Production Schedule Using Integer Linear Programming for Tasty Menu Bakery

Yola, Adamawa State of Nigeria

Aliyu Huzaifa Babando1, Rafiyatu Hafisu2, and Madu Barma3

1Department of Mathematics, Modibbo Adama University, Yola, Adamawa State, Nigeria.
2Department of Statistics, School of Science and Technology, Adamawa State Polytechnic, Yola, Nigeria.
3Department of Operation Research, Modibbo Adama University, Yola, Adamawa State, Nigeria.

E-mail: hababando@mautech.edu.ng*
rafiyatuhafisu@gmail.com
mbarma@mau.edu.ng

ABSTRACT INTRODUCTION

For the Tasty Menu Bakery in Yola, Adamawa Every production company's major goal is to turn
State, this study used integer linear programming a profit in order to keep the business afloat. To
to determine the production plan. Data on the achieve this goal, a variety of elements need to
ingredients required to make each of the five be considered. These include, among other
types of bread were gathered. Additionally, data things, meeting client requests and providing
on each type of bread's unit selling price and goods and services on schedule. To accomplish
production cost was gathered. these, the business should have the necessary
technological know-how and capable
Maximization of profit is the objective function, management to adopt the most recent
and there are 18 specified restrictions. The issue managerial techniques and the required
was run via the Production/Operation technology.
Management Quantitative Method (POMQM)
software as an integer linear programming issue. To provide clear guidance on how the
The solution to the original puzzle indicates that manufacturing process should be carried out, it is
just 529 loaves of sliced bread should be made advisable for a corporation to create a production
each day in order to make a profit of up to plan based on scientific methodologies. All these
N53,164.50. Sensitivity analysis was performed, actions are purposeful initiatives to reduce
and the objective function was modified. The production costs and increase revenue for the
analysis's findings indicate that there are 280 business.
loaves of roll bread and 117 loaves of sliced
bread. To make a daily profit of N55,087, 111 One of the most crucial tasks in manufacturing
loaves of fruit bread, 10 loaves of coconut bread, companies is production planning. A production
and 10 loaves of milk bread must be made. The plan is usually created by many manufacturing
fact that all of the bakery's customers will be companies before the start of each fiscal year.
satisfied and a higher profit will be made in The production plan specifies both the quantity of
comparison to the result of the original problem, commodities to be produced and the demand for
however, demonstrates that the sensitivity each period of the financial year. Depending on
analysis's result is preferable. the company's products, the production plan may
be carried out every week, every month, every
Based on the sensitivity results, the study quarter, or even every year.
suggests that Tasty Menu Bakery, Yola implement
the linear programming model to cut down on Production scheduling is the process of allocating
resource and time waste. Additionally, it suggests the production's resources through time in a way
that a market research study be conducted for the that best satisfies many requirements, including
bakery in order to increase product sales. those for quality, delivery date, demand, and
supply. An ideal production schedule is one that
(Keywords: linear programming model, sensitivity effectively distributes resources over time to best
analysis, production planning, production schedule, meet certain criteria (i.e., the plan that assigns
profit analysis)
the ideal level of production resources required to

