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Production Plan: Bajaj Auto Ltd. Chakan Plant

The production plan outlines the daily production targets for 12 motorcycle models across 3 brands (Bajaj, KTM, and Honda) totaling 3,462 units per day. Ten high-usage parts are identified along with their daily requirements. The parts will be shipped using 3 types of vehicles within weight and volume constraints to minimize total transportation costs of Rs. 3,300. A linear program is formulated to determine the optimal vehicle and loading plan that meets all constraints.

Uploaded by

Pankaj Goenka
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© © All Rights Reserved
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Download as XLSX, PDF, TXT or read online on Scribd
94 views

Production Plan: Bajaj Auto Ltd. Chakan Plant

The production plan outlines the daily production targets for 12 motorcycle models across 3 brands (Bajaj, KTM, and Honda) totaling 3,462 units per day. Ten high-usage parts are identified along with their daily requirements. The parts will be shipped using 3 types of vehicles within weight and volume constraints to minimize total transportation costs of Rs. 3,300. A linear program is formulated to determine the optimal vehicle and loading plan that meets all constraints.

Uploaded by

Pankaj Goenka
Copyright
© © All Rights Reserved
Available Formats
Download as XLSX, PDF, TXT or read online on Scribd
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Production Plan : Bajaj Auto Ltd.

Chakan Plant
Model
Pulsar 150 UG4.5
Pulsar 180 UG4
Pulsar 220 SF
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)

domestic
50000
10000
4000
2232
3554
1175
315

71276

Working days

26

Export
5256
1534
772
5668
846
1040
980
1000
810
20
806
18732

Total
50000
15256
5534
772
7900
4400
1040
2155
1315
810
20
806
90008

Product wise
70790

7900
4400

6146

89236

Daily DOM
1923
385
154
0
86
137
0
45
12
0
0
0
2741

Daily EXP

Total daily

0
202
59
30
218
33
40
38
38
31
1
31
720

1923
587
213
30
304
169
40
83
51
31
1
31
3462

DAILY TOTAL
3462

Daily Plan (From Production Plan Sheet 1923


Sl.
Part No
No

Tag Part Desc

Pulsar 150
UG4.5

Unit of Measurement ---->


1 52DH0177
2 52DH0695
3 52DJ0412
4 52JC0163
5 52JL0013
6 52JM0013
7 DH101898
8 DH161410
9 JG113009
10 JG113800

x1
x2
x3
x4
x5
x6
x7
x8
x9
x10

SF:BALANCER IDLER HOLDER WITH BEAR


COVER LHRR MOONLIGHT K1
GRAB HANDLE KIT BLACK LH/RH WITH B
LH RR COVER ASSLY K2/K3 MOONLIGHT
GRAB HANDLE WITH TPT N WASHER JL
COVER LH RR WITH BOLT FOR JM
INTAKE MANIFOLD K1(UG5)
GRAB HANDLE ASSY
CHANGE LEVER
DUMBLE SPACERS FOR STEPHOLDER

Inputs to Linear Program

1
1
1

1
1

587
Pulsar 180
UG4

213
Pulsar 220
SF

30
Pulsar 220 S

304
PULSAR
200NS

169
AVENGER
220

40
KTM 125
MY14

83
KTM 200
MY14

1
1

1
4

1
4

51

31

KTM 390 MY RC 390


14
( KT06)

1
RC 200
( KT05)

31
RC 125
( KT04)

Total Req.

Weight

Nos per day Kg. / part

1
4

1
4

1
4

1
4

2752
1923
1923
829
304
169
1923
1923
236
946

0.236
0.725
0.585
0.716
0.717
0.762
0.122
0.433
0.220
0.114

No of Parts
per Bin
Nos/Bin
30
14
8
14
20
14
45
10
50
100

Bin Dimension
Wt of
Length Width Height empty Wt per Bin
Bin

Vol per Bin Total No of Bins

Kg/Bin

Kg/Bin

Cu. M / Bin

0.4
0.6
0.6
0.6
0.6
0.6
0.4
0.6
0.4
0.3

0.3
0.4
0.4
0.4
0.4
0.4
0.3
0.4
0.3
0.2

0.1
0.14
0.2
0.14
0.2
0.14
0.08
0.2
0.16
0.05

0.75
1
1
1
1
1
0.75
1
0.75
0.5

7.84
11.15
5.68
11.02
15.35
11.67
6.23
5.33
11.77
11.89

0.012
0.0336
0.048
0.0336
0.048
0.0336
0.0096
0.048
0.0192
0.003

Nos. / day
92
137
240
59
15
12
43
192
5
9
805

Total Vol

Total Wt

Cu. M

Kg
1
5
12
2
1
0
0
9
0
0
30

719
1532
1365
653
233
141
266
1026
56
112
6102

Vehicle Data

TATA 909
TATA 709
TATA ACE

L (m)

