Toy Segmentation % Of Manufactured Toy Categories % Of Sold

0-18 Months 12% Action Figures & Play 7%

Sets

18-36 Months 6% Arts & Crafts 16%

3-5 Years 52% Blasters & Accessories 4%

5-7 Years 18% Construction & Building 6%

Toys*
7-9 Years 9% Dolls & Playsets 12%
9-12 Years 1% Games & Puzzles 22%

12+ Years 2% Infants & Preschool Toys 22%

Ride on & Scooters 1%

Roleplay & Playsets* 10%

Yearly Shipment from PVC Manufacturing to Toy Manufacturing (MT)

From/To Noida Nagpur Bhubaneshwar Lucknow

Pune 48,604 37,390 60,558 19,433

PVC to Toy conversion (2020) Demand in Number of Toys (2020)

Toy Manufacturing Yearly (Number of Toys) Distribution Centers Annual

Location

Noida 3,892,080 Delhi 3,229,340

Nagpur 1,847,652 Chennai 880,737

Bhubaneshwar 1,542,520 Kolkata 1,321,168

Lucknow 979,709 Goa 440,389
Rajkot 1,318,928 Mumbai 4,110,034
 Jaipur 587,172
Bhopal 587,214
Shimla 587,130

PVC Manufacturing to Toy Manufacturing center cost heads

PVC Freight
Capacity (MT Per
Manufacturing annum)
Rates/kg Taxes Lead Time(days)*
Location (INR)
Pune 240,000 0.0023 11.50% 2
Avg Selling Price (INR)

300 Equipment Equipment #

380 Tank T1, A1, B1, T2

800 Reactor R1

700 Column Stripping C1

650 Compressor E1
325 Dryer D1

510 Magnetic Separator M1

1200 Warehouse Tank WH1

750

Freight Cost (in INR per to

Toy
Rajkot Manufacturing Delhi Chennai
Location
25,632 Noida 2 3
Nagpur 3 2
Bhubaneshwar 3 2
Lucknow 3 2
Rajkot 1 3

Lead Time (in days) Lead time greater than 1

Toy
Manufacturing Delhi Chennai
Location
Noida 1 2
Nagpur 2 4
Bhubaneshwar 3 3
 Lucknow 4 5
Rajkot 5 2

Toy Manufacturing to Distribution center cost heads *Error Rate is the percentage of toys
getting rejected due to QA checks

Toy Manufacturing Capacity Number of Packaging Cost/toy

Error Rate*
Location toys (Per annum) (in INR)

Noida 6,486,800 1 1.50%

Nagpur 3,079,421 2 1.65%
Bhubaneshwar 2,570,866 3 4.60%
Lucknow 1,632,849 2 3.60%
Rajkot 2,198,213 1 5.55%
 Equipment Description

Capacity Processing Time (in Waiting Time

Utilization hours) (in hours)

50% - -
80% 4 4

75% 1 -

80% 0.5 -
75% 1.5 -

75% 1 -

50% - -

Freight Cost (in INR per toy)

Kolkata Goa Mumbai Jaipur Bhopal Shimla

1 1 2 2 2 1
2 3 2 3 1 1
1 2 1 3 3 3
1 3 3 2 1 1
3 1 2 1 3 2

n days) Lead time greater than 1 day costs us INR 4/toy/day

Kolkata Goa Mumbai Jaipur Bhopal Shimla

3 2 2 2 3 3
2 3 2 5 4 2
5 2 5 3 3 4
 4 4 3 4 5 1
4 1 2 4 3 3

e is the percentage of toys

Taxes

10.00%
8.00%
5.00%
9.00%
6.00%
 Current Organization Structure (2020)

Shift Manager 1 Shift Manager 2 Shift Manager 3

06:00- 14:00 14:00 - 22:00 22:00 - 06:00
Operations 12
Shift Engineer A1 Shift Engineer B1 Shift Engineer C1
Shift Engineer A2 Shift Engineer B2 Shift Engineer C2
2 Inventory Managers Overall Maintenance lead
2 rotary Mechanical
2 static Mechanical Engineers
Engineers
Technician Technician
Maintenance & 27 Rigger Rigger
Procurement
Helper 1 Helper 1
Helper 2 Helper 2
Helper 3 Helper 3
Helper 4 Helper 4
2 Intrument Engineers 3 Electrical Engineers
Technician Technician
Instrument & Electrical 11
Rigger Rigger

Helper 1 Helper 1
Total Strength 50

Employee Headcount Data

Year 2010 2011 2012 2013
Headcount (Start
of the Year) 35 36 37 39

New Hired 2 5 6
Attrition Count 1 3 3
Attrition Rate 3% 8% 8%
 Current Salary Structure 2020 (in INR)

Shift Manager Standby Operations

Floating/Emegercy/Leave No
Shift Engineer D1(standby) Shift Manager 4
Shift EngineerD2(standby) Shift Engineer 8
ance lead Total
2 warehouse Mechanical
Engineer Maintenance & Procurement
Technician Maintenance Lead 1
Rigger Inventory Manger 2
Helper 1 Mechanical Engineer 6
Helper 2 Technician 3
Helper 3 Rigger 3
Helper 4 Helper 12
Total
Instrument & Electrical