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supply a particular demand at the lowest possible c. The issue must allow the user to select one or
cost) (Amponsah, Ofosu, and Opoku-Sarkodie, more alternate courses of action.
2011).
d. The element in question must be subject to
Making a strategy to please clients while making a one or more constraints. These might be
fair profit is a step in the production planning resource limitations.
process (Lopez and Roubellat, 2008). Production
scheduling issues, machine capacity planning
issues, storage and freight scheduling issues are Integer Programming
all examples of production issues.
Each decision variable, slack variable, and/or
In order to stay competitive, management is surplus variable in linear programming is allowed
encouraged by fierce rivalry to create innovative to take any discrete or fractional value. However,
production and supply processes (Abernathy, there are some real-world issues where the
1995). One major concern is the distribution of choice variables' fractional values are irrelevant.
limited production resources among conflicting Three types of linear integer programming issues
demands, which is a common issue when dealing can be identified:
with several complicated man-made systems
(Cassandras, 1993). i. Pure (all) integer programming issues, in which
all of the decision variables can only take on
Scheduling models and planning models differ integer values.
from one another in a variety of ways, according
to Kreipl and Pinedo (2004). First, scheduling ii. Mixed integer programming issues, in which
models are typically created for a single stage certain decision variables, but not all, are
(facility) and optimize over a short-term horizon, constrained to integer values.
whereas planning models frequently span
numerous stages and optimum over a medium iii. Zero-one integer programming issues, in
term horizon. Second, planning models employ which all variables used to make decisions can
more generalized data whereas scheduling only have integer values of 0 or 1.
models employ more specific data. Thirdly, while
the objective to be minimized in a schedule model
is typically a function of the completion times of Method of Solving Integer Linear
the jobs, the unit in which this is measured is Programming Problem
frequently in time unit, the objective to be
minimized in a planning model is typically a total Cutting Plane Algorithm: Gomory cutting plane
cost objective, and the unit in which this is algorithm starts by solving the continuous LP.
measured is a monetary unit. Although these two Problem. From the optimum LP. Table is selected
types of models differ fundamentally, they a row, called the source row, for which the basic
frequently need to be integrated into a single variable is non-integer. The desired cut is then
framework, share information, and interact closely constructed from the fractional components of the
with one another. coefficients of the source row. For this reason, it
is referred to as the fractional cut.

LINEAR PROGRAMMING (LP) Steps of Gomory’s All Integer Programming

Algorithm: An iterative procedure for the solution
A mathematical method called LP deals with the of an all integer programming problem by
distribution of scarce resources. When a factor Gomory’s cutting plane method can be
(such as labor or machine hours) is constrained, it summarized in the following steps.
is a process to maximize the value of the aim (for
instance, maximum profit or minimum cost). Step 1: Initialization formulate the standard
integer LP problem. If there are any non-integer
a. The issue must be able to be expressed in coefficients in the constraint equations, convert
numerical terms. them into integer coefficients. Solve the problem
by the simple method, ignoring the integer valve
b. There must be a linear relationship between requirement of the variables.
every element contributing to the issue.

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Step 2: Test the Optimality. Branch and Bound Algorithm: Branch and
bound algorithms is the most widely used method
(a). Examine the optimal solution. If all basic for solving pure as well as mixed integer
variables (i.e., xBi= bi ≥ 0 ) have integer problems in practice. Most commercial computer
codes use this method for solving LP Problems.
values, then the integer optimal solution
In this method also, the problem is first solved as
has been obtained and the procedure is
a continuous L.P problem ignoring the integrality
terminated.
condition. If the solution is infeasible or
unbounded, then the given LP also has an
(b). If one or more basic variables with integer infeasible or unbounded solution. If the solution
value requirement have non-integer
satisfies the integer restrictions, the optimal
solution values, then go to Step 3
integer solution has been obtained. If in the
Step 3: Generate cutting plane choose a row r optimal solution some variable, say x j is not an
corresponding to a variable x r that has the largest integer, then:
fractional value and follow the procedure to
develop a ‘cut’ (a Gomory constraint) as explained x < xj < xj +1 (2)
in Equation:
Where xj and xj + 1 are consecutive non-negative
- fr = Sg - ∑f rj xj (1) integers.
where 0 ≤ f r ≤ 1 and 0 < fr < 1
It follows that any feasible integer value between
of must satisfy one of the two conditions,
If there are more than one variables with the same
largest fraction, then choose the one that has the namely:
smallest profit/unit coefficient in the objective
function of maximization LP problem or the largest xi ≤ x j or x j ≥ x j + 1 . (3)
cost/unit coefficient in the objective function of
minimization LP problem. Since variable has no integer value between x j
Step 4: Obtain the new solution Add this and x j +1 .These two conditions are mutually
additional constraint (cut) generated in step 3 to
exclusive and when applied separately to the
the bottom of the optimal simplex table. Find a
continuous LP problem, form two different
new optimal solution by using the dual simplex
subproblems (also called nodes). Thus, the
method, i.e. choose a variable that is to be original problem is ‘branched’ or ‘partitioned’ into
entered into the new solution having the smallest two subproblems. Geometrically it means that the
ratio: {( c ) / y ; y ≤ 0} and return to step 2.
j−z j ij
branching process eliminates that portion of the
feasible region that contains no feasible integer
The process is repeated until all basic variables solution.
with integer value requirement assume non-
negative integer values.

