Production Plan : Bajaj Auto Ltd. Chakan PlantModel domestic Export Total Product wise Daily DOM Daily EXP

Pulsar 150 UG4.5 50000 50000

70790

1923 0

Pulsar 180 UG4 10000 5256 15256 385 202

Pulsar 220 SF 4000 1534 5534 154 59

Pulsar 220 S 772 772 0 30

PULSAR 200NS 2232 5668 7900 7900 86 218

AVENGER 220 3554 846 4400 4400 137 33

KTM 125 MY14 1040 1040

6146

0 40

KTM 200 MY14 1175 980 2155 45 38

KTM 390 MY 14 315 1000 1315 12 38

RC 390 ( KT06) 810 810 0 31

RC 200 ( KT05) 20 20 0 1

RC 125 ( KT04) 806 806 0 31

71276 18732 90008 89236 2741 720

DAILY TOTAL

Working days 26 3462

Production Plan : Bajaj Auto Ltd. Chakan PlantTotal daily

1923

587

213

30

304

169

40

83

51

31

1

31

3462

DAILY TOTAL

3462

Daily Plan (From Production Plan Sheet) 1923 587 213

Part No Tag Part Desc

Unit of Measurement ---->

1 52DH0177 x1 SF:BALANCER IDLER HOLDER WITH BEAR 1 1 12 52DH0695 x2 COVER LHRR MOONLIGHT K1 13 52DJ0412 x3 GRAB HANDLE KIT BLACK LH/RH WITH B 14 52JC0163 x4 LH RR COVER ASSLY K2/K3 MOONLIGHT 1 15 52JL0013 x5 GRAB HANDLE WITH TPT N WASHER JL6 52JM0013 x6 COVER LH RR WITH BOLT FOR JM7 DH101898 x7 INTAKE MANIFOLD K1(UG5) 18 DH161410 x8 GRAB HANDLE ASSY 19 JG113009 x9 CHANGE LEVER

10 JG113800 x10 DUMBLE SPACERS FOR STEPHOLDER

Inputs to Linear Program

Sl. No

Pulsar 150 UG4.5

Pulsar 180 UG4

Pulsar 220 SF

30 304 169 40 83 51 31 1 31

1

11

1

1 1 1 1 1 14 4 4 4 4 4

Pulsar 220 S

PULSAR 200NS

AVENGER 220

KTM 125 MY14

KTM 200 MY14

KTM 390 MY 14

RC 390 ( KT06)

RC 200 ( KT05)

RC 125 ( KT04)

Bin Dimension

Total Req. Weight Length Width Height Wt per Bin Vol per Bin

Nos per day Kg. / part Nos/Bin m m m Kg/Bin Kg/Bin Cu. M / Bin

2752 0.236 30 0.4 0.3 0.1 0.75 7.84 0.0121923 0.725 14 0.6 0.4 0.14 1 11.15 0.03361923 0.585 8 0.6 0.4 0.2 1 5.68 0.048829 0.716 14 0.6 0.4 0.14 1 11.02 0.0336304 0.717 20 0.6 0.4 0.2 1 15.34 0.048169 0.762 14 0.6 0.4 0.14 1 11.67 0.0336

1923 0.122 45 0.4 0.3 0.08 0.75 6.23 0.00961923 0.433 10 0.6 0.4 0.2 1 5.33 0.048236 0.220 50 0.4 0.3 0.16 0.75 11.77 0.0192946 0.114 100 0.3 0.2 0.05 0.5 11.89 0.003

No of Parts per Bin

Wt of empty

Bin

Total No of Bins Total Vol Total Wt

Nos. / day Cu. M Kg

92 1 719137 5 1532240 12 1365

59 2 65315 1 23312 0 14143 0 266

192 9 10265 0 569 0 112

805 30 6102

Vehicle Data

L (m) B (m) H (m)

TATA 909 4.381 2.042 2.13 6000 1800TATA 709 3.833 2.057 2.13 3000 1500TATA ACE 2.14 1.43 1.65 1000 1000

Inputs to Linear Program

Permissible Wt (in Kg)

Trip Cost Rs/trip

Total Vol Cu. M

19.05516.794

5.049

Objective Function 3300.00 (Minimize Transportation cost)

