identify the most suitable machine configuration OSLOSL
for for all stages
all stages
meeting demand
meeting of the
demand subsequent
of the months
subsequent months Compute the summation of TPC, MUL and
option that minimizes TPC, MUL and OSL, capable of
meeting demand of the subsequent months OSL for all stages
Fig.Fig. 2. Modified
2. Modified Wagnerand
Wagner andWhitin
Whitin algorithm
algorithm for
forRVS
RVSMachine
MachineOperations
OperationsPlanning
Planning
Fig. 2. Modified Wagner and Whitin algorithm for RVS Machine Operations Planning
2.6 2.6
DataData Collection
Collection
The pre-ordered granite concentrates demanded by the customers for a period of five (5) months, obtained from a
The pre-ordered
2.6 beneficiation granite concentrates demanded by the customers for a period of five (5) months, obtained from a
Data Collection
plant XYZ was used to validate this model (see Table 2). Furthermore, other data collected from the
beneficiation
The RVS plant
pre-ordered XYZ concentrates
machinegranite
system was used
designer andtomanufacturer,
validate this
demanded model
bywhich (seeutilized
Table
the customers
were 2).
forto Furthermore,
acompute
period of five
the setupother
(5) data
(SC),collected
costmonths, obtainedfrom
inventory fromthea
cost
RVS machine
beneficiation system
plant XYZ
(IC) and production designer
was
cost and
used
(PC) manufacturer,
to validate
incurred for eachthiswhich were utilized
modelconfiguration
feasible (see Table of to compute
2).this the
Furthermore, setup
other
machine is also cost (SC), inventory
data collected
presented 2. cost
in Table from the
(IC)
RVS machine system designer and manufacturer, which were utilized to compute the setup cost (SC), inventory 2.
and production cost (PC) incurred for each feasible configuration of this machine is also presented in Table cost
(IC) 3andDynamic Computation
production Results and
cost (PC) incurred for Discussion
each feasible configuration of this machine is also presented in Table 2.
3 Dynamic Computation Results and Discussion
3.1 InitialComputation
3 Dynamic basic feasible solution
Resultstoandthe Discussion
Model
The result
3.1 Initial basicoffeasible
the initialsolution
basic feasible
to the solution
Model to this model, which involving either configuring the RVS machine to
The either C1,
result C2,initial
of the C3, C4
basicor C5 is depicted
feasible solution in Table
to this3.model,
Based which
on the involving
result of Table
either3,configuring
it could be deduced
the RVSthat the to
machine
3.1 Initial basic
positioning feasible
of the RVS solution
machine toatthe
C5Model
is the only suitable configuration that have the capability of meeting the five
either C1, C2,theC3,
The result C4 basic
or C5feasible
is depicted in Table 3.model,
Based which
on theinvolving
result of either
Table configuring
3, it could the
be deduced that the
month of
positioning varying
of the
initial
granite
RVS concentrate
machine at C5
solution
demand
is the
to
at this
only a suitable
reduced operations
configurationcost. However,
that have thethe TMUL of
capability of
RVSmachine
this machine
meeting
to
the five
eitherconfiguration
C1, C2, C3, C4 or
is very C5Hence,
high. is depicted in Table
other feasible 3. Based on
configuration the result
planning of Table
solutions 3, itminimize
that will could bethededuced
TPC, TOSL that the
month varying
positioning granite
of the concentrate
RVS machine at C5demand at a suitable
is the only reduced configuration
operations cost.that However, the TMUL
have the capability of this machine
of meeting the five
configuration
month varyingis granite
very high. Hence, other
concentrate feasible
demand at aconfiguration planningcost.
reduced operations solutions that will
However, theminimize
TMUL of thethis
TPC, TOSL
machine
configuration is very high. Hence, other feasible configuration planning solutions that will minimize the TPC, TOSL
252 Olasumbo Makinde et al. / Procedia Manufacturing 43 (2020) 247–254
6 Olasumbo/ Procedia Manufacturing 00 (2019) 000–000

and TMUL need to be sought.