Steps for using Branch and Bound Algorithm

Step 1: Initialization consider the following all integer programming problem.

Maximize Z = c1 x1 + c1 x2 + ... + cn xn
Subject to the constraints
a11 x1 + a12 x2 +  + a1n xn =
b1
a21 x1 + a22 x2 +  + a2 n xn =
b2 (4)

am1 x1 + am 2 x2 +  + amn xn =
bm
x ≥ 0 and non-negative intigers

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Obtain the optimal solution of the given LP LP Subproblem B
problem ignoring integer restriction on the Max Z = ∑ cj j
variables.
Subject to = ∑ aj xj = bi (5)
(i). If the solution to this LP problem (say LP- k ≤ [ k]
A) is infeasible or unbounded, the solution
and j ≥ 0
to the given all-integer programming
problem is also infeasible or unbounded,
as the case may be.

(ii). If the solution satisfies the integer LP Subproblem C

restrictions, the optimal integer solution Max Z = ∑ cj j
has been obtained. If one or more basic (6)
variables do not satisfy integer Subject to = ∑ aj j = bi
requirement, then go to Step 2. Let the k ≥ [ k]
optimal value of objective function of LP-A and j ≥ 0
be Z1. This value provides an initial upper
bound on objective function value and is
denote by Zu.
Step 3: Bound step Obtain the optimal solution
(iii). Find a feasible solution by rounding off each of subproblems B and C. let the optimal value of
variables value. The value of objective the objective function of LP-B be Z2 and that of
function so obtained is used as a lower LP-C be Z3. The best integer solution value
bound and is denoted by ZL. becomes the lower bound on the integer LP
problem objective function value (Initial this is the
rounded off value). Let the lower bound be
Step 2: Branching step denoted by ZL.

(i). Let k be one basic variable which does

not have an integer value and also has Step 4: Fathoming step Examine the solution of
the largest fractional value. both LP-B and LP-C

(ii). Branch (or partition) the LP-A into two (i). If a subproblem yields an infeasible
new LP sub problems (also called nodes) solution, then terminate the branch.
based on integer values of k that are
immediate above and below its non- (ii). If a subproblem yields a feasible solution
integer value. That is, it is partitioned by but not an integer solution, then return to
adding two mutually exclusive constraints: step 2.

k ≤ [ k] and k ≥[ k] +1 (iii). If a subproblem yields a feasible integer

solution, examine the value of the objective
To the original LP problem, Here [ k] is the function. If this value is equal to the upper
integer portion of the current non-integer value of bound, an optimal solution has been
reached. But if it not equal to the upper
the variable k. This obviously is done to exclude
bound but exceeds the lower bound, this
the non-integer value of the variables k. value is considered as new upper bound
and return to step 2. Finally, if it less than
The two new LP subproblems are as follows: the lower bound, terminate this branch.

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Step 5: Termination The procedure of branching STUDY AREA
and bounding continues until no further sub-problem
remains to be examined. At this stage, the integer The area of the study is Tasty Menu Bakery Unit,
solution corresponding to the current lower bound is off Army Barracks road, Jimeta, Adamawa State
the optimal all-integer programming problem of Nigeria. Adamawa State is located in the North
solution. East region of Nigeria. It lies between 70 and 110
North of the equator and between longitude 110
and 140 east of the Greenwich Meridian
RESEARCH DESIGN (Adebayo and Tukur, 1999).

The design of the study is the plan for how the Both documentation and interview method were
study will be conducted. It is concerned with what used for data collection from Tasty Menu Bakery
types of information or data will be gathered and Yola. The materials needed for the daily
through what forms of data-collection technique production of the five types of bread were
(Berg, 1995 in Jen, 2007). collected from the record of the production unit
through the production manager. Also, the unit
Evaluation study research design was adopted for cost of production of each type of bread and the
the study. This design was adopted because it corresponding unit selling price was collected
involves collection and analysis of data in order to from sales department. Some of the managers of
guide decision making (Jen, 2007). He further the sales points were interviewed on the supply
explained that the overall objectives of evaluation and demand of the products. Also, some
studies have to do with improvement or achieving customers were interviewed on their satisfaction
efficiency by making necessary adjustments of the products.
and/or modifications.

