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    AText Book on Industrial Engineering, Robotics and Mechatronics Useful for JAS/ GATE / ESE / PSUs and other competitive examinations Dr. Swadesh Kumar Singh B.Tech, AMU Aligarh, Gold Medalist MTech, and Ph.D. from II Delhi Ex IES officer, Govt, of india Professor, GRIET, Hyderabad Dr. Rajesh Purohit MTech, and PhO. from IIT Delhi Associate Professor, MANIT, Bhopal MADE EASY Publications Corporate Office: 44-A/4, Kalu Sarai (Near Hauz Khas Metro Station), New Delhi-110016 E-mail: infomep@madeeasy.in Contact: 011-45124660, 8860378007 Visit us at: www.madeeasypublications.org Atext book on Industrial Engineering, Robotics and Mechatronics ‘© Copyright, by MADE EASY Publications All rights reserved. No part of this publication may be reproduced, stored in or introduced into a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise), without the prior permission of the above mentioned publisher of this book. First Edition: 2016 ‘MADE EASY PUBLICATIONS has taken due caren collecting the data and providing the solutions before publishing this Book Inspite ofthis, fany inaccuracy or printing error accurs then MADE FASY PUBLICATIONS owes no responsibility. We will be (lf you could point out any such ero. Your suggestions will be appreciated. FOREWORD In my long teaching career | have come across many other fellow teachers but Dr. Swadesh Singh is unique. He has the rare combination of being Ex-IES officer in Govt. of India, a Ph.D from reputed Indian Institute of Technology Delhi, a Young Scientist award winner and a Career Award winner for teaching. ‘As a teacher, he is one of those who really tries to understand the students from their perspective and helps them. He has a penchant for guiding and counseling students in choosing their careers and preparing them for their comps for him even years after graduating. Dr. Singh's book on Production Technology has become popular and is a standard among the students who are top rankers in compatitive exams like GATE, CIVIL SERVICES ete. and the present book on Industrial engineering should stand testimony to the expertise of Dr. Singh's in presenting in a compact book what is just appropriate for preparing for such exams. ive exams. Many students have benefited from him and holds regard This book is a must-have for those who are serious in finding success in competitive exams. Prof. S.Raju Director GRIET, Hyderabad, India PREFACE Alter the overwhelming response of my first book on Production Engineering, | thought of writing another book on the core subject of Industrial Engineering, After teaching for various competitive examinations for about 16 years, | found that although there are so many books available on the fundamentals of Industrial Engineering but there is no book available for competitive examinations. The book which student can have and crack any question that appears in examination like GATE, IES and other public sector examination. So in the present book my effort is to teach fundamentals by problem solving so thal students can understand well. Apart from the solved example-problems, numerous objective-type practice problems from various competitive examinations are given, along with the answer keys. The first edition of this book | released in 2011. Since most of the work including the typesetting, editing and so on was carried outby me, there were many grammatical mistakes in that edition. While teaching and students solving the problem we have corrected the text thoroughly and I have also added some more relevant text in each topic making it more suitable for the competitive examinations. Along with Dr. Rajesh Purohit of MANIT Bhopal, | have added Robotics and Mechatronics to make the book suitable for IES and other competitive examinations | express my gratitude t subject matter can be learned through the medium of a teacher only. He thought me both his precept my spiritual teacher who has given me inspiration to write this book. Every and by his personal example how to be sincere at work and what is good for me and how can | help others in a genuine way. The authors are thankful to Sunil Kumar, Deepen Banoriya, Utkarsh Pandey, Bhrant Kumar, Harish Limbadii, Prudvi, Gangadhar andi Srinivasu for taking pain in correcting the manuscript many times We also thank MADE EASY proof editing staff and CMD Sri B. Singh for their full support in publishing this book. We hope that aspirants of scoring high in GATE, ESE, IAS, PSU and any competitive exams find this book as a helpful aid in their preparations. Dr. Swadesh Kumar Singh Dr. Rajesh Purohit Graphical Method 1.4 Introduction Practice Questions Answers. Simplex Method 241 Introduction 2.2 Verification of Simplex Results 2.3. Sensitivity Analysis of Simplex 2.4 Dual Simplex Procedure. Practice Questions Answers. Transportation 3.1. Introduction 3.2 North West Corner Method 3.3 Least Cost Method 36 36 37 3.4 Vogel Approximation Method (VAM) 37 3.5 MODI Method Practice Questions. Answers. Assignment and Sequencing 44 Assignment 4.2 Transferring the Solutions to the ~ 43 Sequencing 4.3.1. Partentry Control Strategies. Practice Questions Ans... Queuing Theory 5.1 Introduction 5.2 Multiple Services Single Queue Practice Questions ASHES oon Inventory 6.1 Introduction 6.2 Production Leveling and Heijunka 6.3 Types of Inventory Costs 6.4 Types of Inventories 40 48 50 5 52 55 55. 61 82 63 70 73 78 79 79 at 82 65 Inventory Models. 82 6.6 Inventory Control 95 Practice Questions 97 Answers. 107 Project Management 7.1 Introduction 108 7.2 Rules for Construction of Precedence Diagram. 