Table 2: RVS Machine Configuration Operations Planning Data
M Monthly FMC MFC for FRM for Other data used for computing SC, IC and NOM
Demand FMC the RVS PC
(tons) (tons)
1 12200 C1 13213 - 0 PC HC SC
2 18500 C2 19440 1-2, 2-3, 3- 45 3 +6
4, 4-5 mins = for C1, R3000 = for C1 to C2
3 29000 C3 25056 1-3, 2-4, 3- 1.2 hrs R1000 C2, C3, 0 R1000 13 for
5 0, C4 and = C1 to C3
4 20900 C4 31680 1-4, 2-5 1.5 hrs = C5 are R5000 = 17 for
R1500 R13590, R1500 C1 to C4
5 40600 C5 41783 1-5 or 5-1 1.8 hrs 0 R19350, 30 + 5
=
R24545 = for C1 to
50000
and R1000 C5
tons
R40017

Table 3: Initial basic feasible solution

RVS MC TPC (R) TOSL (tons) TMUL (%) Remarks
Options
C1 685648 56148 7.67 Low TPC, Very low MUL and Very high TOSL
C2 700585 32270 42.08 Moderate TPC, Low MUL and High TOSL
C3 751652 19488 94.07 Very high TPC, Moderate MUL and Moderate
TOSL
C4 708486 8920 145.58 High TPC, High MUL and Low TOSL
C5 616908 0 208.49 Very low TPC, Very high MUL and Very low TOSL

To this effect, the result of modified Wagner and Whitin algorithm that tends to establish an optimal machine
operations planning configuration solutions that will holistically minimize the TPC, TOSL and TMUL during the
process of meeting the fluctuating five months’ granite concentrates demand is presented in the next section.

3.2 Results of the RVS Machine Configuration Planning solutions obtained from the modified Wagner and Whitin
Algorithm
The result of the stage 1 for the dynamic computation of the model depicted in Table 4 revealed that configuring the
RVS machine to machine configuration C5 minimizes the TPC and TOSL required to meet the granite concentrate
month 1 demand, to the minimum as compared to other feasible configurations. However, the machine utilization
loss for this configuration is high (i.e. 70.80%). In order to deal with this issue, the machine should be fully operated
at C5 for the whole month. This thus ensure the screening of 41783 tons of granite concentrates at a cost of
R233382.24, which thus create an inventory of 29583 tons after meeting 12200 tons of granite concentrates
demanded by the customer.
Table 4: Stage 1 Result
RVS MC TPC TOSL TMUL Remarks Optimal Machine Configuration in
Options (R) (tons) (%) month 1 (X1*)
C1 128588 0 7.67 Very high TPC and Low MUL Fully operate the RVS machine at C5
C2 96014 0 37.24 High TPC and Moderate MUL to screen 41783 tons at TPC of
C3 90158 0 51.31 High TPC and Moderate MUL R233382.24
C4 76982 0 61.49 Moderate TPC and High MUL
C5 62098 0 70.80 Low TPC and High MUL

The result of the stage 2 dynamic computation (see Table 5) revealed that the RVS machine should not be operated
in month 2, since 29683 tons of granite concentrate inventory produced in month 1 can be utilized to meet the
demand of month 2, which is 18500 tons. To this effect, 11083 tons of granite inventory will remain after meeting
 Olasumbo Makinde et al. / Procedia Manufacturing 43 (2020) 247–254 253
Olasumbo/ Procedia Manufacturing 00 (2019) 000–000 7

the demand of month 2, thereby incurring an inventory cost of R7758. However, the MUL experienced at this stage
is 100%, since the machine was not operated at all in this month.
Table 5: Stage 2 Result
RVS MC IC SC PC * TPC* (R) OSL MUL (%) X2*
Options
C5 but not 7758 0 0 7758 233283.24 241141.24 0 100 C5 but not screening
screening operation
operation.

