Hindusthan College of Engineering And Technology

Approved by AICTE, New Delhi, Accredited with ‘A’ Grade by NAAC

(An Autonomous Institution, Affiliated to Anna University, Chennai)
Coimbatore – 641 032
AUTONOMOUSSEMESTER UG DEGREE
MECHATRONICS ENGINEERING
16MA6111 & OPERATIONS RESEARCH

Name of Course Coordinator :Mr.M.Rajendren

Name of the course handling faculty members: 1. Mr.R.Vinoth
2.Mr.M.Rajendren

Test Unit/Portions for INTERNAL EXAM - I

Unit1: LINEAR PROGRAMMING
Introduction - Origin of Operations Research(OR) - Characteristics of Operations Research - Models in Operations
Research - Role of Operations Research in Decision - Making, Methods of Solving OR Problems - Scope of OR.
Steps of Formulating Linear Programming Problem (LPP) - Graphical Method - Special Cases in LP - Simplex
Internal Test 1 Method - Minimization Case - Degeneracy in LP.
Unit 2:TRANSPORTATION PROBLEM
Formulation of General Transportation Problems - Types of Transportation Problems -Solving Transportation
Problem

Define operations research.

Operations research (OR) is an analytical method of problem-solving and decision-making that is
1.
useful in the management of organizations. In operations research, problems are broken down
into basic components and then solved in defined steps by mathematical analysis.
List the phase of OR
The three phases of the process are formulation, analysis, and interpretation. During the
2. formulation phase of the process, the analyst defines the problem, determines assessment criteria,
and develops alternatives. These elements are followed by an analysis phase using modeling and
optimization.

What is the scope of OR?

O.R. has solved successfully many cases of research for military, the government and industry.
The basic problem in most of the developing countries in Asia and Africa is to remove poverty
3.
and hunger as quickly as possible. So there is a great scope for economist, statisticians,
administrators, politicians and technicians working in a team to solve this problem by an O.R.
approach.

1
 List the advantage and limitation of OR

4.

List the applications of OR

 Allocation and distribution of projects
 Production and facilities planning
5.
 Program decision
 Marketing
 Organization behavior
List the four assumption in linear programing
 The constraints and objective function are linear
 Divisibility -- the values of decision variables can be fractions. Sometimes these values
only make sense if they are integers; then we need an extension of linear programming
6. called integer programming.
 Certainty -- the model assumes that the responses to the values of the variables are
exactly equal to the responses represented by the coefficients.
 Data -- formulating a linear program to solve a problem assumes that data are available to
specify the problem.

Define Big M method

Big M Method is a technique used to solve linear programming problems. Generally the methods
used to solve LP must start from the Basic feasible solution(BFS) - (0,0). Now this assumption
holds good for LESS THAN or EQUAL TO ( <= ) constraints for which simplex algorithm is
7.
commonly used. If an LP has any > or = constraints, a starting basic feasible solution may not be
readily apparent. The Big M method is a version of the Simplex Algorithm that first finds a basic
feasible solution by adding "artificial" variables to the problem creating the artificial region and
then moves to real region thus improving the objective solution.

Summarize the graphical method procedure

Graphical method to solve Linear Programming problem (LPP) helps to visualize the procedure
explicitly. It also helps to understand the different terminologies associated with the solution of
8.
LPP. Linear programming problems with two variables can be represented and solved
graphically with ease. Though in real-life, the two variable problems are practiced very little, the
interpretation of this method will help to understand the simplex method.

2
 Explain the limitation of LPP
 Linear programming is applicable only to problems where the constraints and objective
function are linear i.e., where they can be expressed as equations which represent. In real life
situations, when constraints or objective functions are not linear, this technique cannot be used.
9.
 Factors such as uncertainty, weather conditions etc. are not taken into consideration.
 There may not be an integer as the solution, e.g., the number of men required may be a
fraction and the nearest integer may not be the optimal solution.i.e., Linear programming
technique may give practical valued answer which is not desirable

Compare Slack variable and surplus variable

10.

11. Differentiate between simplex and Big M method(REFER Previous Question)

List the steps in solving a simplex problem

12.

3
 Illustrate degeneracy in simplex problem.
 The linear programming is the problem of degeneracy-the breaking down of the simplex
calculation method under certain circumstances. Degeneracy in applying the simplex
method for solving a linear programming problem is said to occur when the usual rules
for the choice of a pivot row or column (depending on whether the primal or the dual
13. simplex method is being discussed) become ambiguous.