108 7.3 Line Balancing 410 7.4 Network Analysis. 412 7.5 Terminology used in CPM and PERT..112 7.6 Critical path method (CPM), 118 7.7 Crashing of Networks 115 7.8 PERT (Program Evaluation Review Technique) 17 Practice QUEStIONS urn 2A ANSWENS.srsannnninninnnnnnnne ASS Forecasting & Break Even Analysis 8.1 Fixed Cost 134 8.2 Variable Cost 135 8.3 Break Even Analysis 136 8.4 Forecasting 140 85 Trend Line, 141 8.6 Forecasting Errors 143 8,7 Moving Average Methods 144 88 Exponential Smoothening 146 Practice Questions 150 Answers. 162 Value Engineering & Work Study 98.1 Introduction 163 9.2 Product life Cycle 164 9.3 Work Study 164 9.4 Time Study 165 9.5 Techniques of Work Measurement...165, 9.6 Method Study 470 9.7 Micro Motion Studies. 178 9.8 The Two-Handed Process Chart..174 9.9 Micro-Motion Study. 174 Practice Questions 175 ANSWEES er rrnnseeninnnrnnneee 190 10. Robots 10.1. Introduction 10.2 Robot Applications 10.3 Robot Types 10.4 Robot Anatomy and Related ~. 10.5 Performance Specifications of Industrial Robots Practice Questions Answers. 11. Quality Control 1144 Introduction 11.2 Seven Quality Control Tools 11.3. Types of Errors in Control Charts 11.4 %-Chants 11.5 Attributes Charts: 11.6 Sampling Inspections. 191 192 193 199 202 208 an 212 212 217 218 228 229 11.7 O.C. Curve (Operating Characteristic Curve), 11.8 Total Quality Control (TAC) 11.9. Edwards Deming’s Award 11.10 Total Quality Management 11.11 Quality Systems and Standards 11.12 Quality Wheel or Cycles Practice Questions ANSWEPS sn 234 233 234 234 234 238 241 248 12. Microprocessor and Microcontrollers 12.1. Microprocessor 12.2 Internal structure of a ~ 12.3 Clock Speed 12.4 Input/Output Ports (I/O Ports) 12.8 Microcontroller. 12.6 How towtite a Simple LCD Program 12.7 The Programmable Logic Conteller Solved Problems Unsolved Subjective Problems... Practice Questions Answers. 250 253 254 254 256 257 259 262 263 264 269 13. Mechatronics Devices 18.1. Piezoelectric Accelerometers 13.2. Optical Eneoder 13.3. Resolvers. 13.4 Inductosyn. 13.8 Stepper Motors. Unsolved Subjective Problems. Practice Questions Answers. 14. Sensors and Actuators 14.1. Sensors 14.2 Hall Effect Sensor 14.3. Actuators Practice Questions Answers. 15. Control Systems 15.1. Introduction 15.2 Characteristics of Control Systems. 15.3 Examples of Control Systems 15.4 Controller 15.5 Compensator. 15.6 Control System Configuration 18.7 Controllability, 15.8 Reachability, 15.9. Gramians 15.10 Observabiity 15.11 Detectabilty 15.12 Constructability 15.13 Duality Principle 15.14 Math Modeling and Simulation Practice Questions. Answers. 270 274 280 283 289 300 303 315 316 327 333 ai 345 346 346 347 347 347 348, 349 350 350 351 352 353 383 357 964 369 CHAPTER Graphical Method 1.1 INTRODUCTION Optimization is @ process of either maximizing or minimizing a specific quantity called objective which depends upon a finite number of variables, These vatiables can be altogether independent or related to each other. Depending upon the availabilty of facilities in the department or plant, constraints will be formed, Graphical Method of solving these problems is limited to two dimensions only and the method can be understood by the following examples Example: 1.1 Assume that the following specify a generalized linear programming problem: Max Z Subjectto 2¢+ys90 x+2ys80 x+ys50 x y20 45x + 40y Solve it by using Graphical Method and slope method. Solution: (a) The equation of lines can be changed into this form 2x+y xe2ys80 = & y 80 xtys50 > y 50 Yes xy 45" 90 oS Xs 50 (b) Now plot these lines on the graph (c) Mark the feasible region as shown in above graph 1 Fig. 1.4 (d) Locate the end points of feasible region as O, A, B,C, D (e) Find ‘x’ andy’ coordinates of those points as shown below: ‘0 (0,0) ‘A’ > (0, 40) 'B > (20, 30) ‘C (40, 10) 'D (48, 0) Z = 45x + doy Zag = 45(0) + 40(0) =0 Zon = 45(0) + 40(40) = 1600 Zovie = 45(20) + 40(80) = 2100 Zee: = 45(40) + 40{10) = 2200 optimum point Zyoq = 48(45) + 40(10) = 2025 2. | Atextbook on Industrial Engineering, Robotics and Mechatronics MADE ERSY (f) To find point of maxima directly we need to understand the following theory + Initially the objective function line is drawn passing through the origin, the moment the objective functon line first touches the feasible region or feasible point that is the point of minima. +The farthest point at which objective function line is touching the feasible region's the point of maxima. SS (Q) % Utlization of machines at the optimum point: Sy x Now optimum points (40, 10) so, Inport NS pumum points (49.10) Mn Pant SS once Futon Line Utilization of machine 1 is Fig. 12 2x + y= 2(40) + 10= 90590 ‘ 90 % Uilization of machine ts 29100 = 100% Utiization of machine 2is x + 2y = (40) + 2(10) = 60<80 +. % Utilzation of machine 2is 82100 = 75% Utiization of machine Sis x4 y= 40+ 10 - 50550 - % Utlizaton of machine 3s 59.109 = 100% Slope Metho 48 lope of the objective function (m) = -“2 Slope i (m) = ~75 2 Slope of first constraint (m,) 1 Slope of second constraint (m,) =~ Slope of thied constraint (m,) = -1 ‘As mlies between mand m, the o: Note: ifm, For stamping machine => y 3000 For forming machine => 15x + Sy < 30,000 => —~. 0(0,0) > 2,4 =-45,000 (2000.0) = Z, = 5,000 (1800,600) => Z,, = 9,000 (0.1800) = Z, = 0 % 9000 is the net profit per day Example: 1.3 ‘Assume that the following specify a generalized linear programming problem: Max f(x) = 2x, +x, Subjectto x, +x, $6 xS3 2x, +x,24 xy 220 Graph this problem, identitying the three constraint equation lines and the feasible zone common to all of them,Plot dotted lines for values of 3, 6, 9 and 12 for the objective function (x). What appears to be the highest feasible value of f(x) and for what values of x, and x, does it occurs? Solution: xytx,s6 > eet Ao), 240.6), point at 20), at E30). 