Instruments Engineers 2

Electrical Engineers 3
Technician 2
Rigger 2
Helper 2
Total
Grand Total

2014 2015 2016 2017 2018

42 46 46 49 52

7 5 8 9 8
3 5 5 6 7
7% 11% 11% 12% 13%
ons
Salary Total Salary
1,500,000 6,000,000
600,000 4,800,000
l 10,800,000

1,500,000 1,500,000
700,000 1,400,000
600,000 3,600,000
216,000 648,000
108,000 324,000
54,000 648,000
l 8,120,000

600,000 1,200,000

600,000 1,800,000
216,000 432,000
108,000 216,000
54,000 108,000
l 3,756,000
otal 22,676,000

2019 2020

53 50

8
11
21%
Toy Segmentation % Of Manufactured Toy Categories % Of Sold

0-18 Months 12% Action Figures & Play 7%

Sets
18-36 Months 6% Arts & Crafts 16%
3-5 Years 52% Blasters & Accessories 4%

5-7 Years 18% Construction & Building 6%

Toys*
7-9 Years 9% Dolls & Playsets 12%
9-12 Years 1% Games & Puzzles 22%

12+ Years 2% Infants & Preschool Toys 22%

Ride on & Scooters 1%

Roleplay & Playsets* 10%

Yearly Shipment from PVC Manufacturing to Toy Manufacturing (MT)

From/To Noida Nagpur Bhubaneshwar Lucknow

Pune 48,604 37,390 60,558 19,433

Number of Toys
Est 2430200 1869500 3027900 971650
% 1.6015471977615 0.988313453 0.509435582416857 1.008294138836

PVC to Toy conversion (2020) Demand in Number of Toys (2020)

Toy Manufacturing
Yearly (Number of Toys) Distribution Centers Annual
Location

Noida 3,892,080 Delhi 3,229,340

Nagpur 1,847,652 Chennai 880,737

Bhubaneshwar 1,542,520 Kolkata 1,321,168

Lucknow 979,709 Goa 440,389
Rajkot 1,318,928 Mumbai 4,110,034
 Jaipur 587,172
Bhopal 587,214
Shimla 587,130

PVC Manufacturing to Toy Manufacturing center cost heads

PVC
Capacity (MT Per Freight
Manufacturing annum) Rates/kg (INR)
Taxes Lead Time(days)*
Location
Pune 240,000 0.0023 11.50% 2
perday 657.534246575342
actual 526.027397260274 591.7808219
one cycle 175.342465753425 197.260274
max toys 12,000,000
actual 9,580,889 9,580,889
eff 0.798407416666667
actual 9600000 10800000
eff 0.998009270833334 10778500.13
1.125
Avg Selling Price (INR)
1000
300 Equipment Equipment #
21000
380 60800 Tank T1, A1, B1, T2
800 32000 Reactor R1

700 Column Stripping C1

42000
650 78000 Compressor E1
325 71500 Dryer D1

510 Magnetic Separator M1

112200
1200 12000 Warehouse Tank WH1
750 75000
504.5

Freight Cost (in INR per to

Toy
Rajkot Manufacturing Delhi Chennai
Location
25,632 Noida 2 3
Nagpur 3 2
1281600 9580850
1.02912609238452 0.99999592939653 Bhubaneshwar 3 2
Lucknow 3 2
Rajkot 1 3

Lead Time (in days) Lead time greater than 1

Toy
Manufacturing Delhi Chennai
Location
Noida 1 2
Nagpur 2 4
Bhubaneshwar 3 3
 Lucknow 4 5
Rajkot 5 2

Toy Manufacturing to Distribution center cost heads *Error Rate is the percentage of toys
getting rejected due to QA checks

Toy Manufacturing Capacity Number of Packaging Cost/toy

Error Rate*
Location toys (Per annum) (in INR)

Noida 6,486,800 1 1.50%

Nagpur 3,079,421 2 1.65%
Bhubaneshwar 2,570,866 3 4.60%
Lucknow 1,632,849 2 3.60%
Rajkot 2,198,213 1 5.55%
 Equipment Description

Capacity Processing Time (in Waiting Time required

Utilization hours) (in hours) I/p o/p max o/p i/p
50% - -
80% 4 4 355 399.375
75% 1 -
355 248 297.6
80% 0.5 - 248 213 239.625
75% 1.5 - 213 195 234
75% 1 -
195 177 212.4 C1
50% - - 177 0

C2
Freight Cost (in INR per toy)

Kolkata Goa Mumbai Jaipur Bhopal Shimla

1 1 2 2 2 1
2 3 2 3 1 1
1 2 1 3 3 3
1 3 3 2 1 1
3 1 2 1 3 2

C3
n days) Lead time greater than 1 day costs us INR 4/toy/day

Kolkata Goa Mumbai Jaipur Bhopal Shimla

3 2 2 2 3 3
2 3 2 5 4 2
5 2 5 3 3 4
 4 4 3 4 5 1
4 1 2 4 3 3

e is the percentage of toys

Taxes
MT Capacity Yearly
10.00% 129736
8.00% 61588.42
5.00% 51417.32
9.00% 32656.98
6.00% 43964.26
 531
Hours 708
4 R1 4 1.3333333333
1 C1 1