In this study, data were collected from Tasty Menu METHOD OF DATA ANALYSIS
production unit through the production manager.
The data includes all the materials needed for the Integer Linear Programming model was
production of bread. Also, data were collected formulated to determine the quantity of each type
from the bakery sales department on the unit cost of bread to be produced by Tasty Menu Bakery
of production and unit selling price of each with available resources in order to maximized
product. A visit was made to some sales point of profit. Production/Operation Management,
the products. Quantitative Method (POMQM) software was
used to run the data.The general linear
programming problem (or model) with n decision
variables and m constraints can be stated in the
following form:

Optimize (Max. or Min.) Z = c1 1 + c2 2 + ……+ cn n

Subject to the linear constraints, (≤, =, ≥)

a11x1 + a12 2 + ……+ a1n n (≤, =, ≥) b1

a11x1 + a12 2 + ……+ a1n n (≤, =, ≥) b2
. . . . (7)
. . . .
am1 1 + am2 2 + ……+ amn n (≤, =, ≥) bm
and 1, 2, ……, n ≥ 0

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The above formulation can also be expressed in a compact form as follows.
Optimize (Max. or Min.) Z = ∑ cj j (Objective function)

(8)
∑ aij j (≤, =, ≥) bi; I = 1, 2, ….., m (constraints)
and j ≥ 0; j = 1, 2, ….., n (Non negativity conditions) .

Where the cj s are coefficients representing the iii. Greater than or equal to ( ≥)
per unit profit (or cost) of the decision variable j
to the value of objective function. The aij’s are
referred as technological coefficients (or input – DATA PRESENTATION
output coefficients). These represent the amount
of resource, say I consumed per unit of variable The following data were collected from Tasty
(activity). These coefficients xj can be positive, Menu Bakery Yola, as shown in Tables 1 and 2
negative or zero. below.

The bi represents the total availability of the ith Table 1 shows the five types of bread produced
resource. The term of a resource is used in a very by Tasty Menu Bakery Yola. The weight of sliced,
general sense to include any numerical value with fruit, coconut and milk bread are of the same size
the right-hand side of a constraint. It is assumed and weight (750gm), while roll bread is a bit
that bi ≥ 0 for all i. however, if any bi < 0, then longer and weighs (700gm).
both sides of constraint I is multiplied by -1 to
make bi > 0 and reverse the inequality of the Table 2 shows all the materials needed with the
constraint. exception of egg, fruit, coconut powder and milk
are required for all types of bread. Egg is an
In general LP problem, the expression (≤, =, ≥) additional requirement for roll bread only, fruit is
means that in any specific problem each an additional requirement for fruit bread only, and
constraint may take only one of three possible coconut powder is an additional requirement for
forms: coconut bread only while milk is an additional
requirement for milk bread only.
i. Less than or equal to (≤)

ii. Equal to (=)

Table 1: Types of Bread Produced by Tasty Menu Bakery Yola.

Bread type Unit Cost of production (N) Unit selling price (N) Profit (N)
Sliced 219.50 320 100.5
Roll 232.70 320 87.30
Fruit 219.50 320 100.5
Coconut 219.50 320 100.5
Milk 235.60 320 84.40

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 Table 2: Material Requirement for the Unit production of the Five Types of Bread.

Material Sliced Bread Roll Bread Fruit Bread Coconut Bread Milk Bread Requirement

Flour 0.472 0.472 0.472 0.472 0.472 250kg

EDC 1.887 1.887 1.887 1.887 1.887 1000g
Preservative 1.415 1.415 1.415 1.415 1.415 750gm
Salt 0.755 0.755 0.755 0.755 0.755 3750gm
Improver 0.943 0.943 0.943 0.943 0.943 500gm
Yeast 2.358 2.358 2.358 2.358 2.358 1250gm
Sugar 0.066 0.066 0.066 0.066 0.066 35kg
Butter 0.009 0.009 0.009 0.009 0.009 5kg
Vegetable oil 0.009 0.009 0.009 0.009 0.009 5Litre
Coloring 0.472 0.472 0.472 0.472 0.472 250gm
Energy 1.949 1.949 1.949 1.949 1.949 1033(#)
Water 0.222 0.222 0.222 0.222 0.222 117.5Litre
Flavor 1.415 1.415 1.415 1.415 1.415 750gm
Nylon 1 1 1 1 1 530pieces
Egg 0 0.189 0 0 0 20pieces
Fruit 0 0 0.009 0 0 1kg
Coconut 0 0 0 0.019 0 2kg
Milk 0 0 0 0 0.019 2kg