The result of the stage 3 dynamic computation (see Table 6) revealed that reconfiguring the RVS machine from C5
to C2 and fully operating this machine at this new configuration for the whole month 3 minimizes the TPC, OSL
and MUL incurred by the beneficiation company to R384841.74, 0 and 0% respectively as compared to the cost of
operating the machine at configuration C5 to meet the demand of month 3.
Table 6: Stage 3 Result
RVS MC IC SC PC * TPC* (R) OSL MUL X3*
Options (%)
C5 16706.2 0 159193.23 175899.43 241141.24 417040.67 0 0 Operate
Reconfigure 1066.1 1500 141134.40 143700.50 241141.24 384841.74 0 0 RVS
the RVS machine
machine at C2
from C5 to
C2

The result of the stage 4 dynamic computation (see Table 7) revealed that the RVS machine must be fully operated
at C2 to incur a minimum TPC, OSL and MUL of R526020, 0 and 0% respectively as compared to the cost of
reconfiguring the machine from C2 to C3 and thereby operating the machine at a configuration C3, in order to meet
month 4 demand.
Table 7: Stage 4 Result
RVS MC IC SC PC * TPC* (R) OSL MUL X4*
Options (%)
C2 44.10 0 141134.4 141178.5 384841.74 526020.24 0 0 Operate
Reconfigure 3975.3 750 167374.08 172099.38 384841.74 556941.12 0 0 RVS
the RVS machine
machine at C2
from C2 to
C3

The result of the stage 5 dynamic computation (see Table 8) revealed that reconfiguring the RVS machine from C2
to C5 and fully operating this machine at this new configuration for the whole month 3 minimizes the TPC, OSL
and MUL incurred by the beneficiation company to R681966.21, 0 and 2.98% respectively, in order to meet month
5 granite concentrate demand. In light of these results, it could be inferred that, by using the modified Wagner and
Whitin algorithm to obtain the RVS machine operations planning solution, the TMUL reduced by 50.61% (i.e. from
240.81% to 102.98%) while the TPC increased by 10.54% (i.e. from R616908 to R681966.21).
Table 8: Stage 5 Result
RVS MC IC SC PC * TPC* (R) OSL MUL X5*
Options (%)

Reconfigure 0 1500 154445.97 155945.97 526020.24 681966.21 0 2.98 Reconfigure

the RVS the RVS
machine machine from
from C2 to C2 to C5
C5
254 Olasumbo Makinde et al. / Procedia Manufacturing 43 (2020) 247–254
8 Olasumbo/ Procedia Manufacturing 00 (2019) 000–000

The utilisation of this operations planning solution for the reconfiguration of the RVS machine contribute to mineral
processing sustainability in a couple of ways. The utilisation of this operations planning solution by the RVS
machine users on the one hand: (i) reduces the total operations cost of screening mineral concentrates demanded by
the customers, (ii) minimize the energy consumed by the machine during the screening of varying runoff mine, and
(iii) reduce drastically to the barest minimum the underutilization of the machine. On the other hand, it: (i) ensure
just-in-time and exact screening of mineral concentrates demanded by the customers with a view to avoid over-
screening and (ii) minimize the amount of RVS machine component modules held in the warehouse. These
sustainability goals are attained for this machine since the operations planning solution proposed in this study
advises the RVS machine users on the suitable RVS machine configuration, which has the exact or approximate
capacity of screening the varying mineral concentrates demanded by the customers in an economic and
environmental friendly manner.

4. Conclusion

Stochastic and changing mineral concentrate demand by the customers have called for the design of a customized-
flexible machine with an adjustable hardware structure that could meet this demand in a cost effective manner.
Hence, the design of a RVS machine was sought in order to address this plight in the mineral beneficiation
community. In light of this latest development, the establishment of suitable machine configurations that the RVS
machine must be configured to with a view to: (i) meet the stochastic mineral concentrate demand, (ii) minimize
machine underutilization loss and (iii) minimize the total screening operation cost required to meet fluctuating
customer demands was sought in this study. The results of the modified Wagner and Whitin algorithm utilized to
achieve the aforementioned research objective, on the one hand inferred that the RVS machine must be configured
to C5 to meet the months 1 and 2 granite concentrates demand and the machine must be reconfigured from machine
configuration C5 to C3 with a view to meet months 3 and 4 granite concentrates demand. On the other hand, it was
inferred that the machine must be reconfigured from C3 to C5 in order to meet month 5 granite concentrates demand
at a total minimum screening operations cost of R681966.21.

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