0.5 E1 0.5 PROCESS

WAIT R1
1.5 D1 1.5 R2

1 M1 1

1 C1 1 C1
1 E1 R1 0.5 E1
Idle
1 D1 PROCESS 1.5 D1
1 M1 1 M1 Work
1 C1 1 C1
0.5 E1 0.5 E1
WAIT R1
1.5 D1 1.5 D1
1 M1 Work 1 M1

1
1

0.5
1
1 1.5

1
1
1
0.5

1.5

1
8850 4336500
Microsoft Excel 16.0 Sensitivity Report
Worksheet: [Book1.xlsx]Sheet4
Report Created: 24-08-2021 1.04.09 PM

Variable Cells
Final Reduced Objective Allowable
Cell Name Value Cost Coefficient Increase
$D$72 Noida Delhi 3229340 0 3.1 10.06
$E$72 Noida Chennai 0 0.04 12.1 1E+030
$F$72 Noida Kolkata 0 1.94 14.1 1E+030
$G$72 Noida Goa 0 8.04 10.1 1E+030
$H$72 Noida Mumbai 0 0.04 11.1 1E+030
$I$72 Noida Jaipur 587172 0 11.1 4
$J$72 Noida Bhopal 587214 0 15.1 0.96
$K$72 Noida Shimla 0 10.92 14.1 1E+030
$L$72 Noida Noida 0 0 0 1E+030
$M$72 Noida Nagpur 0 0 0 1E+030
$N$72 Noida Bhubaneshwar 0 0 0 1E+030
$O$72 Noida Lucknow 0 0 0 1E+030
$P$72 Noida Rajkot 0 0 0 1E+030
$D$73 Nagpur Delhi 0 10.06 13.16 1E+030
$E$73 Nagpur Chennai 0 8.1 20.16 1E+030
$F$73 Nagpur Kolkata 1321168 0 12.16 1.94
$G$73 Nagpur Goa 0 15.1 17.16 1E+030
$H$73 Nagpur Mumbai 0 1.1 12.16 1E+030
$I$73 Nagpur Jaipur 0 14.06 25.16 1E+030
$J$73 Nagpur Bhopal 0 4.06 19.16 1E+030
$K$73 Nagpur Shimla 0 7.98 11.16 1E+030
$L$73 Nagpur Noida 0 0 0 1E+030
$M$73 Nagpur Nagpur 0 0 0 1E+030
$N$73 Nagpur Bhubaneshwar 0 0 0 1E+030
$O$73 Nagpur Lucknow 0 0 0 1E+030
$P$73 Nagpur Rajkot 0 0 0 1E+030
$D$74 Bhubaneshwar Delhi 0 12 18.15 1E+030
$E$74 Bhubaneshwar Chennai 0 2.04 17.15 1E+030
$F$74 Bhubaneshwar Kolkata 0 8.94 24.15 1E+030
$G$74 Bhubaneshwar Goa 0 8.04 13.15 1E+030
$H$74 Bhubaneshwar Mumbai 0 10.04 24.15 1E+030
$I$74 Bhubaneshwar Jaipur 0 4 18.15 1E+030
$J$74 Bhubaneshwar Bhopal 0 0 18.15 2.04
$K$74 Bhubaneshwar Shimla 0 15.92 22.15 1E+030
$L$74 Bhubaneshwar Noida 0 0 0 1E+030
$M$74 Bhubaneshwar Nagpur 0 0 0 1E+030
$N$74 Bhubaneshwar Bhubaneshwar 0 0 0 1E+030
$O$74 Bhubaneshwar Lucknow 0 0 0 1E+030
$P$74 Bhubaneshwar Rajkot 0 0 0 1E+030
 $D$75 Lucknow Delhi 0 18.08 21.18 1E+030
$E$75 Lucknow Chennai 0 12.12 24.18 1E+030
$F$75 Lucknow Kolkata 0 7.02 19.18 1E+030
$G$75 Lucknow Goa 0 19.12 21.18 1E+030
$H$75 Lucknow Mumbai 0 6.12 17.18 1E+030
$I$75 Lucknow Jaipur 0 9.08 20.18 1E+030
$J$75 Lucknow Bhopal 0 8.08 23.18 1E+030
$K$75 Lucknow Shimla 587130 0 3.18 7.98
$L$75 Lucknow Noida 0 0 0 1E+030
$M$75 Lucknow Nagpur 0 0 0 1E+030
$N$75 Lucknow Bhubaneshwar 0 0 0 1E+030
$O$75 Lucknow Lucknow 0 0 0 1E+030
$P$75 Lucknow Rajkot 0 0 0 1E+030
$D$76 Rajkot Delhi 0 18.96 22.06 1E+030
$E$76 Rajkot Chennai 880737 0 12.06 0.04
$F$76 Rajkot Kolkata 0 7.9 20.06 1E+030
$G$76 Rajkot Goa 440389 0 2.06 8.04
$H$76 Rajkot Mumbai 4110034 0 11.06 0.04
$I$76 Rajkot Jaipur 0 6.96 18.06 1E+030
$J$76 Rajkot Bhopal 0 0.96 16.06 1E+030
$K$76 Rajkot Shimla 0 11.88 15.06 1E+030
$L$76 Rajkot Noida 0 0 0 1E+030
$M$76 Rajkot Nagpur 0 0 0 1E+030
$N$76 Rajkot Bhubaneshwar 0 0 0 1E+030
$O$76 Rajkot Lucknow 0 0 0 1E+030
$P$76 Rajkot Rajkot 0 0 0 1E+030
$D$77 Pune Delhi 0 0 0 1E+030
$E$77 Pune Chennai 0 0 0 1E+030
$F$77 Pune Kolkata 0 0 0 1E+030
$G$77 Pune Goa 0 0 0 1E+030
$H$77 Pune Mumbai 0 0 0 1E+030
$I$77 Pune Jaipur 0 0 0 1E+030
$J$77 Pune Bhopal 0 0 0 1E+030
$K$77 Pune Shimla 0 0 0 1E+030
$L$77 Pune Noida 4403726 0 2.3 0.96
$M$77 Pune Nagpur 1321168 0 2.3 1.94
$N$77 Pune Bhubaneshwar 0 3.05 2.3 1E+030
$O$77 Pune Lucknow 587130 0 2.3 7.98
$P$77 Pune Rajkot 5431160 0 2.3 0.04