Trip Cost 1800 1500 1000Truck Type y1 y2 y3

1 1 0

x1 x2 x3 x4Decision Variable and Constraints pertaining to Truck Type1

x1y1 x2y1 x3y1 x4y1

96 100 177 0

Weight Constraint 7.84 11.15 5.68 11.02Volume Constraint 0.012 0.0336 0.048 0.0336

Decision Variable and Constraints pertaining to Truck Type2x1y2 x2y2 x3y2 x4y2

0 37 64 59

Weight Constraint 7.84 11.15 5.68 11.02Volume Constraint 0.012 0.0336 0.048 0.0336

Decision Variable and Constraints pertaining to Truck Type3x1y3 x2y3 x3y3 x4y3

0 0 0 0

Weight Constraint 7.84 11.15 5.68 11.02Volume Constraint 0.012 0.0336 0.048 0.0336

Constaint pertaining to total Number of Bins of each type should be in required range

Total Number of Bins of each type 96 137 240 59

Condition >Min, <MaxMin Req. Constaint 92 137 240 59Max Req. Constaint ( +5% tol.) 96 144 252 62

2 <= 100

Note :-Non-negative constaint for all decision variableFor Vehicle - Interger constaint

Decision Variable - No of trucks of each type

Decision Variable - No of Bins of each type

Decision Variable - No of Bins of each type

Decision Variable - No of Bins of each type

Constaint on total number of vehicles

x5 x6 x7 x8 x9 x10

x5y1 x6y1 x7y1 x8y1 x9y1 x10y1

0 0 43 0 0 0 LHS RHS

15.34 11.67 6.23 5.33 11.77 11.89 3138 <= 60000.048 0.0336 0.0096 0.048 0.0192 0.003 13 <= 19

x5y2 x6y2 x7y2 x8y2 x9y2 x10y2

15 12 0 192 5 9 LHS RHS

15.34 11.67 6.23 5.33 11.77 11.89 3000.00 <= 30000.048 0.0336 0.0096 0.048 0.0192 0.003 16.79 <= 17

x5y3 x6y3 x7y3 x8y3 x9y3 x10y3

0 0 0 0 0 0 LHS RHS

15.34 11.67 6.23 5.33 11.77 11.89 0 <= 00.048 0.0336 0.0096 0.048 0.0192 0.003 0 <= 0

15 12 43 192 5 9

>Min, <Max15 12 43 192 5 916 13 45 202 5 10

(Total Wt loaded in vehicle is less than max. permissible)(Total Vol loaded in vehicle is less than max. allowable)

(Total Wt loaded in vehicle is less than max. permissible)(Total Vol loaded in vehicle is less than max. allowable)

(Total Wt loaded in vehicle is less than max. permissible)(Total Vol loaded in vehicle is less than max. allowable)

(Production Requirement constraint)(A tolerance of upto 5% extra material supply is allowed)

Output

Vehicle Selection

Tag Total No Trips

TATA 909 y1 1TATA 709 y2 1TATA ACE y3 0

Vehicle Loading Plan

Sl. No Part No Tag Part Desc

1 52DH0177 x1 SF:BALANCER IDLER HOLDER WITH BEAR 922 52DH0695 x2 COVER LHRR MOONLIGHT K1 1373 52DJ0412 x3 GRAB HANDLE KIT BLACK LH/RH WITH B 2404 52JC0163 x4 LH RR COVER ASSLY K2/K3 MOONLIGHT 595 52JL0013 x5 GRAB HANDLE WITH TPT N WASHER JL 156 52JM0013 x6 COVER LH RR WITH BOLT FOR JM 127 DH101898 x7 INTAKE MANIFOLD K1(UG5) 438 DH161410 x8 GRAB HANDLE ASSY 1929 JG113009 x9 CHANGE LEVER 5

10 JG113800 x10 DUMBLE SPACERS FOR STEPHOLDER 9

Vehicle Type

No of Bins (Min)

TATA 909 TATA 709 TATA ACE

96 96 0 0 96144 100 37 0 137252 177 64 0 24062 0 59 0 5916 0 15 0 1513 0 12 0 1245 43 0 0 43

202 0 192 0 1925 0 5 0 5

10 0 9 0 9

Loading Pattern (Nos of Bins per trip)

No of Bins (Max)

Total Shipped