FORMULATION OF LINEAR PROGRAMMING MODEL

Definition of Decision Variables

Let 1 = represent the number of loaves to be produced for sliced bread per daily production.

2 = represent the number of loaves to be produced for roll bread per daily production.

3 = represent the number of loaves to be produced for fruit bread per daily production.

4 = represent the number of loaves to be produced for coconut bread per daily production.

5 = represent the number of loaves to be produced for milk bread per daily production.
Z = total profit of the various types of bread per daily production (in Naira).

Objective function
Maximize Z = 100.5 1 + 87.3 2 + 100.2 3 + 100.5 4 + 84.4 5

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Subject to:
Flour 0.472 1 + 0.472 2 + 0.472 3 + 0.472 4 + 0.472 5 ≤ 250
EDC 1.887 1 + 1.887 2 + 1.887 3 + 1.887 4 + 1.887 5 ≤ 1000
Preservative 1.415 1 + 1.415 2 + 1.415 3 + 1.415 4 + 1.415 5 ≤ 750
Salt 0.755 1 + 0.755 2 + 0.755 3 + 0.755 4 + 0.755 5≤ 3750
Improver 0.943 1 + 0.943 2 + 0.943 3 + 0.943 4 + 0.943 5 ≤ 500
Yeast 2.358 1 + 2.358 2 + 2.358 3 + 2.358 4 + 2.358 5 ≤ 1250
Sugar 0.066 1 + 0.066 2 + 0.066 3 + 0.066 4 + 0.066 5≤ 35
Butter 0.009 1 + 0.009 2 + 0.009 3 + 0.009 4 + 0.009 5 ≤5
Vegetable oil 0.009 1 + 0.009 2 + 0.009 3 + 0.009 4 + 0.009 5 ≤5
Coloring 0.472 1 + 0.472 2 + 0.472 3 + 0.472 4 + 0.472 5 ≤ 250
(9)
Energy 1.949 1 + 1.949 2 + 1.949 3 + 1.949 4 + 1.949 5 ≤ 1033
Water 0.222 1 + 0.222 2 + 0.222 3 + 0.222 4 + 0.222 5 ≤ 117.5
Flavour 1.415 1 + 1.415 2 + 1.415 3 + 1.415 4 + 1.415 5 ≤ 750
Nylon 1 + 2 + 3 + 4 + 5 ≤ 530
Egg 0.189 2 ≤ 20
Fruit 0.009 3 ≤1
Coconut Powder 0.019 4 ≤2
Milk 0.019 5 ≤2

1, 2, 3, , 5 ≥ 0 and integer

Table 3: Integer Linear Programming Solution for Tasty Menu Bakery Yola, Generated by POMQM
Software of the above model (Equation 9).

Variable Type Value

1
Integer 529
2
Integer 0
3
Integer 0
4
Integer 0
5
Integer 0
Solution Value 53,164.5

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Sensitivity Analysis The objective function is then run against the
constraints of Equation 9. The following results
The study of how sensitive the best solution to an were obtained as shown in Table 4.
LP problem is to discrete variations (Changes) in
its parameters is known as sensitivity analysis.
The ideal solution to the specific LP problem can DISCUSSION OF RESULTS
alter significantly or not at all depending on how
sensitive the solution is to these differences. The From Table 4 (result of the original problem)
range of LP model parameters that can vary shows that value of the objective function is ₦
without having an impact on the existing optimal 53,164.5 while the value of the five variables
solution is thus determined through sensitivity 1,……, 5 are 529, 0, 0, 0 and 0, respectively.
analysis. According to the results, the study
advised changing each product's unit profit to see
These indicate that only 1 variable contributed
the changes it would bring about. It indicates that
just the objective function has changed. That is meaningfully to improve the value the objective
when the profit contribution of: function. The integer linear programming model
showed that it is economical Tasty Menu Bakery
Yola, to concentrate on the production of sliced
Sliced bread ( 1) has been changed from 100.5 bread only. The total production of 529 loaves of
to 80.5 sliced bread should be produce daily. This will
generate the Bakery an optimum profit of
Roll bread ( 2) has been changed from 87.3 to ₦53,164.50 daily based on the cost of raw
107.3 materials only.

