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Application of linear programming techniques in production planning

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 International Journal of Applied Operational Research
Vol. 9, No. 3, pp. 11-19, Summer 2019

Journal homepage: ijorlu.liau.ac.ir

Application of linear programming techniques in production

planning
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O. Solaja 1*, J. Abiodun2, M. Abioro3, J. Ekpudu4, O. Olasubulumi5

Received: 2 March 2019; Accepted: 15 June 2019

Abstract Optimum utilization of limited resources in the production floor demands that the production
manager makes decisions on the best allocation of limited resources. Linear programming techniques
are applied in this study to a production planning problem in a feed mill producing company. The
linear Programming model was formulated based on data obtained from the company operations’
diary. Data was processed with the help of Management Scientist Version 5.0. The study reveals
improved profit through streamlining of the product range and cutting off the less productive products.
This suggests the company may adopt the outcome of the linear programming techniques in
production planning to improve monthly profit. This study has shown that linear programming
techniques are powerful tools that can be of help to managers in decision making and allocation of
limited resources and indicate operations and profit improvement.

Keyword: Production, Optimization, Planning, Feed, Linear Programming.

1 Introduction

Decision making is one of the major functions of managers; they are often faced with
decisions relating to the allocation and use of scarce resources. Resources available for
production, according to the classical economists, are limited and have multidimensional uses.
This makes it pertinent for operations managers as decision makers to contemplate on
allocation of resources in production planning. Poor resources allocation may result into

* Corresponding Author. ()

E-mail: [email protected] (S. Oluwasegun Abraham)

O. Solaja
Department of Business Administration, College of Management Sciences, Federal University of Agriculture, Abeokuta, Ogun State,
Nigeria

J. Abiodun
Department of Business Administration, College of Management Sciences, Federal University of Agriculture, Abeokuta, Ogun State,
Nigeria

M. Abioro
Department of Business Administration, College of Management Sciences, Federal University of Agriculture, Abeokuta, Ogun State,
Nigeria

J. Ekpudu
Department of Business Administration, College of Management Sciences, Federal University of Agriculture, Abeokuta, Ogun State,
Nigeria

O. Olasubulumi
Department of Business Administration, College of Management Sciences, Federal University of Agriculture, Abeokuta, Ogun State,
Nigeria
 12 O. Solaja , J. Abiodun, M. Abioro, J. Ekpudu and O. Olasubulumi/ IJAOR Vol. 9, No. 3, 11-19, Summer 2019 (Serial #33)

operations failure and endanger the financial health and survival of organizations. In practice,
firms often produce below the installed capacity of their plants, thus, there is a thoughtful
need for an efficient and effective control of the firms’ production capacity planning [4]. For
organization to maximize the usage of resources must be efficient and effective in achieving
the result with little or minimum resources.
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Proper allocation of scarce resources enhances organizational efficiency and

effectiveness in meeting profit goals. Indeed, there will be evident improvement in the
economy if sectors maximize productivity with little resources. Akpan, and Iwok [3] opined
that an economy can only grow if management decisions at the firm level result in boosted
output through cost minimization or output maximization culminating in increased production
in the real sector. Failure to minimize cost will make it more difficult for organization to
maximize profit or benefit. However, in order to minimize cost, it is pertinent for a production
manager to decide on the best way to allocate limited resources in such a manner that it will
lead to higher output and profit. There is a need to identify products that maximally contribute
to profit and those that yield zero or negative profit. Production manager must keep idle time
in the production floor to the minimum, excess idle time tends to waste resources in the
production floor.
Managers are apt to make decisions with the rule of thumb (experience, intuition) which
tends to expose the organization to the danger of uncertainty. Adebiyi et al. [2] argued that
organizational entities managed by non-professional, but experienced managers are more
dependent on experience, intuition and knowledge in making decisions which expose
organizations to danger of uncertainty in terms of result.
The rate at which production companies, especially feed mill producing companies
liquidate in Nigeria is alarming which can be traced to wastage of production resources, high
level of idleness on the production floor and inability of the production companies to
maximize meaningful profit that will enable these companies to meet up with the expectations
of its stakeholders. This is so because the majority of these companies make use of traditional
techniques in production planning; only few of them are aware about the application of these
techniques in production planning. Though different studies have been done in Nigeria to alert
management of these companies about the importance of linear programming techniques in
production planning, but there is a paucity of such study that address feed mill production
planning problem in Nigeria.
This study is set to utilize linear programming in production planning in a feed mill
company in Nigeria, realize the optimal profit and extent of resource utilization.