 In other words, two or more values in the minimum ratio column are the same. To resolve
degeneracy, the following method is used. Divide the key column values (of the tied
rows) by the corresponding values of columns on the right side. This makes the values
unequal and the row with minimum ratio is the key row.
What is meant by duality in simplex problem?

 Duality in linear programming is essentially a unifying theory that develops the

relationships between a given linear program and another related linear program stated in
terms of variables with this shadow-price interpretation. The importance of duality is
twofold.

 First, fully understanding the shadow-price interpretation of the optimal simplex

multipliers can prove very useful in understanding the implications of a particular linear-
14. programming model. Second, it is often possible to solve the related linear program with
the shadow prices as the variables in place of, or in conjunction with, the original linear
program, thereby taking advantage of some computational efficiencies.

 Every minimization problem is associated with a maximization problem and vice-versa.

The original linear programming problem is known as primal problem, and the derived
problem is known as its dual problem. The optimal solutions for the primal and dual
problems are equivalent.

What is transportation model?

The transportation problem is a special type of linear programming problem where the objetive
consists in minimizing transportation cost of a given commodity from a number of sources or
origins (e.g. factory, manufacturing facility) to a number of destinations (e.g. warehouse, store).
15.
Each source has a limited supply (i.e. maximum number of products that can be sent from it)
while each destination has a demand to be satisfied (i.e. minimum number of products that need
to be shipped to it). The cost of shipping from a source to a destination is directly proportional to
the number of units shipped.

Predict degeneracy happen in transportation problem?

In a standard transportation problem with m sources of supply and n demand destinations, the
16 test of optimality of any feasible solution requires allocations in m + n – 1 independent cells. If
the number of allocations is short of the required number, then the solution is said to be
degenerate.

4
 What is an unbalanced transportation problem?
When the total supply of all the sources is not equal to the total demand of all destinations, the
problem is an unbalanced transportation problem.

17 Total supply ≠ Total demand

Classify the types of transportation problem.

18  Balanced type
 Unbalanced type
Show some practical application of transportation problem.

19

Define transshipment problem.

One requirement of the transportation problem is advance knowledge of the method of
distribution of units from each source i to each destination j, so that the corresponding cost per
20
unit (xij) can be determined. Sometimes, however, the best method of distribution is not clear
because of the possibility of transshipments, whereby shipments would go through intermediate
transfer points (which might be other sources or destinations).

Test Unit/Portions for INTERNAL EXAM – II

Unit 2:TRANSPORTATION PROBLEM
Loops in Transportation Method - Transportation Algorithm - Modified Distribution Method - Stepping
Stone Method.
Internal Test 2
Unit 3:ASSIGNMENT PROBLEM
Mathematical Formulation of Assignment Problem (AP) - Solution Methods of AP -Enumeration
Method - The Hungarian Method - Variations of the Assignment Problem - Multiple Optimal Solutions.

Show optimality test in transportation problem

1. There are m + n – 1 allocations, whose m is number of rows, n is number of columns. Here
m + n – 1 =6. But number of allocation is five.
1.
2. These m + n – 1 allocations should be at independent positions. I.e. it should not be
possible to increase or decrease any allocation without either changing the position of the
allocations or violating the row or coloumn restrictions.
2.
Classify the common methods to obtain an initial basic feasible solution for a Transportation
problem.
 Northwest corner cell method
 Least cost cell

5
  Vogel approximation method
Illustrate DENTZY’s method.
3. The North-West Corner Rule is a method adopted to compute the initial feasible solution of
the transportation problem. The name North-west corner is given to this method because the
basic variables are selected from the extreme left corner
What is Least Cost Method?
The Least Cost Method is another method used to obtain the initial feasible solution for the
4. transportation problem. Here, the allocation begins with the cell which has the minimum cost.
The lower cost cells are chosen over the higher-cost cell with the objective to have the least
cost of transportation.

What is Stepping Stone method?

The Stepping Stone Method is used to check the optimality of the initial feasible solution determined
5.
by using any of the method Viz. North-West Corner, Least Cost Method or Vogel’s Approximation
Method. Thus, the stepping stone method is a procedure for finding the potential of any non-basic
variables (empty cells) in terms of the objective function.

Define MODI (Modified Distribution method )method?

The Modified Distribution Method or MODI is an efficient method of checking the optimality of
6. the initial feasible solution.
Choose the largest positive opportunity cost, which is 7 and draw a closed path, as shown in the matrix
below. Start from the unoccupied cell and assign “+” or “–“sign alternatively.
Interpret Vogel’s approximation method.
The Vogel’s Approximation Method or VAM is an iterative procedure calculated to find out the
initial feasible solution of the transportation problem. Like Least cost Method, here also the shipping
cost is taken into consideration, but in a relative sense.