Fruit bread ( 3) has been changed from 100.2 to Table 4 (result of the sensitivity analysis) shows
120.5 that the value of the objective function is N55,087
while the value of five variables 1,. .. . .. , 5
Coconut bread ( 4) has been changed from are 117, 280, 111, 10 and 10 respectively. This
100.5 to 120.5 indicated that 117 loaves of sliced bread, 280
loaves of roll bread, 111 loaves of fruit bread, 10
Milk bread ( 5) has been changed from 84.4 to loaves of coconut bread and 10 loaves of milk
104.4 bread should be produced daily to generate a
total profit of ₦55,087. This result shows that it is
This resulted in: economical for Tasty Menu Bakery to produce all
the five types of bread daily.
Maximize Z = 80.5 1 +107.3 2+ 120.5 3+

120.5 4+ 104.4 5

Table 4: Integer Linear Programming Solution with Regards to the Change in Objective Function.

Variable Type Value

1
Integer 117
2
Integer 280
3
Integer 111
4
Integer 10
5
Integer 10
Solution Value 55,087

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Comparing the sensitivity analysis result with the Learning. Department of Mathematics, Kwame
result of the original problem, it shows that more Nkrumah University of Science and Technology:
profit will be generated (increment of ₦1,922.50 Kumasi, Nigeria.
daily) when the result of the sensitivity analysis is
5. Barbier, J.P. 1994. “Nicolas Appert inventeur et
implemented and all the five types bread will be humaniste”. Edition Royer: Paris, France.
produced daily. In other words, the bakery will http://www.appert-aina.com/ (Accessed 20th
satisfy all its customers by producing all the five March, 2012).
types of bread.
6. Bauer, T. and K. Zimmermann. 1999. “Overtime
Work and Overtime Compensation in Germany”.
SUMMARY IZA Discussion Paper 48.

The objective of the study was to determine the 7. Ben-Awuah, E., H. Askari-Nasab, and K. Awuah-
Offei. 2012. “Production Scheduling and Waste
optimal production schedule for Tasty Menu Disposal Planning for Oil Sands Mining Using
Bakery Unit taken into consideration the raw Goal Programming”. Journal of environmental
materials needed for the daily production of the informatics. 20(1): 20-33.
five types of bread. The problem was formulated
as linear programming problem and QM software 8. Bitran, G., E. Hass, and A. Hax. 1982.
was used to solve the problem. Result was “Hierarchical Production Planning: A Two-Stage
generated for the original problem and for a System”. Operations Research. 30(2): 232-251.
sensitivity analysis where changes were made
only at the objective function of the original 9. Balogun, O.S., E.T. Jolayemi, T.J. Akingbade, and
H.G. Muazu. 2006. International Journal of
problem. Engineering Research and Application (IJERA).
ISSN: 2248-9622 www.ijera.com 2(5): 2012.

CONCLUSION 10. Canales-Kriljenko, J. 2003. Foreign Exchange

Intervention in Developing and Transition
The study has successfully determined the Economies: Results from a Survey”. IMF Working
number of breads to be produced daily in order to Paper 03/95.
maximize profit at Tasty Menu Bakery Yola. The
sensitivity result showed that 117 loaves of sliced 11. Cassandras, C.G. 1993. Discrete Event System:
Modeling and Performance Analysis. Irwin and
bread, 280 loaves of roll bread, 111 loaves of fruit Aksen Associates.
bread, 10 loaves of coconut bread and 10 loaves
of milk bread should be produced daily to make a 12. Cheng, T.C.E., J.E. Diamond, and B.M.T. Lin.
maximum profit of N55,087.00. 1993. “Optimal Scheduling in Film Production to
Minimize Talent hold Cost”. Journal of
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