2 Literature review

2.1 Concept of production

Production is one of the key functions in organizations, and it is concerned with the
transformation of input resources into required outputs (products). Production involves the
conversion of one form of material into another form through chemical or mechanical process
to create or enhance the utility of the product to the users. It is a value addition process. Buffa
(nd) cited in [10] defined production as a process by which goods and services are created.
Production is an activity that is primarily concerned with the transformation or conversion of
inputs into finished goods and services [5]. Olamade and Oni [11] observed that economic
growth is positively related to the growth of the manufacturing sector in Africa countries.
 Application of linear programming techniques in production planning 13

Abiodun [1] was of the opinion that production activities are the life wires of a country’s
economy, which create present and future value in utility and exchange.

2.1.1 Production planning

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Wild [13] defined production planning as the determination, acquisition and arrangement of
all facilities needed for production of items. Production planning is a key activity of
production manager; it is the determination of objectives to be achieved during production
and combination of resources (input) to be used to achieve goals efficiently.
Production planning estimates the resources required and prepares a detailed plan for
achieving the production goals efficiently and timely [4]. Production planning is a basic
function of manufacturing management applicable in all manufacturing companies in which it
shows the direction and coordination of firms’ resources towards attaining their prefixed goals
[10]. Achievement of efficiency and effectiveness in production floor, require planning [7].
It gives direction on what to achieve in the production, how we want to achieve it and
materials needed for its actualization. Production planning involves the generation and
identification of alternative courses of action and to select the optimum alternative. Goutham
[7] argues that production planning improves the performance of the manufacturing entity,
especially when an entity operates in an uncertain environment. Umoh et al. [12] posits that
production planning enhances operational efficiency in the organization. Production planning
helps managers to improve the system and production process in an uncertain environment.
Higgins [8] reported that firms that effectively implement production planning to their
operations performs better than those that make use of adhoc approach. Goutham [7] was of
the opinion that production planning plays a significant role in ensuring optimization.

2.1.2 Production system

Production systems are methods and procedures used to produce goods for the market.
Production systems utilize material, capital, transportation, and labour resources to produce
and distribute products.
Production system can be categorized into continuous production, job shop production,
batch production and mass production. It has the following characteristics; production system
transforms various inputs to useful outputs, production system does not operate in isolation
from the other organization system, production is an organized activity, so every production
system has an objective.
Amole et al. [4] are of the opinion that a production system is considered to incorporate
an organizational element in addition to physical facilities.

2.2 Linear programming

Linear Programming is that branch of mathematical programming which is designed to solve

optimization problems where objectives and all the constraints involved can be expressed as a
linear function. It was developed by George Dantzig, in 1947 for finding optimal solutions to
problems of supplies to the Force during World War II. It is a powerful tool in management
science and operations research for decision making under certainty. Linear Programming can
also be used for verification and checking mechanism to ascertain the accuracy and the
 14 O. Solaja , J. Abiodun, M. Abioro, J. Ekpudu and O. Olasubulumi/ IJAOR Vol. 9, No. 3, 11-19, Summer 2019 (Serial #33)

reliability of the decisions which are taken solely on the basis of manager's experience
without the aid of a mathematical model [4]. It is useful in the allocation of scarce resources
like materials, machine, man, time, etc.
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2.2.1 Advantages of linear programming

i. Quality Decision: Linear Programming technique helps to decision makers in making

quality decisions. With the help of this technique, decision makers are more objective
in their decision.
ii. Maximization of Resources: This technique helps in maximization of resources that
are limited in nature. Managers can deploy this technique in allocating limited
resources
iii. Complex Problem: The technique has the ability to solve complex problem we
encounter in real life.
iv. Multiple Constraint: These techniques are more suitable to solve problems with
multiple constraints
v. Simplicity: Linear programming model can be solved with the help of a simple and
straight method called simplex.
vi. Multipurpose: This technique can be employed to solve different real life problems

2.2.2 Limitations of linear programming

Linear programming techniques have been applied to real life problems to derive an optimal
solution which aid decision making process but the techniques has some limitations:
i. It assumes parameters are constant in nature meanwhile it is not so in real life.
ii. There is no assurance that the value we will get will be an integer value. For instance,
the linear programming solution might result in 4.2 machines which is not possible in
real life.
iii. Linear programming deals with a single objective; it does not have the capacity to deal
with a problem that has multiple objectives. In real life, decision makers at times
encounter problem with conflicting objectives
iv. Linear programming is only can only be used in a situation whereby constraints and
objectives can be expressed as straight line equations i.e. linear in nature.
v. This technique assumes a certainty, but in some situations, values in objective and
constraint might not be known beforehand. In this case, this technique cannot be used.