2=6 x Mey 2x, +m24 = ym 20 Corresponding to Z= 12, there is over utilization of all facilities Corresponding to Z = 9, since it is an optimum value there is 100% utilization of all facilities. At Z= 6, there is under utilization of all facilities, Corresponding to Z = 3, it is not a feasible solution Fig. 1.4 By slope method Z= 2B,+x, 4 | A textbook on Industrial Engineering, Robotics and Mechatronics MADE ERSY atm $6 m= x3 m=0 2 tx 24 m, = -2 Here mand m, are equal but its important to note that in maximization of Z value, we will consider the equations which always have less than or equal to°s sign, and not consider the equation having "2" sign. In minimization, the converse is true. Example: 1.4 Assume that the following specify a generalized linear programming problem: Min Z = 2x+3y Subjectedto 5x+y2100 3x+2y2120 x+3y290 x y20 Solve it by using Graphical Method. Solution: soy xy xy Arvo a5 Arde “700 40" 60" a0 30 co st A(0, 100), 29300 80 200), _ 1080 ° oP Pee * frc( 3) 2-8] — opiate °0 51 (90.0), 2= 189 2 Fig. 1.8 Example: 1.5 Assume that the following specify a generalized linear programming problem: Max z = 300x, +400x, Subjectedto 3x, + 6x, $150 Bx, + 3x, $180 5x, + 4x, 2 100 2x, + 4x, 280 Solve it by using shortcut slope method. Solution: As itis maximization problem, do not consider equations having '>' sign 3 3 m= 72-075; m= E205; m= 1.33 ‘me(m,,m,) :. Optimum points the intersection of ine (1) and (2) Le. (30, 10) > max Z = 13000 MADE EASY Graphical Method | 5 Example 1.6 ‘Assume that the following specify a generalized linear programming problem: Max Z = 6x, + 4x, Subjectedto 2x, + 3x, $30 Bx; + 2x, $24 xy +x, 23 4220 Solve it by using Graphical Method & slope methods. Solution: By graphical method 2s 10 ‘ ee 72 <1! at A(3,0)2= 18 at 0, 3)Z= 12 at 600, 10) at E(@, 0). 25 48 + a 01 02003°04 05 06 07 08 09 10 11 1213 14 15 Fig1.6 ‘+ Inthese situations at the farthest point, objective function line superimposes over one of the constraint lines, so all the points falling on ‘DE line will be optimum + Thisis the case of alternate solution because the slope of objective function line is same as that of one of the constraints and objective function line is superimposing over the constraint line at the outermost point By slope method: Ithas alternative solutions, 6 | A textbook on Industrial Engineering, Robotics and Mechatronics MADE ERSY Example: 1.7 ‘Assume that the following specify a generalized linear programming problem: Max Z = 3x, + 2x, Subjectto x, -x, $1 x, +x, 23 XyX,20 Solve it by using Graphical Method. Solution: Feasible Region > Fig. 1.7 In problem feasible region extends to infinite, so for max Z, it Il be unbounded solution Example: 1.8 ‘Assume that the following specify a generalized linear program MaxZ = x, +x, Subjectedto x, +x, 51 “Bx, +x,23 yx, 20 Solve it by using Graphical Method. 1g problem: Solution: Fig 1.8 Regions (1) and (2) are not having any intersection region so there is no feasible region, sono solution 9000 PRACTICE QUESTIONS 1. Consider the following linear programming problem Max. Z= 2A + 8B, subject to A+ B <10, 44+ 6B <30,2A+ B < 17, A, B2 0whatcan one say about the solution? (a) Itmay contain alternative optima —_(b). The solution will be unbounded (c) The solution will be degenerate (d) It cannot be solved by simplex method 2. In case of solution of a two variable linear programming problem by graphical method one constraint ine comes parallel to the objective function line. Which ane of the following is correct? The problem will have (@) Infeasible solution (b)_ Unbounded solution (c) Degenerate solution (@) Infinite number of optimal solutions 3. Which of the followng are correct in respect of graphically solved linear programming problems? 1. The region of feasible solution has concavity property 2, The boundaries of the region are lines or planes. 3, There are corners or extreme points on the boundary. Select the correct answer using the codes given below: (@) tands (o) 2and3 (6) tands (@) 1,2and3 4. If mis the number of constraints in a linear programming with two variables x and y and non- negativity constraints x > 0, Y> 0; the feasible region in the graphical solution will be surrounded by how many lines? @m (o) m+ () m+2 (a) m4 Which one of the following is true in case of simplex method of linear programming? (@) The constants of constraints equation may be positive or negative. (b) Inequalities are not converted into equations. (¢) Itcannotbe used for two-variable problems. (a) The simplex algorithm is an iterative procedure. The linear programming is used for optimization problems which satisfy the following conditions: 1. Objective function expressed as a linear function of vatiables. 2, Resources are unlimited, 8, The decision variables are interrelated and non-negative. Which of these statements is/are correct? (@) 1,2and3 (0) 2and3 only (©) 1only (@) 1 and only Consider the following statements: 1, Resources limitations must be known, 2. Relationship of variables must be known, Which of these statements must be satisfied to deal with the programming effectively? (@) tony (©) 2only (c) both t and 2 (@) neither 1 nor 2 aphical techniques of linear A textbook on Industrial Engineering, Robotics and Mechatronics MADE ERSY 10. ". 12. 13. 