Constraints
Final Shadow Constraint Allowable
Cell Name Value Price R.H. Side Increase
$D$78 Delhi 3229340 3.1 3229340 0
$E$78 Chennai 880737 12.06 880737 0
$F$78 Kolkata 1321168 12.16 1321168 0
$G$78 Goa 440389 2.06 440389 0
$H$78 Mumbai 4110034 11.06 4110034 0
$I$78 Jaipur 587172 11.1 587172 0
$J$78 Bhopal 587214 15.1 587214 0
$K$78 Shimla 587130 3.18 587130 0
$H$84 Total Demand = 11743184 0 12000000 1E+030
$L$78 Noida 4403726 0 648582698 1E+030
$M$78 Nagpur 1321168 0 307891289.55 1E+030
$N$78 Bhubaneshwar 0 0 256968340.16 1E+030
$O$78 Lucknow 587130 0 163226117.44 1E+030
$P$78 Rajkot 5431160 0 219699299.18 1E+030
$Q$72 Noida MF to DS 4403726 0 0 4403726
$Q$73 Nagpur MF to DS 1321168 -1.136868E-13 0 1321168
$Q$74 Bhubaneshwar MF to DS 0 3.05 0 587214
$Q$75 Lucknow MF to DS 587130 -1.136868E-13 0 587130
$Q$76 Rajkot MF to DS 5431160 0 0 0
$Q$77 Pune MF to DS 11743184 2.3 0 214268139.18
Allowable
Decrease
1E+030
0.04
1.94
8.04
0.04
1E+030
2.04
10.92
0
0
0
0
0
10.06
8.1
1E+030
15.1
1.1
14.06
4.06
7.98
0
0
0
0
0
12
2.04
8.94
8.04
10.04
4
3.05
15.92
0
0
0
0
0
 18.08
12.12
7.02
19.12
6.12
9.08
8.08
1E+030
0
0
0
0
0
18.96
1E+030
7.9
1E+030
1E+030
6.96
0.96
11.88
0
0
0
0
0
0
0
0
0
0
0
0
0
0.04
1.1
3.05
6.12
0.96

Allowable
Decrease
3229340
880737
1321168
440389
 4110034
587172
587214
587130
256816
644178972
306570121.55
256968340.16
162638987.44
214268139.18
0
0
0
0
1E+030
0
PVC year efficiency 240,000
Working Efficiency 192000

Toy Manufacturing
Location Estimated Number
PVC Shipped MT of toys conversion
Noida 48,604 2430200
Nagpur 37,390 1869500
Bhubaneshwar 60,558 3027900
Lucknow 19,433 971650
Rajkot 25,632 1281600
191,617 9,580,850
eff 79.84% 100.0004%

Toy Manufacturing
60% Capacity Number of toys (Per annum) Actual PVC to TOY
Location
Noida 6,486,800 3,892,080
Nagpur 3,079,421 1,847,652
Bhubaneshwar 2,570,866 1,542,520
Lucknow 1,632,849 979,709
Rajkot 2,198,213 1,318,928

Toy Manufacturing Location Delhi

Noida 2
Nagpur 3
Bhubaneshwar 3
Lucknow 3
Rajkot 1

Lead Time (in

Toy Manufacturing Location Delhi
Noida 1
Nagpur 2
Bhubaneshwar 3
Lucknow 4
Rajkot 5
 Fre
From/To Delhi
Noida 2
Nagpur 11
Bhubaneshwar 15
Lucknow 19
Rajkot 21

From/To Delhi
Noida 3.10
Nagpur 13.16
Bhubaneshwar 18.15

Lucknow 21.18

Rajkot 22.06
Pune -

Delhi
Demand 3,229,340

From/To Delhi
Noida 3229340
Nagpur 0
Bhubaneshwar 0

Lucknow 0
Rajkot 0
Pune 0
 3229340
=
3,229,340

Total Cost 127323159.68

Shipped eff
0.998005208333333 258420

Conversion to toys

3,892,080 389149618.8
1,847,652 184734713.742
1,542,520 154181044.08
979,709 97935630.476
1,318,928 131819599.496
9,580,889 957,820,607
99.9724039718814