2.3 Empirical framework

Adebiyi et al. [2] applied linear programming techniques to achieve optimal product mix to
improve profit contribution of five products of a paint producing company in Nigeria. The
obtained solution suggested that the company should produce only two of its products and
drop other three products. Akpan, and Iwok [3] utilized Simplex algorithm in linear
programming maximize the profit contribution in the bread producing company. Amole et al.
[4] applied linear programming techniques to the production planning problem of the
Detergent producing company in Nigeria The result suggested that the total monthly cost of
production could be reduced up to N2 million on an average. Benedict and Uzochukwu [6]
 Application of linear programming techniques in production planning 15

applied linear programming techniques to a plastic producing company and obtained the
optimal solution to the company’s production problem The study suggested the company
should produce 114,317.2 pieces of 25mm by 5.4m conduit pipes and 7,136.564 pieces of
20mm by 5.4m thick pressure pipes, and zero quantities of the rest sizes of pressure pipes per
month in order to obtain a maximum profit of N1, 964,537. Igbinehi et al. [9] formulated
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linear programming model of Local Soap Manufacturing Company and achieved optimum
solution The result of the analysis showed that the company spends more on coloured soap
and get more from. They suggested that the company should produce more of white soap and
less of coloured soap. Yahya et al. [14] showed that linear programming techniques are useful
in production planning by analyzing the production planning problem of KASMO Industry in
Nigeria, the obtained solution suggested that the company should produce only two of its
products and drop other three products. Despite the popularity of linear programming
techniques and different studies done on linear programming, there is a paucity of study that
address production planning of feed producing company especially in Nigeria which is the
focus of this study. This study will demonstrate the relevance of linear programming
techniques in any production planning problem and strengthen claims of previous authors.

Fig. 1 Conceptual Model for the Study

The model above describes the generalized production process of the case organization. The
process takes the inputs (Maize, G.N.C., Soya Beans, Oystel Shell Etc.) for conversion
through the process of grinding and mixing using the right quantity of materials to generate
the outputs or products that are marketed to the customers. The outputs consist of Layer
Mash, Grower Mash, Broiler Starter Mash and Broiler Finisher Mash.

2.4 Case organization

The case organization produces animals’ feeds in its factory located in Abeokuta. The
organization is a medium sized organization and specializes in the production and selling of
different kinds of animal feeds such as Layer Mash, Grower Mash, Broiler Starter Mash and
Broiler Finisher Mash are the major products the company deals with. Administratively, the
company is headed by a manager who oversees the operation of the firm.
 16 O. Solaja , J. Abiodun, M. Abioro, J. Ekpudu and O. Olasubulumi/ IJAOR Vol. 9, No. 3, 11-19, Summer 2019 (Serial #33)

3 Materials and methods

Data for the study was obtained from the company’s record book, clarification and
explanation were obtained from the production manager in some aspect of the dataset. Data
was obtained on the quantity of each raw material used per month as well mix of these basic
raw materials and the costs. Finally, data were collected on the cost of production of the four
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products of the company.

3.1 Model formulation

The objective of the study was to maximize the profit.

