Linear Programming Technique for Cotton Mixing

Pavani Harsha

MB 30 - Quantitative Methods in Decisions

Prof.Jaideep Naidu

LPT for Cotton Mixing

Acknowledgements

Prof. Jaideep Naidu, Philadelphia University

Mr. Thavasi Vijayakumar, Spinning Manager, Pt. Gokak, Indonesia

LPT for Cotton Mixing

Introduction:
Quantitative methods used in Textile industry: Linear programming technique - Cotton mixing - Scheduling Forecasting in apparel industry - Seasonal Forecasting Inventory control Various production stages CPM/ PERT - two or more simultaneous projects on time Transportation technique Raw materials & finished goods

LPT for Cotton Mixing:

Why is cotton mixed?

LPT for Cotton Mixing

Balancing Cost and Quality

Achieve best quality yarn at lowest production Cost Why cotton quality varies? Natural fiber

Uneven and non-uniform

How are Cost & Quality related?

As Quality increases cost increases

LPT for Cotton Mixing Is Cotton Cost a big factor? Around 60 % of total production cost
Cost Breakdown in a Typical Textile Mill (%)
Fiber Cost Capital Cost Labor Cost Operating Cost

http://www.cottoninc.com/EFSConference/homepage.cfm?page=1099

LPT for Cotton Mixing

Properties of Raw Materials that affect the final product:

Length
Strength Maturity Coefficient Fineness Micronaire

Why is LPT used?

Minimize Total cost Maximize quality

LPT for Cotton Mixing

Formulation of LPT model:

Let
C1, C2, C3,.Cn be the costs of n cottons P1, P2, P3,..Pn be the Percentages of each cotton to be mixed

L1, L2, L3,.Ln be the lengths of each cotton

S1, S2, S3,.Sn be the strengths of each cotton M1, M2, M3,.Mn be the maturity coefficients of each cotton F1, F2, F3,.Fn be the micronaire value of each cotton

LPT for Cotton Mixing

Objective Function:
Min Z = (C1*P1) + (C2*P2) + (C3*P3) + + (Cn*Pn)

S.T. Constraints
L1*P1 + L2*P2 + L3*P3 + + Ln*Pn Lr S1*P1 + S2*P2 + S3*P3 + + Sn*Pn Sr M1*P1 + M2*P2 + M3*P3 + + Mn*Pn Mr

F1*P1 + F2*P2 + F3*P3 + + Fn*Pn Fr

P1 + P2 + P3 + + Pn = 1 P1, P2, P3,.. Pn 0 Right Hand Side values are obtained from given set of Norms

LPT for Cotton Mixing

Example:
Aim:
To manufacture 10 Tex cotton yarn

Required properties for the raw material:

Length: 31.5mm 34mm Strength: 20gpt 23gpt Maturity Coefficient: 80% - 83% Micronaire Value: 3.6 3.9

The values shown above are examples and do not represent any cottons as such.

LPT for Cotton Mixing

Properties of Cottons available and their Costs:

Properties Length (mm) Strength (gpt) Maturity Coefficient (%) Micronaire 1 33 24 83 3.5 Cottons 2 31 20.5 80.2 3.85 3 30 19 79.8 3.9 Norms 32 21.5 82 3.7

Cost per lb (US $)

2.05

1.70

1.66

The values shown above are examples and do not represent any cottons as such.

Objective Function:
Min Z = (2.05*P1) + (1.70*P2) + (1.66*P3)

LPT for Cotton Mixing

S.T. Constraints:
33*P1 + 31*P2 + 30*P3 32 24*P1 + 20.5*P2 + 19*P3 21.5

0.83*P1 + 0.802*P2 + 0.798*P3 0.82

3.5*P1 + 3.85*P2 + 3.9*P3 3.7 P1 + P2 + P3 = 1

Non-Negativity Constraints: P1, P2, P3 0 P1, P2, P3 values are obtained by solving this LP Model using SIMPLEX method (Microsoft Excel can be used)

LPT for Cotton Mixing

Results:
Objective Function Value: Min Z = 1.925

Cotton Percentage to be Mixed (%) 1 64.3 2 35.7 3 0

Conclusion:
LPT can be efficiently used in cotton mixing LPT eliminates wastage of raw materials and hence reduces the total Production Cost.