14, The first algorithm for Linear Programming was given by: (a) Beliman (0) Dantzig (c) Kulm (@) Van Neumann Let y, and y, be the decision variables of the dual and v, and v, be the slack variables of the 0,x,>0 The maximum profit which can meet the constraints is (a) 29 (0) 38 (o) 44 (a) 75 Consider the following Linear Programming Problem (LPP): Maximize: = 3x; + 2x, Subjectto. x,<4 x6 3x, +8x,< 18 x,20, x20 (@) The LPP has a unique optimal solution (0) The LPP is infeasible (6) The LPP s unbounded. (@) The LPP has multiple optimal solution Match List-I with List-Il and select the correct answer using the codes given below the lists: List- List-I1 A. Linear programming 1, Ritchie B. Dynamic programming 2. Dantzig ©. °C’ programming 3. Bell D. Integer programming 4, Gomory MADE EASY Graphical Method | 9 15. 16. 7. 18. 19. 20. Codes: ABCD @2 1 4 3 (1 2 3 4 (2 31 4 (23 414 Linear programming model can be applied to: 1. Line balancing problem 2. Transportation problem 3. Project management Of these statements: (@) 1,2and3 are comrect (0) tand2 are correct (6) 2and3are correct (d) 1andSare correct The primal of a LP problem is maximization of objective function with 6 variables and 2 constraints Which of the following correspond to the dual of the problem stated? 1. Ithas 2 variables and 6 constraints. 2, Ithas 6 variables and 2 constraints, 3, Maximization of objective function 4, Minimization of objective function. Select the correct answer using the codes given below: (a) 1and3. () 1ana4 (©) 2and3. (a) 2anda Maximize: P=x + 12y Subjected to 20x + 10y< 200 10x + 20y< 120 10x + 30y< 150 x20and y20 (a) 0 (0) 66 (c) 60 (a) 120 feasible solution to the linear programming problem should (a) satisty the problem constraints, (b) optimize the objective function. (c) satisty the problem constraints and non-negativty restrictions, (d) satisty the non-negativity restrictions Solutionto 2= 4x, + Gx, xy tx s4 Br, +4, 812 X44 20 is (@) unique (0) unbounded (6) degenerate (2) infinite Assumptions of linear programming include: 1. Linearity 2. Additvity 3. Divisibility 4, Certainty 10 A textbook on Industrial Engineering, Robotics and Mechatronics MADE ERSY 21. 22. 23. 24. 25. 26. 27. Select the correct option (a) 1and2 (0) Tanda (©) 1,3and4 (9) 1,2,3and4 Divisibilty assumption in linear programming employs (@) resources can be divided among product. (©) product can be divided among the customers. (6) decision variable may take an integer value. (@) decision variable may take a traction value Which of the following conditions are necessary of applying linear programming? 1, There must be a well-defined objective function, 2. The decision variables should be interrelated and non-negative, 3, The resources must be in limited supply. (a) 1 and 2 only (b) 1 and3 only (©) 2and 3 only (d) 1,2and3 A variable which has no physical meaning, but is used to obtain an initial basic feasible solution to the linear programming problems referred to as (2) Basic variable (©) Non-basic variable (©) Artificial variable (a) Basis Consider the following statements regarding the characteristics ofthe standard form of a linear programming problem 1. Allthe constraints are expressed in the form of equations, 2. The right-hand side of each constraint equation is non-negative. 3, Allthe decision variables are non-negative. Which of these statements are correct? (@) 1, 2ana3 (0) tand2 (©) 2ana3. (@) tand3 Which one of the following statements is NOT correct? (a) Assignment model is a special ease of a linear programming problem, (b) In queuing models, Poisson arrivals and exponential services areassumed. (6) Intransportation problems, the non-square matrixis made square byadding a dummy row or a dummy column. (d) In linear programming problems, dual of a dual is a primal Which of the following are correct in respect of graphically solved linear programming problems? 1. The region of feasible solution has concavity property 2, The boundries of the region are lines or planes. 3, There are comers of extreme points on the boundary, Select the correct answer using the code given below. (a) 1and2 (0) 2and3 (©) 1and3. (a) 1,2and3 In case of solution of linear programming problem using graphical method, ifthe constraint line of one of the non-redundant constraints is parallel to the objective function line, then it indicates (@) an infeasible solution (b) adegenerate solution (@) an unbound solution (a) amuttiple number of optimal solutions MADE EASY Graphical Method | 11 28. In alinear programming problem, which one of the following is (2) a point in the feasible region is not a solution to the problem is correct for graphical method (b) one of the corner points of the feasible region is not the optimum solution. (c) any point in the positive quadrant does not satisty the non-negativity constraint, (d) the lines corresponding to different values of objective functions are paralle! 29. A company produces two types of paper towels, called regular and super soakers. Marketing has imposed a constraint that the total monthly production of regular should not be more than twice the production of super soakers. Letting x be the number of units of regular produced per month and y represents number of super soakers produced per month, appropriate constraints will be (a)xs2y (b) 2vsy (c)x+05ys0 (d) x-O.5y20 9000, GRAPHICAL METHOD 1.) 2@ 3.) 46) 5. 6.) 