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Workload Balancing Case Analysis

This document describes a case problem involving workload balancing across two production lines. The optimal solution without workload balancing constraints produces 80 units of model DI-950 for $6960 profit. Adding a constraint to produce a minimum number of model DI-910 units results in a solution of 53 units of each model for $6880 profit, but does not balance workload between the lines. Additional constraints are added to balance workload within 30 minutes between lines, resulting in a solution of 97 units of DI-910 and 32 units of DI-950 for $6815 profit. The perfectly balanced solution of 107 units of DI-910 and 27 units of DI-950 generates $6800 profit.

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307 views3 pages

Workload Balancing Case Analysis

This document describes a case problem involving workload balancing across two production lines. The optimal solution without workload balancing constraints produces 80 units of model DI-950 for $6960 profit. Adding a constraint to produce a minimum number of model DI-910 units results in a solution of 53 units of each model for $6880 profit, but does not balance workload between the lines. Additional constraints are added to balance workload within 30 minutes between lines, resulting in a solution of 97 units of DI-910 and 32 units of DI-950 for $6815 profit. The perfectly balanced solution of 107 units of DI-910 and 27 units of DI-950 generates $6800 profit.

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  • Case Problem 1: Workload Balancing
  • Continuation of Calculations
  • Solution and Comparison

Case Problem 1: Workload Balancing

1.
Production Rate
(minutes per printer)
Model Line 1 Line 2 Profit Contribution ($)

DI-910 3 4 42
DI-950 6 2 87

×
Capacity: 8 hours 60 minutes/hour = 480 minutes per day

Let D1 = number of units of the DI-910 produced


D2 = number of units of the DI-950 produced

Max 42D1 + 87D2


s.t.

3D1 + 6D2 ≤ 480 Line 1 Capacity


4D1 + 2D2 ≤ 480 Line 2 Capacity
D1, D2 ≥ 0

Using The Management Scientist, the optimal solution is D1 = 0, D2 = 80. The value of the optimal
solution is $6960.

Management would not implement this solution because no units of the DI-910 would be produced.

2. Adding the constraint D1 ≥ D2 and resolving the linear program results in the optimal solution D1 =
53.333, D2 = 53.333. The value of the optimal solution is $6880.

3. Time spent on Line 1: 3(53.333) + 6(53.333) = 480 minutes

Time spent on Line 2: 4(53.333) + 2(53.333) = 320 minutes

Thus, the solution does not balance the total time spent on Line 1 and the total time spent on Line 2.
This might be a concern to management if no other work assignments were available for the
employees on Line 2.

4. Let T1 = total time spent on Line 1


T2 = total time spent on Line 2

Whatever the value of T2 is,

T1 ≤ T2 + 30
T1 ≥ T2 - 30

Thus, with T1 = 3D1 + 6D2 and T2 = 4D1 + 2D2

CP - 1
3D1 + 6D2 ≤ 4D1 + 2D2 +
30 3D1 + 6D2 ≥ 4D1 + 2D2 −
30

CP - 2
Hence,

−1D1 + 4D2 ≤ 30
−1D1 + 4D2 ≥ −30

Rewriting the second constraint by multiplying both sides by -1, we obtain

−1D1 + 4D2 ≤ 30
1D1 − 4D2 ≤ 30

Adding these two constraints to the linear program formulated in part (2) and resolving using The
Management Scientist, we obtain the optimal solution D1 = 96.667, D2 = 31.667. The value of the optimal
solution is $6815. Line 1 is scheduled for 480 minutes and Line 2 for 450 minutes. The effect of
workload balancing is to reduce the total contribution to profit by $6880 - $6815 = $65 per shift.

5. The optimal solution is D1 = 106.667, D2 = 26.667. The total profit contribution is

42(106.667) + 87(26.667) = $6800

Comparing the solutions to part (4) and part (5), maximizing the number of printers produced (106.667 +
26.667 = 133.33) has increased the production by 133.33 - (96.667 + 31.667) = 5 printers but has reduced
profit contribution by $6815 - $6800 = $15. But, this solution results in perfect workload balancing
because the total time spent on each line is 480 minutes.

CP - 3

Case Problem 1: Workload Balancing 1. Production Rate (minutes per printer) Model Line 1 Line 2 Prof
3D1 + 6D2 ≤ 4D1 + 2D2 + 30 3D1 + 6D2 ≥ 4D1 + 2D2 − 30 CP - 2
Hence, −1D1 + 4D2 ≤ 30 −1D1 + 4D2 ≥ −30 Rewriting the second constraint by multiplying both sides by -1,

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