Packaging Cost/toy (in INR) Error Rate* Taxes Packagin cost

1 1.50% 10.00% 389,149,619

2 1.65% 8.00% 369,469,427
3 4.60% 5.00% 462,543,132
2 3.60% 9.00% 195,871,261
1 5.55% 6.00% 131,819,599

Freight Cost (in INR per toy)

Chennai Kolkata Goa Mumbai

3 1 1 2
2 2 3 2
2 1 2 1
2 1 3 3
3 3 1 2

Lead Time (in days) Lead time greater than 1 day costs us INR 4/toy/day
Chennai Kolkata Goa Mumbai
2 3 2 2
4 2 3 2
3 5 2 5
5 4 4 3
2 4 1 2
 Freight Cost (in INR per toy) Include Lead Time Cost
Chennai Kolkata Goa Mumbai
11 13 9 10
18 10 15 10
14 21 10 21
22 17 19 15
11 19 1 10

Per Toy Cost - Freight, Lead, Packaging+TAX

Chennai Kolkata Goa Mumbai
12.10 14.10 10.10 11.10
20.16 12.16 17.16 12.16
17.15 24.15 13.15 24.15

24.18 19.18 21.18 17.18

12.06 20.06 2.06 11.06

- - - -

Chennai Kolkata Goa Mumbai

880,737 1,321,168 440,389 4,110,034

Chennai Kolkata Goa Mumbai

0 0 0 0
0 1321168 0 0
0 0 0 0

0 0 0 0
880737 0 440389 4110034
0 0 0 0
 880737 1321168 440389 4110034
= = = =
880,737 1,321,168 440,389 4,110,034

Total Demand 11,743,184

 Packaging Cost + tax
Optimal Toys Scrap Earn
per Toy
648,582,698 2,919,060 1.10
307,891,290 1,524,313 2.16
256,968,340 3,547,796 3.15
163,226,117 1,763,476 2.18
219,699,299 3,660,025 1.06

Jaipur Bhopal Shimla

2 2 1
3 1 1
3 3 3
2 1 1
1 3 2

Jaipur Bhopal Shimla Delhi

2 3 3 1
5 4 2 8
3 3 4 12
4 5 1 16
4 3 3 20
Jaipur Bhopal Shimla
10 14 13
23 17 9
15 15 19
18 21 1
17 15 14

Plant Cost
Jaipur Bhopal Shimla Noida Nagpur
11.10 15.10 14.10 - -
25.16 19.16 11.16 - -

18.15 18.15 22.15

- -

20.18 23.18 3.18

- -
18.06 16.06 15.06 - -
- - - 2.3 2.3

Jaipur Bhopal Shimla

587,172 587,214 587,130

Jaipur Bhopal Shimla Noida Nagpur

587172 587214 0 0 0
0 0 0 0 0

0 0 0
0 0

0 0 587130
0 0
0 0 0 0 0
0 0 0 4403726 1321168
 587172 587214 587130 4403726 1321168
= = = ≤ ≤
587,172 587,214 587,130 648,582,698 307,891,290

≤ 12,000,000
 Lead Time Cost
Chennai Kolkata Goa Mumbai Jaipur

8 12 8 8 8
16 8 12 8 20
12 20 8 20 12
20 16 16 12 16
8 16 1 8 16
 Plant Cost per toy
Capacity(error
Bhubaneshwar Lucknow Rajkot adjusted)
- - - 648,582,698
- - - 307,891,290

256,968,340
- - -

163,226,117
- - -
- - - 219,699,299
2.3 2.3 2.3 12,000,000

Bhubaneshwar Lucknow Rajkot

MF to DS
0 0 0 4,403,726 ≤
0 0 0 1,321,168 ≤

0
0 0 0 ≤

587,130
0 0 0 ≤
0 0 0 5,431,160 ≤
0 587130 5431160 11,743,184 =
 0 587130 5431160
≤ ≤ ≤
256,968,340 163,226,117 219,699,299
Bhopal Shimla

12 12
16 8
12 16
20 1
12 12
 Freight Cost (in IN
From/To
Noida
Nagpur
Bhubaneshwar

Lucknow

Rajkot
Pune

Demand

From/To

4403726 Noida
1321168 Nagpur
Bhubaneshwar
0

Lucknow
587130
5431160 Rajkot
11,743,184 Pune
256,816

Total Cost
 Freight Cost (in INR per toy) Include Lead Time Cost
Delhi Chennai Kolkata Goa Mumbai Jaipur Bhopal Shimla
2 11 13 9 10 10 14 13
11 18 10 15 10 23 17 9
15 14 21 10 21 15 15 19

19 22 17 19 15 18 21 1

21 11 19 1 10 17 15 14
- - - - - - - -

Delhi Chennai Kolkata Goa Mumbai Jaipur Bhopal Shimla

3,229,340 880,737 1,321,168 440,389 4,110,034 587,172 587,214 587,130

Solution 1

Delhi Chennai Kolkata Goa Mumbai Jaipur Bhopal Shimla

3229340 880737 0 0 1202337 587172 587214 0

0 0 1321168 0 1758253 0 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 587130
0 0 0 440389 1149444 0 0 0
0 0 0 0 0 0 0 0
 3229340 880737 1321168 440389 4110034 587172 587214 587130
= = = = = = = =
3229340 880737 1321168 440389 4110034 587172 587214 587130