7.

Define Assignment problem.

Assignment problem is a special type of linear programming problem which deals with the
9.
allocation of the various resources to the various activities on one to one basis. It does it in
such a way that the cost or time involved in the process is minimum and profit or sale is
maximum.

6
 Compare between transportation problem and Assignment problem?

Transportation Problem
Assignment Problem
(i)      Assignment means allocating various (i)       A transportation problem is
jobs to various people in the organization. concerned with transportation method or
Assignment should be done in such a way selecting routes in a product distribution
that the overall processing time is less, network among the manufacture plant and
overall efficiency is high, overall distribution warehouse situated in different
productivity is high, etc. regions or local outlets.
(ii)     We solve an assignment problem (ii)      We use three methods for solving
by using two methods. a transportation problem i.e., to find
IBFS :
(a)     Completer enumeration
method. (a) VAM (b) NWCR (c) LCM

10. (b)     Hungarian method Thereafter we find the optimum solution
by using the MODI method.
 
(iii)    In an assignment problem only one (iii)     A transportation problem is not
allocation can be made in particular row subject to any such restrictions. Such
or a column. restriction are peculiar to assignment
problems only. Many allocations can be
done in a particular row or particular
column.
(iv)    In assignment problem (iv)     In transportation method,
management aims at assignment jobs to management is searching for a
various people. distribution route, which can lead to
minimization of cost and maximization
of profit.
(v)     When no. of jobs no. of workers, it (v)      When the total demand is not
is a unbalanced problem. equal to total supply it is unbalanced
problem.
List Some areas of Assignment problem application

i. assignment of employees to machines.

ii. assignment of operators to jobs.
11. iii. effectiveness of teachers and subjects.
iv. allocation of machines for optimum utilization of space.
v. salesmen to different sales areas.
vi. clerks to various counters.

Demonstrate how a maximization problem is solved using assignment model.

There are problems where certain facilities have to be assigned to a number of jobs so as to
maximize the overall performance of the assignment.The problem can be converted into a
minimization problem in the following ways and then Hungarian method can be used for its
12. solution.

i. Change the signs of all values given in the table.

ii. Select the highest element in the entire assignment table and subtract all the elements
of the table from the highest element.

7
 Outline the mathematical formulation of assignment problem.

13.

Let n be the number of jobs and number of operators.

Relate traveling salesman problem with an assignment problems.

The ‘Travelling salesman problem’ is very similar to the assignment problem except that in
the former, there are additional restrictions that a salesman starts from his city, visits each city
once and returns to his home city, so that the total distance (cost or time) is minimum.

Procedure:
14.
Step 1: Solve the problem as an assignment problem.
Step 2: Check for a complete cycle or alternative cycles. If the cycle is complete, Go to Step
4. If not, go to the Step 3.
Step 3: To start with, assign the next least element other than zero, (only for first allocation)
and complete the assignment. Go to Step 2.
Step 4: Write the optimum assignment schedule and calculate the cost/time.
Illustrate Hungarian method.
Assignment problem Hungarian method example. An assignment problem can be easily
15.
solved by applying Hungarian method which consists of two phases. In the first phase, row
reductions and column reductions are carried out. In the second phase, the solution is
optimized on iterative basis.
16
Depict the flow chart for Hungarian method.

8
 Show the sensitivity analysis used in the Assignment Problem.
Information of sensitivity analysis, in a linear programming problem, is usually more
17
important than the optimal solution itself. An optimal basic solution of the assignment
problem is inherently degenerate, so it may be that the optimal base has changed but the
optimal assignment remains unchanged.

Test Unit/Portions for MID SEMESTER EXAM

Unit1: LINEAR PROGRAMMING
Introduction - Origin of Operations Research(OR) - Characteristics of Operations Research - Models in
Operations Research - Role of Operations Research in Decision - Making, Methods of Solving OR
Problems - Scope of OR. Steps of Formulating Linear Programming Problem (LPP) - Graphical Method
- Special Cases in LP - Simplex Method - Minimization Case - Degeneracy in LP.
Unit 2:TRANSPORTATION PROBLEM
Formulation of General Transportation Problems - Types of Transportation Problems -Solving
Mid-Sem Test Transportation Problem- Loops in Transportation Method - Transportation Algorithm - Modified
Distribution Method - Stepping Stone Method.
Unit 3:ASSIGNMENT PROBLEM
Mathematical Formulation of Assignment Problem (AP) - Solution Methods of AP -Enumeration
Method - The Hungarian Method - Variations of the Assignment Problem - Multiple Optimal Solutions.
Unit 4:REPLACEMENT AND MAINTENANCE ANALYSIS
Types of Maintenance - Types of Replacement Problem - Determination of Economic Life of an Asset