7.6) ao) 9@ 66 ME We Be HE) 15. (b) 16. (b) 17. @ 18. (0) 19. (a) 20. (@) 21. (c) 2. () ao 2@ 2 6H wh we 28. (b) CHAPTER Simplex Method 2.1 INTRODUCTION When there are more than two variables, graphical method cannot be used to solve optimization problems. As it was explained in the previous chapter that optimal solution exists always at the comer point at the feasible region, the simplex method is a systematic procedure at finding corner point solution and taking them for optimality. Simplex procedures are meant for profit maximization and if our objective is loss minimization then the problems has to be converted into profit maximization by multiplying the Objective function by “sign before starting the simplex procedures While solving problems using simplex methods, we take slack variables, surplus variables and artificial variables. After solving the simplex problem, we can do the verification test of the result to make sure that the answer is correct. In many practical problems we want to find not only an optimal solution but also want to determine what happens to this optimal solution when certain changes are made in the system, For this we do the sensitivity. While doing sensitivity analysis if negative value appears in solution matrix, the matrix is not an optimum one and we move towards optimality by dual simplex procedure. While solving problems using simplex methods if many artilicial variables are to be used we will write a dual problem for the given problem and then solve it by simplex procedure. The intermediate steps and fundamentals involved in simplex procedure are given in the following problems. Slack variables are those which are added to the constraint equations to get equal to sign ("=") Example: 2.1 Assume that the following specify a generalized linear programming problem: May Z= xox, + 8x Subjectedto 2x, —x, $2 x, +p 7458 10 2x, ~ 2x, + 3x50 ty 20 Solve it by using Simplex Method. Solution: Let s,, s,, 8, be slack variables then the constraints become 2x, xy + 8) = 2; xX, 44) —x, +8, = 10 2x, — 2x, + Bxy + 5 = 0: Kye Xpeys Sq, Spy SBO = Max Z = x,—x, + 3x, +05, +05, +05, MADE EASY Simplex Method | 13 Table 1 * The cosfficients of allthe variables in the objective function are writen inthe firstrow against Gj + The coetticients of the slack variables in the objective function are written in the first column under "Basis ‘+The coefficients of allthe variables in the constraints are writen in the corresponding rows as shown below. ‘+ The constants in he constraints are written under “b" ‘+The E,values of the variables are the sum of the products of the coetficien's in the respective columns and the corresponding basis, + 0g. 2x041x04+2x0=0 2 © a ]-4 3 o o o 5 Balai aletele]? | vs & o}|o}ofolol/o 6-5 |} +] 1] -3}] o | o | o + In Grow the value represents the corresponding proftton each machine. ‘+ Select the maximum negative value in the pivot row, so that we select the max profit or min loss. The column corresponding to that value is called as entering column (C). This row is, called pivot or key column, + The O values are calculated by dividing the values under b with corresponding elements in the entering colurnn, + Sekt ihe mrimum postive value nang 'o)in tne (2= 22) coun ‘* This represents idleness of the machine as shown in above table. The corresponding raw is called the leaving row. This row is called pivot or key row, Sy +]ofafofo]o > 4 b 2 a alalalalels Gi os [2 [0 tfefol[e2| - o 1 */-+/o[+[o][w| -w oe) 2-2} me] ol ol + | o | 0 eMinwvevaue = incuding ze ‘ eo ofoljofoto (leness) 5-4 | -1 ofolfo x Max ve value [means 3 units of profit] = —ve(max) t profit] +The element common inthe entering column and leaving rowis called pivotal value, ‘The basis variable in the leaving row is replaced by the variable in entering column. .e., loaves the basis, x, enters the basis (s, © x) 14 | A textbook on Industrial Engineering, Robotics and Mechatronics MADE EASY eys[e]- [et ‘© Pivotal value in row is made ‘1’ by applying only row operations and all other values in the column are made zero and only by following row operations. Reco = +3 Fioew = Prog * Bano Recon = Food * Fanon * The E\and &;~C,values are calculated as explained earlier. 7=)s)2)°)°)°)°)e) es os, | 53 im| o | o | 1 [ 1 [ 10 30 fe-Leaving row & 2 2|3 o 0 1 Entering column ‘+The entering column is identified and the @ values are calculated, then the leaving row are identtied as explained earlier Note: The pivotal element should not be a negative number. So instead of “0" the next minimum positive number (here “30") is taken for the leaving row. F=lT-)))°)°)°]. i platale|s ost ws|o [1] o fw] 2 3 « [ose] se fe] oo) +) ml] w 35 [ao |-as| +] 0) o|mlol| o 6 [2i-2fs;o,o|1 a6 [4 ole els ‘+ For the new simplex table, the pivotal element is selected according to previous procedure. + 5, leaves the basis, x, enters the basis Table 3: + Pivotal value in row is made ‘1’ by applying only row operations and all other values in the column are made zero and only by following row operations. MADE EASY Simplex Method | 15 Ronen = Reaa* (U3) R Ry aa + (2/3) Ro new Rooe = Reais * (23) Rosen ‘+ The Band 6, Gyvalues are calculated as explained earlier G 1-1] 3s] o]o]o nialals|a|s efof[o[1[2|[1 s{7[e[e|[s|[1 ¢feo[+[o[2|[1 7[[s[o[s [2 efeo[ol[o|[s|[e2 + Asall the elements of E,- C;row are positive, it means itis an optimum matrix. * The variable present in the basis are called basic variables. ‘+ The variables which are not in the basis but are in the objective function are called non basic variables. (The non-basic variables are assigned zero solution.) * So solution can be read it out from matrix ie. 5) =22 %=0 x» = 30} Basic variables s, = 0} Non-basic variables xy =20) 4 =0) ~ by putting (x), x, x3) = (0, 30, 20) in the objective functior Z=x,-x, + Bx, = 