112588365.2
 Plant Capacity
Bhubanes
Noida Nagpur hwar Lucknow Rajkot Capacity

- - - - - 6,486,800
- - - - - 3,079,421

2,570,866
- - - - -

1,632,849
- - - - -
- - - - - 2,198,213
2.3 2.3 2.3 2.3 2.3 12,000,000

Bhubanes
Noida Nagpur Lucknow Rajkot
hwar
0 0 0 0 0 6486800 ≤ 6486800
0 0 0 0 0 3079421 ≤ 3079421

0 0 0 0 0 0≤ 0

0 0 0 0 0 587130 ≤ 587130
0 0 0 0 0 1589833 ≤ 1589833
6486800 3079421 0 587130 1589833 11743184 = 11743184
 6486800 3079421 0 587130 1589833
≤ ≤ ≤ ≤ ≤
6486800 3079421 2570866 1632849 2198213 256816
 Per Toy Cost - Freight, Lead, Packaging
From/To Delhi Chennai Kolkata Goa Mumbai
Noida 3.1 12.1 14.1 10.1 11.1
Nagpur 13.16 20.16 12.16 17.16 12.16
Bhubane
shwar 18.15 17.15 24.15 13.15 24.15

Lucknow
21.18 24.18 19.18 21.18 17.18
Rajkot 22.06 12.06 20.06 2.06 11.06
Pune - - - - -

Delhi Chennai Kolkata Goa Mumbai

Demand 3229340 880737 1321168 440389 4110034

From/To Delhi Chennai Kolkata Goa Mumbai

Noida 3229340 0 0 0 0
Nagpur 0 0 1321168 0 0
Bhubane
shwar 0 0 0 0 0

Lucknow
0 0 0 0 0
Rajkot 0 880737 0 440389 4110034
Pune 0 0 0 0 0
 3229340 880737 1321168 440389 4110034
= = = = =
3229340 880737 1321168 440389 4110034

Total Cost 127323159.68

ging Plant Cost per toy
Jaipur Bhopal Shimla Noida Nagpur Bhubaneshwar Lucknow

11.1 15.1 14.1 - - - -

25.16 19.16 11.16 - - - -

18.15 18.15 22.15 - - - -

20.18 23.18 3.18 - - - -

18.06 16.06 15.06 - - - -
- - - 2.3 2.3 2.3 2.3

Jaipur Bhopal Shimla

587172 587214 587130

Solution 2 - Adjusted error of each plant

Jaipur Bhopal Shimla Noida Nagpur Bhubaneshwar Lucknow

587172 587214 0 0 0 0 0
0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 587130 0 0 0 0
0 0 0 0 0 0 0
0 0 0 4403726 1321168 0 587130
 587172 587214 587130 4403726 1321168 0 587130
= = = ≤ ≤ ≤ ≤
587172 587214 587130 648582698 307891289.554 256968340.164 163226117.44
er toy
Capacity(error
Rajkot adjusted)
- 648582698
- 307891289.5535

- 256968340.164

- 163226117.436
- 219699299.1785
2.3 12000000

Rajkot

0 4403726 ≤ 4403726
0 1321168 ≤ 1321168

0 0≤ 0

0 587130 ≤ 587130
0 5431160 ≤ 5431160
5431160 11743184 = 11743184
 5431160
≤
219699299.179 256816
 Time 4 hours 4 hours 4 hours 4 hours

Reactor R1_P R1_W R1_P R1_W

Supply_1 Supply_2 Supply_3

R2_P R2_W R2_P

4 cycles/day = 177*4 = 708MT

708 * 30 = 21240 MT monthly
21240 * 12 = 254880 MT yearly

From exh-9 , We were shipping 191617MT yearly from

Now 254880 MT toys shipped from PVC manufacturin

1 MT to 50 toys …So 254880 MT *50 = 12744000 toy

As opposed to 9580850 toys from previous setup

Updated Exhibit - 9

Yearly Shipment from PVC Manufacturing to Toy

Manufacturing (MT)
Bhubaneshw
From/To Noida Nagpur
ar
Pune 51,074 39,290 63,636

Updated Exhibit - 10 Esp_Capacity(no of toys)2553705.606 1964510.2 3181781.42

Conversion to
toys

4,088,483 Updated Exhibit - 12

1,941,525
1,620,799 PVC Manufacturing to Toy Manufacturing center cost
heads
 PVC Freight
1,029,199 Manufacturi Capacity (MT
Per annum)
Rates/kg Taxes
ng Location (INR)
1,385,788 Pune 254,880 0.0023 11.50%
 4 hours 4 hours

R1_P R1_W

Supply_4 177 MT O/P per cycle

R2_W R2_P

191617MT yearly from Pune PVC Man plant to toy man (mt) which now has increased to 254880MT

om PVC manufacturing plant to 5 toy manufacturing plants

T *50 = 12744000 toys

m previous setup

Manufacturing to Toy
ng (MT)

Lucknow Rajkot

20,421 26,935 201,355

79.8% eff 0.253652 0.195129 0.316037 0.101416
1021030.4 1346732.4 Assumptions made : 1) Reactors and whole supply chain works in same efficienc

1.601
0.9883
 Lead
Time(days)*
0.5094
2 1.008
1.029
o 254880MT

0.133767
ain works in same efficiency
PVC year efficiency 254,880
Working Efficiency 203904