B (m)

H (m)

4.381
3.833
2.14

2.042
2.057
1.43

2.13
2.13
1.65

Inputs to Linear Program

Permissible Wt
(in Kg)
6000
3000
1000

Trip Cost
Rs/trip
1800
1500
1000

Total Vol Cu. M


19.055
16.794
5.049

Objective Function

3300.00 (Minimize Transportation cost)

Trip Cost
Truck Type
Decision Variable - No of trucks of
each type

1800
y1

1500
y2

1000
y3

x1
x2
Decision Variable and Constraints pertaining to Truck Type1
x1y1
x2y1
Decision Variable - No of Bins of
96
100
each type
Weight Constraint
7.84
11.15
Volume Constraint
0.012
0.0336

x3
x3y1
177
5.68
0.048

Decision Variable and Constraints pertaining to Truck Type2


x1y2
x2y2
x3y2
Decision Variable - No of Bins of
0
37
64
each type
Weight Constraint
7.84
11.15
5.68
Volume Constraint
0.012
0.0336
0.048
Decision Variable and Constraints pertaining to Truck Type3
x1y3
x2y3
x3y3
Decision Variable - No of Bins of
0
0
0
each type
Weight Constraint
7.84
11.15
5.68
Volume Constraint
0.012
0.0336
0.048
Constaint pertaining to total Number of Bins of each type should be in required
Total Number of Bins of each type

96

137

240

Condition
Min Req. Constaint
Max Req. Constaint ( +5% tol.)

92
96

137
144

240
252

Constaint on total number of


vehicles

2 <=

Note :Non-negative constaint for all decision variable


For Vehicle - Interger constaint

100

ation cost)

x4

x5

x6

x7

x8

x9

x10

x4y1

x5y1

x6y1

x7y1

x8y1

x9y1

x10y1

43

11.02
0.0336

15.35
0.048

11.67
0.0336

6.23
0.0096

5.33
0.048

11.77
0.0192

11.89
0.003

x4y2

x5y2

x6y2

x7y2

x8y2

x9y2

x10y2

59

15

12

192

11.02
0.0336

15.35
0.048

11.67
0.0336

6.23
0.0096

5.33
0.048

11.77
0.0192

11.89
0.003

x4y3

x5y3

x6y3

x7y3

x8y3

x9y3

x10y3

11.02
0.0336

15.35
0.048

11.67
0.0336

6.23
0.0096

5.33
0.048

11.77
0.0192

11.89
0.003

12

43

192

12
13

43
45

192
202

5
5

9
10

uld be in required range


59

15

>Min, <Max
59
15
62
16

LHS

RHS

3138 <= 6000 (Total Wt loaded in vehicle is less than max. permissible)
13 <= 19 (Total Vol loaded in vehicle is less than max. allowable)

LHS

RHS

3000.00 <= 3000 (Total Wt loaded in vehicle is less than max. permissible)
16.79 <= 17 (Total Vol loaded in vehicle is less than max. allowable)

LHS

RHS
0 <=
0 <=

0
0

(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)

x. permissible)
ax. allowable)

x. permissible)
ax. allowable)

x. permissible)
ax. allowable)

pply is allowed)

Output
Vehicle Selection
Vehicle
Type
TATA 909
TATA 709
TATA ACE

Tag

Total No Trips

y1
y2
y3

1
1
0

Vehicle Loading Plan

Sl. No

Part No

Tag

1 52DH0177
2 52DH0695
3 52DJ0412
4 52JC0163
5 52JL0013
6 52JM0013
7 DH101898
8 DH161410
9 JG113009
10 JG113800

x1
x2
x3
x4
x5
x6
x7
x8
x9
x10

Loading Patter
(Nos of Bins per
Part Desc
SF:BALANCER IDLER HOLDER WITH BEAR
COVER LHRR MOONLIGHT K1
GRAB HANDLE KIT BLACK LH/RH WITH B
LH RR COVER ASSLY K2/K3 MOONLIGHT
GRAB HANDLE WITH TPT N WASHER JL
COVER LH RR WITH BOLT FOR JM
INTAKE MANIFOLD K1(UG5)
GRAB HANDLE ASSY
CHANGE LEVER
DUMBLE SPACERS FOR STEPHOLDER

No of
Bins
(Min)
92
137
240
59
15
12
43
192
5
9

No of
Bins
(Max)
96
144
252
62
16
13
45
202
5
10

TATA 909
96
100
177
0
0
0
43
0
0
0

Loading Pattern
(Nos of Bins per trip)
TATA 709 TATA ACE
0
37
64
59
15
12
0
192
5
9

0
0
0
0
0
0
0
0
0
0

Total
Shipped
96
137
240
59
15
12
43
192
5
9

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