0-30 + 60 = 30 1@ maximum value of Example: 2.2 Assume that the following specity a generalized linear programming problem: Maximize: Z = ASx+40y Subjectedto 2x +y< 90 x + 2yS80 x+ys50 xy 20 Solve it by using Simplex Method. Solution: et S,, 5p, 8, be slack variables then the constraints become Bes yes, = 90 x42y+s, = 8 xty+s, = 50 XY, Sy Sy 8, 2 0 > Z = 45x + 40y + 0s, + 05, + 05, ‘+ The above information is tabulated. + Gand 6, -C; are calculated. ‘+The entering column is identified and the @ values are calculated, then the leaving row are identified ‘+ The pivotal elementvalue is identitied from the table, 16 | A textbook on Industrial Engineering, Robotics and Mechatronics MADE EASY fF alafale| ve 4 Table-1 5, leaves the basis and x enters into the basis. * The following row operations are performed: Froew = Fro! Rene = Rocia~ Fi new Perew = Aeoia By nen * Then the table 1 becomes table 2 + Gand E- Care calculated ‘+ Theentering columnis identfied and the @ values are calculated, then the leaving row are identified ‘+ The pivotal element/value is identified from the table. + 5, leaves the basis, and y enters the basis, w|ofo|o a ylatala|? | o> w|i o fo | a | 0 a2 || 1 |o | 35 | 700 vi | | o [1 | 5 | 0 252 | 452] 0 | 0 =a5i2| 452] 0 | 0 Table-2 + The following row operations are performed Ry neu = Fy ois Ro new)2 Renew = Boos 3 (Renew)? Renew = 2Faoa ‘* Then the table 2becomes: 2 wfaololofo], 2 rf ylalels +Lo]t[e oes MADE EASY Simplex Method | 17 * Band 6 -C, are calculated ~ G} Values present in the matrix are positive. So it is an optimum matrix. * So solution can be read it out from matrix Le. x=40 y=10 | Basic variables s=0 Non-basic variables 5, =0| by putting (x, ) = (40, 10) in the objective function the maximum value of Z= 45x 4 40y = 2200 ‘+ Surplus variables are those which are subtracted {rom the constraint equation to get equal to sign (=) * Artificial variables are those which are added to the constraint equations whenever we introduce a surplus variable in order to get the initial feasible solution, which incurs a heavy loss in the above function, And so we assign a large penalty "-M" to these variables in the objective function. Example: 2.3 Assume that the following specify a generalized linear programming problem: Minimize: Z= 4x, +x, Subjectedto 3x, + 4x, 220 xy + 5x, $15 xy X22 0 Solve it by using Big M Method or artificial variable Method. Solution: By introducing surplus variable s, artificial variable a, and slack variable s, the problem may be written as follows: Maximize: Z = ~Ax,~ xy + 05, - Ma, + 08, Subjectto: 3x, + 4x,-s, +a, = 20 x, +5r, + 5,515 Xp Xp. Sy, Sp, 20 ‘+ The above information is tabulated. * In any constraint if artificial variable is present that should enter first in the basis. (Once the attificial variable leaves the basis it will never enter again, so from the next simplex table ‘onwards that variable can be deleted permanently.) © Gand & - Care calculated ‘+The entering column is identified and the @ values are calculated, then the leaving row are identified + The pivotal elementvalue is identitied from the table, oe 2 5 | % eek o [7 || s o[t o}s) 3 ra Famea-awei] w | 0) 0 Table-1 18 | A textbook on Industrial Engineering, Robotics and Mechatronics MADE EASY + S,leaves the basis and X, enters the basis. * The following row operations are performed: Rerew = (Reali Ry * Then the table 1 becomes: Z 4 $s} ol > i a] = Me, was [1 |e | aon 1 o| w [ols| za 5 wet | ow mere] Ss Mm | 4Mat ° Table-2 Band E,-C,are calculated * The entering column is identified and the @ values are calculated, then the leaving row are identified. * The pivotal element/value is identified from the table. + ayleaves the basis and x, enters the basis. + AS a; leaves the basis, it wll never come bac is removed from matrix. + The folowing row operations are performed Fnen = 5(Fral!11: Boney = Fea (Fine iS + Then the table 2 becomes table 3 + Gand &~Care calculated + Itisan optimum matix since al the values obtained in E,— Grow are postive the basis again, so that particular column ~a]a]e]. o . s & ’ ot fam) am a1 | sont | tana ° o | tom | vant Table-3 * So solution can be read it out from matrix ie. ao s-0 ts Basic variables =O} Non-basic variables 2-8 4-0 a 2 by itting (x4, x5) = = y puting ty. x0)= (2.2 =) in tne objective unetion the masimum value o 185 22-4, =m = 1% MADE EASY Simplex Method | 19 Example: 2.4 ‘Assume that the following specify a generalized linear programming problem: Minimum: Z = 3x, 42%, Subjectto: 2x, +x,52 Bx, + 4x, 212 xp X20, Solve it by using Big M Method. Solution: By introducing slack variable s, surplusvariable s, and artificial variable a, the problem may be written as follows: Maximize: Z = ~Bx,-2x, + 05, + 05, — Ma, Subjectto: Br, +x, +8, = 2 Br, +4x,- 8, +a, = 12 XX 8, Sy & 2 + The above informations tabulated. ‘+ In any constraint i artificial variable is present that should enter first in the basis. (Once the artical variable leaves the basis it will never enter again, so from the next simplex table ‘onwards that variable can be deleted permanently.) =>.) ) = = 2 | & |e | am | & 1G «fa |o fo | 2 |e 5-6 |-amea o [mio Table-1 + Gand E- Care calculated ‘+The entering colurmn is identified andthe @ values are calculated, then the leaving row are identified ‘+ The pivotal elementvalue is identitied from the table, + 5, leaves the basis, x, enters the basis. ‘+ The following row operations are performed Ronen Foca 45 non + Then the table 1 becomes 3 zp ays if? a | a | ° = [21 )*7)e°|°]2 a = [owe -? [awe] 6-6 | svi) 0 laa) |e Table-2 ‘+ Itis an optimum matrix since all the values obtained in E)~ G; row are positive, ial variable, this indicates infeasible solution ., (there is no feasible region). 