Apparel Industry Case Study

By:Ankit Mozika 211018 Apoorva Agarwal 211030

The Case
Large amount of wastage in cutting operation The process involved putting several layers of cloth of standard width on a table and putting stencils, i.e. the templates in order to cut the cloth. To reduce the wastage the decision was to be made by R&D department.

Case Background
Zodiac manufactures different types of shirts in different sizes.

Objective Function
Minimize the setup cost.
Minimize the number of rotation Upper bound on the number of layer is 35.

Decision Variable
X1= Number of rotations required to fulfill the demand of 54 shirts for size 38 X2= Number of rotations required to fulfill the demand of 84 shirts for size 40 X3= Number of rotations required to fulfill the demand of 91 shirts for size 42 X4= Number of rotations required to fulfill the demand of 60 shirts for size 44 X5= Number of rotations required to fulfill the demand of 29 shirts for size 46

 Objective Function Min Z =X1+X2+X3+X4+X5 Subject to constraints X1>=2 X2>=3 X3>=3 X4>=2 X5>=1 X1, X2, X3, X4, X5 >= 0 and all are integers

Adding Surplus Variable

Objective Function Min Z =X1+X2+X3+X4+X5+0S1+0S2+0S3+0S4+0S5 Subject to constraints X1+S1=2 X2+S2=3 X3+S3=3 X4+S4=2 X5+S5=1 Xi, Si >= 0 and all are integers Where i is 1 to 5

Cj

1
X1

1
X2 0 1 0 0 0

1
X3 0 0 1 0 0

1
X4 0 0 0 1 0

1
X5 0 0 0 0 1

0
S1 -1 0 0 0 0

0
S2 0 -1 0 0 0

0
S3 0 0 -1 0 0

0
S4 0 0 0 -1 0

0
S5 0 0 0 0 -1 Sol. 2 3 3 2 1

BV X1 X2 X3 X4 X5 1 1 1 1 1 1 0 0 0 0

Cj-Zj

Optimal Solution
X1=2 X2=3 X3=3 X4=2 X5=1 Min Z = 2+3+3+2+1 = 11