Toy Manufacturing
Location Estimated Number
PVC Shipped MT of toys conversion
Noida 51,074 2553705.6056613
Nagpur 39,290 1964510.1760282
Bhubaneshwar 63,636 3181781.4185589
Lucknow 20,421 1021030.3891617
Rajkot 26,935 1346732.4105899
201,355 10,067,760
eff 79.00% 99.9805%

Toy Manufacturing
60% Capacity Number of toys (Per annum) Actual PVC to TOY
Location
Noida 6,814,138 4,088,483
Nagpur 3,235,876 1,941,525
Bhubaneshwar 2,701,332 1,620,799
Lucknow 1,715,331 1,029,199
Rajkot 2,309,646 1,385,788

Toy Manufacturing Location Delhi

Noida 2
Nagpur 3
Bhubaneshwar 3
Lucknow 3
Rajkot 1

Lead Time (in

Toy Manufacturing Location Delhi
Noida 1
Nagpur 2
Bhubaneshwar 3
Lucknow 4
Rajkot 5
 Fre
From/To Delhi
Noida 2
Nagpur 11
Bhubaneshwar 15
Lucknow 19
Rajkot 21

From/To Delhi
Noida 3.10
Nagpur 13.16
Bhubaneshwar 18.15

Lucknow 21.18

Rajkot 22.06
Pune -

Delhi
Demand 3,229,340

From/To Delhi
Noida 3229340
Nagpur 0
Bhubaneshwar 0

Lucknow 0
Rajkot 0
Pune 0
3229340
=
3,229,340
Total Cost 127323159.68
Shipped eff
0.9875 258420

Conversion to toys

4,088,483 408786940.226253
1,941,525 194120505.527654
1,620,799 162005388.686478
1,029,199 102882812.076739
1,385,788 138501853.835096
10,065,794 1,006,297,500
99.9524720843782

Packaging Cost/toy (in INR) Error Rate* Taxes Packagin cost

1 1.50% 10.00% 408,786,940

2 1.65% 8.00% 388,241,011
3 4.60% 5.00% 486,016,166
2 3.60% 9.00% 205,765,624
1 5.55% 6.00% 138,501,854

Freight Cost (in INR per toy)

Chennai Kolkata
3 1
2 2
2 1
2 1
3 3
Goa Mumbai
1 2
3 2
2 1
3 3
1 2

Lead Time (in days) Lead time greater than 1 day costs us INR 4/toy/day
Chennai Kolkata Goa Mumbai
2 3 2 2
4 2 3 2
3 5 2 5
5 4 4 3
2 4 1 2
 Freight Cost (in INR per toy) Include Lead Time Cost
Chennai Kolkata Goa Mumbai
11 13 9 10
18 10 15 10
14 21 10 21
22 17 19 15
11 19 1 10

Per Toy Cost - Freight, Lead, Packaging+TAX

Chennai Kolkata Goa Mumbai
12.10 14.10 10.10 11.10
20.16 12.16 17.16 12.16
17.15 24.15 13.15 24.15

24.18 19.18 21.18 17.18

12.06 20.06 2.06 11.06

- - - -

Chennai Kolkata Goa Mumbai

880,737 1,321,168 440,389 4,110,034

Chennai Kolkata Goa Mumbai

0 0 0 0
0 1321168 0 0
0 0 0 0

0 0 0 0
880737 0 440389 4110034
0 0 0 0
880737 1321168 440389 4110034
= = = =
880,737 1,321,168 440,389 4,110,034
Total Demand 11,743,184
 Packaging Cost + tax
Optimal Toys Scrap Earn
per Toy
681,311,567 3,066,362 1.10
323,534,176 1,601,758 2.16
270,008,981 3,727,839 3.15
171,471,353 1,852,558 2.18
230,836,423 3,845,561 1.06

Jaipur Bhopal Shimla

2 2 1
3 1 1
3 3 3
2 1 1
1 3 2

Jaipur Bhopal Shimla Delhi

2 3 3 1
5 4 2 8
3 3 4 12
4 5 1 16
4 3 3 20
Jaipur Bhopal Shimla
10 14 13
23 17 9
15 15 19
18 21 1
17 15 14

Plant Cost
Jaipur Bhopal Shimla Noida Nagpur
11.10 15.10 14.10 - -
25.16 19.16 11.16 - -

18.15 18.15 22.15

- -

20.18 23.18 3.18

- -
18.06 16.06 15.06 - -
- - - 2.3 2.3

Jaipur Bhopal Shimla

587,172 587,214 587,130

Jaipur Bhopal Shimla Noida Nagpur

587172 587214 0 0 0
0 0 0 0 0

0 0 0
0 0

0 0 587130
0 0
0 0 0 0 0
0 0 0 4403726 1321168
587172 587214 587130 4403726 1321168
= = = ≤ ≤
587,172 587,214 587,130 681,311,567 323,534,176
≤ 12,744,000
 Lead Time Cost
Chennai Kolkata Goa Mumbai Jaipur
8 12 8 8 8
16 8 12 8 20
12 20 8 20 12
20 16 16 12 16
8 16 1 8 16
 Plant Cost per toy
Capacity(error
Bhubaneshwar Lucknow Rajkot adjusted)
- - - 681,311,567
- - - 323,534,176