20 | A textbook on Industrial Engineering, Robotics and Mechatronics MADE EASY * If we do the same problem by graphical method we get My ey a 172 4 Note: After selecting the entering column, if all the values appear to be negative, it indicates that the solution is unbounded. Example: 2.5 ‘Assume that the following specify a generalized linear programming problem: Maximize: Z = 6x, 44x, Subjectto 2x, + 3x, $30 Bx, + 2x, $24 xy +3223 xy Xp 20 Solve it by using Big M Method. Solution: By introducing slack variables s,, s, surplus variable s, and artificial variable a, the problem may be written as follows: Maximize: Z= 6x, +44, Subjectto 2x, + Bx, + 8, = 30 3x, + 2x, + 5) = 24 xy tas +a, = 3 ys ps Sy Spy Sys BO + The above informations tabulated. * In any constraint if artificial variable is present that should enter first in the basis, + Gand E- Care calculated * The entering column is identified and the @ values are calculated, then the leaving row are identified ‘+The pivotal elementivalue is identified from the table, Os, +0.s, + 0.s,- Ma, 6 | «]ol]o]o PB 2 —«|sl{sfa]s 2 3s | 1 fo fo | o | » [os MADE EASY Simplex Method | 21 * 5, leaves the basis, x, enters the basis * The following row operations are performed: a 2 Renew ‘+ Thenthe table 1 becomes. + Gand E- Care calculated ‘+The entering column is identified and the @ values are calculated, then the leaving row are identified + The pivotal elementvalue is identified from the table, + 5, leaves the basis, s, enters the basis Lette [> os tT o |: i@el*els=— Table-2 * The following row operations are performed: Rosen = (ool3 = Roca~ 2Re naw = Poca * Renan + Thonthe able 2becomae sel |e}e|?fe Table-3 + Band E,~ Care calculated + tis an optimum matrix since al the values ablained in E,~ C row are positive * So solution can be read it out from matrix i., 22 | A textbook on Industrial Engineering, Robotics and Mechatronics MADE EASY * Normally in simplex, zero will appear in E)— C)row corresponding to every basic variable. If it so happens that zero appears below a non basic variables it means there are alternate solutions. + Here x, is anon basic vatiable and is having ‘0' in row. So, this is the case of solution ‘+ To getthe alternative solution the entering column is identified as x, is having 0” in and is not inthe basis and the @ values are calculated, then the leaving row are identified. ‘+ The pivotal elementvalue is identified from the table. ‘+ The following row operations are performed: Binoy = SRS Ronen = Roca + (Fs ney)! Facer = Poa (Re seul * Then the table $ becomes. nate ml slelelefal> Atel 0 1 | 35 | 25 | 0 [fare] fe. 0 o | ww | w | 1 [fsa] lsh 1 o | 5 | a6 | o [p15 } 5-5 0 o 0 2 ° 1 E,and &- Care calculated ‘+ Itis an alternative optimum matrix since all the values obtained in °E,- C; row are positive. So solution can be read it out from matrix ie. % Here alternate solution means infinitely many solutions may be there because the objective function line is coinciding with the constraint line at the farthest point. The infinite number of solutions is represented as x= (xy + (1-Ax, ye (01) Example: 2.6 ‘Assume that the following specify a generalized linear programming problem: Maximum: Z= By tx Subjectto: 4x, + 3x, $12 4x, +x, 58 4x, —x, $8 x20 Solve it by using Simplex Method. MADE EASY Simplex Method | 23 Solution: By introducing slack variables s,, s, and s, the problem may be written as follows: Maximum Z = 2x, +x, +05, + 08, +05, Subjecte 4x, +x, +5, = 12 4x, +x, +8) = B 4x, =x, + 5) = 8, Hy. Xpy Sy Sp. Sy BO The above information is tabulated G 72 2]+1]of]o]o Hes |e] ate fe]? Os, 4 3} 1 fo fof 2 fs os 4 *[of:+f[: |e fe «boat | 0} ofols fle 5 ° o | of of o = 2 7) oo fo] o a6 | Table-1 + Gand E—Cyare calculated ‘+The entering column is identified and the @ values are calculated + In the ‘@'column when two minimum positive values are same and we are not able to decide which row to enter itis called degeneracy in simplex. + Tofind degenerate solution of simplex we have to find minimum & ¢, Herein s, columabot ( | ac same Butin s, column Min (3.9) is 0’. So sis identitied as leaving row. © The pivotal element/value is identified from the table. + 5,leaves the basis, x, enters the basis + The following row operations are performed Bren = Foal Banew = Fi oa~ 4a new) onew = Reaa~ 4(Ranew) Ss ilelleleisee EHS ee 2a 7) 0 0 1 2 -8 Table-2 24 | A textbook on Industrial Engineering, Robotics and Mechatronics * Gand E-C,are calculated * The entering column is identified and the @ values are calcul identified + 5, leaves the basis, x, enters the basis Poven Bi cow R, ‘sre Then the table 1 becomes. The following row operations are performed: Real? R, ols 4 ote 40Re now) Frota + (Re now The pivotal elementivalue is identified from the table. fed, then the leaving row are 7=|21l*)°]. an acl e é Coat} « [0 =a 7 a rr a Table-3 E,and E- Gare calculated ‘+ The entering column is identified and the 0 values are calculated, then the leaving row are identified. + The pivotal elementvalue is identified from the table, * 5, leaves the basis, s, e the basis * The following row operations are performed: R, R, Then the table 3 becomes, Road t (Rr nel? Ry ca~ (Rs null + Gand E- Care calculated is an optimum m efafsfalale epee ° 1 | 1 |e] o [fat + [0 | - | oe | o | foal 2 >a fm | |e a Table-4 ix since all the values obtained in ‘E,- C} row are positive. MADE EASY Simplex Method | 25 * So solution can be