Illustrate maintenance.
Maintenance involves functional checks, servicing, repairing or replacing of necessary
1. devices, equipment, machinery, building infrastructure, and supporting utilities in industrial,
business, governmental, and residential installations. Over time, this has come to include
multiple wordings that describe various cost-effective practices to keep equipment operational;
these activities take place either before or after a failure.
2.
Classify the types of maintenance?
9
 corrective, preventive, risk-based and condition-based maintenance.
Define mean time between failure(MTBF)?
3. Mean time between failures is the predicted elapsed time between inherent failures of a
mechanical or electronic system, during normal system operation. MTBF can be calculated as
the arithmetic mean time between failures of a system.
Classify the objective of maintenance
(a) Keep the system operating at design standard at all times;

4. (b) Obtain the longest life and greatest use of the systems facilities by providing adequate
maintenance and timely repairs;

(c) Achieve the foregoing two objectives at the lowest possible cost.
Depict the cost curve for maintenance

Describe the replacement of item? Why is important?

There are certain items which deteriorate gradually with usage and such items decline in
efficiency over a period of time. Generally, the maintenance cost of certain items always
6
increase gradually with time and a stage comes when the maintenance cost becomes so large
that it is better and economical to replace the item with a new one. There may be number of
alternatives and we may have a comparison between various alternatives by considering the
costs due to waste, scrap, loss of output, damage to equipment and safety risks etc.

Test Unit/Portions for INTERNAL EXAM – III

Unit 4:REPLACEMENT AND MAINTENANCE ANALYSIS
Basics of Interest Formulae - Examples - Simple Probabilistic Model for Items which Completely Fail.
Unit 5:PRODUCTION SCHEDULING
Internal Test 3 Single Machine Scheduling - Measures of Performance - Shortest Processing Time Rule to Minimize
Mean Flow Time - Weighted Shortest Processing Time Rule - Earliest Due Date Rule - Introduction to
Branch and Bound Technique. Flow Shop Scheduling - Johnsons Algorithm - Branch and Bound
Methods for n Jobs and m Machines - Job Shop Scheduling.

1.
Distinguish between breakdown maintenance and preventive maintenance

Preventive maintenance Breakdown maintenance

10
 Preventive maintenance (PM) is work that Breakdown maintenance (BM) is work
is scheduled based on calendar time, asset that is only performed when a piece of
runtime, or some other period of time. equipment breaks down or has a
downtime event.
Time Downtime event
Low Low
12% to 18% [1] Dependent on equipment and breakdown
maintenance plan
 Maintenance software for  Maintenance software for
scheduling downtime triggers
 Maintenance scheduler (for larger  Necessary replacement equipment
organizations)
 Preventive maintenance checklists

 Extends the lifetime of assets  Lowers overall costs of non-

 Optimizes planning of critical manufacturing equipment
maintenance and resources  Minimizes preventive
maintenance costs on nonessential
equipment

 Can be expensive to keep up over  Can’t be used for many types of

the long term equipment, especially safety
 Labor intensive due to constant equipment
maintenance tasks  Requires careful planning and
execution to work effectively

An organization wants to decrease An organization wants to lower the cost

unplanned downtime and emergency of constantly replacing a variety of light
maintenance but does not have a large bulbs in a facility. Instead of replacing
maintenance budget. As a solution, they them at designated intervals, the
implement a PM program for select organization decides to adopt a
assets. Work orders are scheduled for breakdown maintenance plan, only
inspections, lubrication, filter replacing light bulbs when they are
replacements, and parts replacements completely burned out. This saves time
based on recommendations from OEMs. and reduces the overall cost of buying
light bulbs as the necessary amount of
spares is lower.
What is the replacement of item? Why is important?
Replacement becomes necessary when the job-performing units such as men, machines,
2.
equipment, parts etc. lose their efficiency and effectiveness because of gradual deterioration or
sudden failure or breakdown. Planned replacement of these items would reduce maintenance cost
and other overhead expenses.

What is salvage value in replacement of items?

3 Salvage value is the estimated resale value of an asset at the end of its useful life. It is subtracted
from the cost of a fixed asset to determine the amount of the asset cost that will be depreciated.
Thus, salvage value is used as a component of the depreciation calculation.