270,008,981
- - -

171,471,353
- - -
- - - 230,836,423
2.3 2.3 2.3 12,744,000

Bhubaneshwar Lucknow Rajkot

MF to DS
0 0 0 4,403,726 ≤
0 0 0 1,321,168 ≤

0
0 0 0 ≤

587,130
0 0 0 ≤
0 0 0 5,431,160 ≤
0 587130 5431160 11,743,184 =
0 587130 5431160
≤ ≤ ≤
270,008,981 171,471,353 230,836,423
Bhopal Shimla
12 12
16 8
12 16
20 1
12 12
 Freight Cost (in IN
From/To
Noida
Nagpur
Bhubaneshwar

Lucknow

Rajkot
Pune

Demand

From/To

4403726 Noida
1321168 Nagpur
Bhubaneshwar
0

Lucknow
587130
5431160 Rajkot
11,743,184 Pune

1,000,816
Total Cost
 Freight Cost (in INR per toy) Include Lead Time Cost
Delhi Chennai Kolkata Goa Mumbai Jaipur Bhopal Shimla
2 11 13 9 10 10 14 13
11 18 10 15 10 23 17 9
15 14 21 10 21 15 15 19

19 22 17 19 15 18 21 1

21 11 19 1 10 17 15 14
- - - - - - - -

Delhi Chennai Kolkata Goa Mumbai Jaipur Bhopal Shimla

3,229,340 880,737 1,321,168 440,389 4,110,034 587,172 587,214 587,130

Solution 1

Delhi Chennai Kolkata Goa Mumbai Jaipur Bhopal Shimla

3229340 880737 0 0 1202337 587172 587214 0

0 0 1321168 0 1758253 0 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 587130
0 0 0 440389 1149444 0 0 0
0 0 0 0 0 0 0 0
3229340 880737 1321168 440389 4110034 587172 587214 587130
= = = = = = = =
3229340 880737 1321168 440389 4110034 587172 587214 587130
112588365.2
 Plant Capacity
Bhubanes
Noida Nagpur hwar Lucknow Rajkot Capacity

- - - - - 6,486,800
- - - - - 3,079,421

2,570,866
- - - - -

1,632,849
- - - - -
- - - - - 2,198,213
2.3 2.3 2.3 2.3 2.3 12,000,000

Bhubanes
Noida Nagpur Lucknow Rajkot
hwar
0 0 0 0 0 6486800 ≤ 6486800
0 0 0 0 0 3079421 ≤ 3079421

0 0 0 0 0 0≤ 0

0 0 0 0 0 587130 ≤ 587130
0 0 0 0 0 1589833 ≤ 1589833
6486800 3079421 0 587130 1589833 11743184 = 11743184
6486800 3079421 0 587130 1589833
≤ ≤ ≤ ≤ ≤
6486800 3079421 2570866 1632849 2198213 256816
 Per Toy Cost - Freight, Lead, Packaging
From/To Delhi Chennai Kolkata Goa Mumbai
Noida 3.1 12.1 14.1 10.1 11.1
Nagpur 13.16 20.16 12.16 17.16 12.16
Bhubane
shwar 18.15 17.15 24.15 13.15 24.15

Lucknow
21.18 24.18 19.18 21.18 17.18
Rajkot 22.06 12.06 20.06 2.06 11.06
Pune - - - - -

Delhi Chennai Kolkata Goa Mumbai

Demand 3229340 880737 1321168 440389 4110034

From/To Delhi Chennai Kolkata Goa Mumbai

Noida 3229340 0 0 0 0
Nagpur 0 0 1321168 0 0
Bhubane
shwar 0 0 0 0 0

Lucknow
0 0 0 0 0
Rajkot 0 880737 0 440389 4110034
Pune 0 0 0 0 0
3229340 880737 1321168 440389 4110034
= = = = =
3229340 880737 1321168 440389 4110034
Total Cost 127323159.68
ging Plant Cost per toy
Jaipur Bhopal Shimla Noida Nagpur Bhubaneshwar Lucknow

11.1 15.1 14.1 - - - -

25.16 19.16 11.16 - - - -

18.15 18.15 22.15 - - - -

20.18 23.18 3.18 - - - -

18.06 16.06 15.06 - - - -
- - - 2.3 2.3 2.3 2.3

Jaipur Bhopal Shimla

587172 587214 587130

Solution 2 - Adjusted error of each plant

Jaipur Bhopal Shimla Noida Nagpur Bhubaneshwar Lucknow

587172 587214 0 0 0 0 0
0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 587130 0 0 0 0
0 0 0 0 0 0 0
0 0 0 4403726 1321168 0 587130
587172 587214 587130 4403726 1321168 0 587130
= = = ≤ ≤ ≤ ≤
587172 587214 587130 648582698 307891289.554 256968340.164 163226117.44
er toy
Capacity(error
Rajkot adjusted)
- 648582698
- 307891289.5535

- 256968340.164

- 163226117.436
- 219699299.1785
2.3 12000000

Rajkot

0 4403726 ≤ 4403726
0 1321168 ≤ 1321168

0 0≤ 0

0 587130 ≤ 587130
0 5431160 ≤ 5431160
5431160 11743184 = 11743184
5431160
≤
219699299.179 256816