read it out from matrix i., 3, «| | 2 ‘0 0 4 © By putting (x,.) = (3 2) in the objective function the maximum value of Z= 2x, +x, 22 VERIFICATION OF SIMPLEX RESULTS, Ifthe product of the matrix under the slack or surplus variables in the final optimal table and the matrix of constants in the given constraints is equal to the solution matrix then the solution is corre Example 2.7 Assume that the following specify a generalized linear programming problem: Maximum: Z = 3x,+2x, Subjectto: x, +x, 56 2x +x, $8 mx, +4, $1,x,$2 Solve it by using Simplex Method and verify the result. Solution: By introducing slack variable s,, s,, 8, and s, the problem may be written as follows Maximum Z = 3x, + 2x, + 05, + Os, + Os, + 05, Ht ts = dr tts = attr +8, = tS = ys Tye Sys Spy Sy, Sy 2 Ono * The above information is tabulated. pele lelelelelels [ve Ee SSS AS & 0 0 oO 0 0 o Table-1 26 | A textbook on Industrial Engineering, Robotics and Mechatronics MADE EASY E, and E,- Care calculated ‘The entering column is identified and the @ values are calcul identified The pivotal elementivalue is identified from the table. S, leaves the basis, x, enters the basis The following row operations are performed Focey = (Ral fed, then the leaving row are Bi new = Fy cis Ro noun Peron = Boos * Bonen Then the table 1 becomes, Band E,-C, are calculated The entering column is identiied and the @ values are calculated, then the leaving row are identified The pivotal elementivalue is identified from the table. 5, leaves the basis, x, enters the basis. S mlelelslels al a o | w|i [-w{o | o | 2 | a Bay + | | o 12 o o 4 8 05, o |) 0 | m1 ]o ils | tas Los ° eofofefl:f[elen 5 s | wl] o | wo lo ° wo | | o | o 4 Table-2 The following row operations are performed: Renew = Br oia~ (Re newll2, Roven = Focid~ (Re neu), Boren = Bese Ra nen) Then the table 2 becomes table 3 E and E~C,are caloulated s[ale{efs fale 0 o |f1 | -w] o | -1)] 1 ope tte poe fe fp Jp. Table-3 MADE EASY Simplex Method | 27 * [tis an optimum matt singe all the values obtained in *E,~ C} row are positive. 8 1-1/2 0 -12 x, 0 2 0 -12 From table, Br= A= 35/84 lo 12 4-372 % o 0 0 4 6 8 From table, 18-11 2 + Hore as Ax B= Xthe solution is correct 23 SENSITIVITY ANALYSIS OF SIMPLEX The process of determining the effects of these changes without solving the problem from the very beginning is known as sensitivity analysis. Example: 2.8 In (Q.No. 2.7) determine the effectin solution if the constant’6' in first constraintis changed to'7’ Solution: The simplex problem can be expressed in the form of matrices as follows: -- 0) m+2ys6 ot 2 6 nt <8 2 1//)_]8 ree Las ¥y $2 o4 2. Its optimum simplex matrix is gle lzlelelel |. [alice teiels om, o | © |p [| o |v) 4 3% ce ee o | o |» [fe | | + | -aall 2 zm | o | + {[t [of o | WJ 2 5 2 [| 2fof«i{o |i aol |°|o[#|lol|« 1-1/2 0 -1/2 0 1/2 0 -1/2 o 12 1 -3/2) ooo 1 x 28 | A textbook on Industrial Engineering, Robotics and Mechatronics MADE EASY If we change constant value in problem the matrices will be become e x+2mS7 1 2 ? 2x, +2 58 2 tm) 28 mmtmst—> [a1 ttle) S]1 a S2 04 2 Note: By changing the constants as negative values appeared in Ax Bmatrix, the matrixis not an optimum one and sowe move towards optimality by dual simplex procedure. <2 0-1/2 2 0 -1/2 |s ve 1 re 2 = 2x, =3,5- AxB = coos Example: 2.9 In (Q.No. 2.7) determine the effect in solution if the constant ‘6 and 8’ in constraints are changed to'5 and 10°. Solution: The simplex problem can be expressed in the form of matrices as follows: C rx, Z=( al me ayt2y 6 4 2x, + $8 2 sytem st [1 wy $2 0 Its optimum simplex matrix is cl c feilsdaldedele Os, 0 0 {4 12 0 =12 -1 an ° 1 0 0 0 iJ 2 5-c 0 oO oO we 0 42 I we change constant value in problem the matrices will be become xt2n58 91 2 5y ayemst0 [2 4 (")s 10 sytnst > [at iflnJ Sa x82 01 2 Note: By any change in the constant, if all the values of Ax 8 appears to be "sve" then, matrix is stil an optimum one but the solution will change as below, MADE EASY Simplex Method | 29 24 DUALSIMPLEX PROCEDURE 1-lo 2 2) rs) [4 1 4 axe= 0 2 ° 3] /')-/8 o 413} }2] [2 2 2| 2) Le ooo ‘The above matrices is tabulated as table 1 We will not calculate ‘6! column instead we will selec leaving row. ‘ax negative value from‘b’ column as 3 a] steals falslele os | 0 | o | 1 |-w]o | -w [1 a, | 1 | |o |] e|-wl« o, | 0 |1|e |) |-s2/a @ [9 | *7]°),°]°]1 ie 5 2 |2[e|«|e«| safe fe[el#fe|e Table-2.1 Select the min positive value excluding zero in &; - C,row as entering column. Get the pivotal element (whichmay be negative also), 5, leaves the basis, s, enters the basis The following row operations are performed: row = Fh aja 20R, Renew = Boos + (Rs newN/3 Renew = Raven + 2R%3 neud!3 ‘Then the table 1 becomes statatals] sl? o fof 2fs1fo]. | 1 of-+[ + fo | o [ist o |o° [3] 2|-2| o [fe ° + | 2 {-17 0 | o [fof 2 [2,[+/: [el]. o ]o;:f:{ol|o Table-2.2 Thus the optimum solution will change as: x, = 5, x, = 0, x = 6, 5, = 2. 30 | A textbook on Industrial Engineering, Robotics and Mechatronics MADE EASY Example: 2.10 Convert the following simplex problem into a dual problem Minimum: Z = Sx, 42x, +35 Subjectedto 2x, + 3x, +x,220 6x, + Bx, + Sx, 230 Tx, +x; + 9x52 40 xy + Dey + 4,250 xy Xp %y20 Solution: The simplex problem can be expressed in the form of matrices as follows: 231 20 6 8 5"), |30 Minimum, 2= A 2 tf al wle[ Plc “= ( ee 71 3]? |*] 40 % 12 4) 50, a min Z=AX) maxZ=Cly Note: If primal problem s( Bxec en Dual Problem is ( vest So the dual for the given problem becomes: Yee 7 nh) Maximum, z= (20304050) "|. |3 8 1 2|/%?|

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