11
 List out the types of replacement policies
 Constant-Interval Replacement Policy (CIRP)
 Age-Based Replacement Policy (ABP)
 Time-Based Replacement Policy.
4
 Inspection Replacement Policy (IRP)
 Just-in-Time Replacement Policy (JITP)
 Modified-Age Replacement Policy (MARP)
 Block Replacement Policy (BRP)
 Order/Rank-Based Replacement Policy (ORP)

Define the term present worth factor

5 The present value factor formula is based on the concept of time value of money. Time value of
money is the idea that an amount received today is worth more than if the same amount was
received at a future date. Any amount received today can be invested to earn additional monies.

What is the difference between individual replacement policy and group replacement
policy?

What is production scheduling?

7 Scheduling is the process of arranging, controlling and optimizing work and workloads in a
production process or manufacturing process. Scheduling is used to allocate plant and machinery
resources, plan human resources, plan production processes and purchase materials

Classify production scheduling.

8 Types of Scheduling in Production Planning and Control. In the manufacturing world, production
planning and control features four stages: Routing, Scheduling, Dispatching, and Follow Up. The
first two relate to production planning while the second two relate to control

What is lateness(Lj)?
9. The term lateness is a general term used to represent the deviation from the due. date. Lateness
Lj = Cj –Dj where Dj is the due date for job j and Cj is the completion. time of job j. If Lj is tardy
it is early and negative it is early.
Define Tardiness (Tj)?
10. tardiness is a measure of a delay in executing certain operations and earliness is a measure of
finishing operations before due time. The operations may depend on each other and on the
availability of equipment to perform them.
11.
What is WSPT Rule in single machine scheduling?
Hodgson's Algorithm minimizes the number of tardy jobs in the single machine environment with
12
 ready time equal to zero. Let E denote the set of early jobs and L denote the set of late jobs.
Initially, all jobs are in set E and set L is empty.
What is EDD Rule in single machine scheduling?
Minimising maximum lateness
12 Assume that the jobs are numbered in non-decreasing order of their due dates dj. In order to
minimize the maximum lateness it is quite natural to process the jobs in this order. This
dispatching rule is known as EDD (Earliest Due Date), sometimes it is called Jackson's rule due
to R.
State branch bound technique.
Branch and bound is a systematic method for solving optimization problems. B&B is a rather
13
general optimization technique that applies where the greedy method and dynamic programming
fail. However, it is much slower. Indeed, it often leads to exponential time complexities in the
worst case.
What are the assumption for flow shop scheduling?
Flow shop scheduling problems, are a class of scheduling problems with a workshop in which the
flow control shall enable an appropriate sequencing for each job and for processing on a set of
14 machines or with other resources 1,2,...,m in compliance with given processing orders. Especially
the maintaining of a continuous flow of processing tasks is desired with a minimum of idle time
and a minimum of waiting time. Flow shop scheduling is a special case of job shop scheduling
where there is strict order of all operations to be performed on all jobs. Flow shop scheduling may
apply as well to production facilities as to computing designs.
Distinguish between flow shop problem and job shop problem
 In flow shop processes, process is set in a linear structure. Therefore, most of the times the
machines necessary to finish the process are set in a convenient way in order to minimize idle
times. I think that this is convenient when you have a standardized product. McDonalds could be a
somewhat comparable example. For example, BigMacs are going through one and the same pre-
15 set process.
 In the job shop processes, processes are set according to the functions of various parts of the
process. I think that would be convenient when you cannot standardize your product to make a
assembly like process. For example, a fine dining restaurant with a changing menu. As a result,
processes in such kitchen are divided into workstations by functions (e.g. saucier, grill, pastry and
other workstations). This order helps to maintain the variety and flexibility of a restaurant.
What are the assumption for job shop scheduling?
 Job shop scheduling or the job-shop problem (JSP) is an optimization problem in computer
science and operations research in which jobs are assigned to resources at particular times. The
most basic version is as follows: We are given n jobs J1, J2, ..., Jn of varying processing times,
which need to be scheduled on m machines with varying processing power, while trying to
minimize the makespan. The makespan is the total length of the schedule (that is, when all the jobs
have finished processing).
16
 The standard version of the problem is where you have n jobs J1, J2, ..., Jn. Within each job there is
a set of operations O1, O2, ..., On which need to be processed in a specific order (known as
Precedence constraints). Each operation has a specific machine that it needs to be processed on
and only one operation in a job can be processed at a given time. A common relaxation is the
flexible job shop where each operation can be processed on any machine of a given set (the
machines in the set are identical).

13