Where Ci represents the profit derived from the sales of the products (i = 1,2,3,4) and Xi
represents number of bags produced for each of the products (i = 1,2,3,4)
Z = C1X1 + C2X2 + C3X3 + C4X4
s.t.
a11x1+a12x2 +a13x3+a14x4 ≤b1
a12x1+a22x2 +a23x3+a24x4 ≤b2
a13x1+a22x2 +a33x3+a34x4 ≤ b3
aj1x1+aj2x2 +aj3x3+aj4x4 ≤ bj
Non Negativity = X1, X2, X3, X4, X5 ≥0

The model can be written in this Canonical form

4
Z c x
j 1
j j

s.t.
15
∑ aijxj ≤ bi
j = 1,2…,4

j = Layer Mash, Grower Mash, Broiler Starter Mash and Broiler Finisher Mash.
i = kg of materials to be used
bi = Resources available

3.2 Linear programming model of the company

Maximize Z= C1X1 + C2X2 + C3X3 + C4X4

Maximize Z= 207.25X1 + 97.75X2 + 128.75X3 + 153.5X4
s.t.
Input Used
13.5X1 + 11.2X2 + 15X3 + 13X4 ≤ 11,700 (Maize)
6X1 + 4.5X2 + 6.5X3 + 6X4 ≤ 2,600 (Soya Beans)
2X1 + X2 + 0.75X3 + 2X4 ≤ 1,820 (Lime Stone)
0.65X1 + X2 + 0.5X3 +0. 65X4 ≤ 1,820 (Bone)
2.75X1 + 4.5X2 + 2X3 + 2.5X4 ≤ 7,800 (Wheat Offal)
0X1 +0X2 + 0.5X3 + 0.1X4 ≤ 50 (Fish Offal)
0.025X1 + 0X2 + 0.025X3 + 0.025X4 ≤ 25 (Lysine)
0.025X1 + 0X2 + 0.025X3 + 0.025X4 ≤ 25 (Methionine)
 Application of linear programming techniques in production planning 17

0.1X1 + 0.05X2 + 0.075X3 + 0.1X4 ≤ 100 (Salt)

0.075X1 + 0X2 + 0X3 + 0X4 ≤ 39 (Layer Premix)
0X1 + 0X2 + 0.1X3 + 0.075X4 ≤ 26 (Broiler Premix)
0X1 + 0.063X2 + 0X3 + 0X4 ≤ 26 (Grower Premix)
0X1 + 3X2 + 0X3 + X4 ≤ 3,900 (P.K.C.)
X1, X2, X3, X4 ≥ 0
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(Non Negativity)

3.3 Techniques for Model Solution

The model was solved using The Management Scientist Version 5.0.

4. Result and discussion

The production planning problem of the feed producing company formulated into a linear
programming model in this study covers a period of a month. The company produces a mix of
40 bags of layer mash, 100 bags of grower mash, 25 bags of broiler starter mash and 70 bags
of broiler finisher mash with profit potential of N32,028.75 in a month.
The materials used for production of a bag of Layer Mash, Grower Mash, Broiler Starter and
Broiler Finisher is presented in the table 1 below

Table 1 Materials used in the production

PRODUCTS
Materials Layer Mash Grower Mash Broiler starter Broiler Finisher Available
(kg) (kg) Mash (kg) Mash (kg) Quantity per
month
Maize 13.5 11.2 15 13 11,700
Soya Beans 6 4.5 6.5 6 2,600
Lime Stone 2 1 0.75 2 1,820
Bone 0.65 1 0.5 0.65 1,820
Wheat Offal 2.75 4.5 2 2.5 7,800
Fish Offal ** ** 0.5 0.1 50
Lysine 0.025 ** 0.025 0.025 25
Methionine 0.025 ** 0.025 0.025 25
Salt 0.1 0.05 0.075 0.1 100
Layer Premix 0.075 ** ** ** 39
Broiler Premix ** ** 0.1 0.075 26
Grower Premix ** 0.063 ** ** 26
P.K.C ** 3 0 1 3,900
Source: Company’s Record, 2019 **= Not use in feed

Table 2 shows the cost of producing, selling and expected profit from a bag of Layer Mash,
Grower Mash, Broiler Starter Mash and Broiler Finisher Mash.
 18 O. Solaja , J. Abiodun, M. Abioro, J. Ekpudu and O. Olasubulumi/ IJAOR Vol. 9, No. 3, 11-19, Summer 2019 (Serial #33)

Table 2 Average Cost of producing a kg of each product

Product Parameter Estimated Cost of Estimated Selling Estimated

Production a bag Price of a bag (N) Profit on a
(N) bag
(N)
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Layer Mash C1 2,792.75 3,000 207.25

Grower Mash C2 2,502.25 2,600 97.75
Broiler Starter Mash C3 3,271.25 3,400 128.75
Broiler Finisher Mash C4 2,846.5 3,000 153.5
Total profit 587.25
Source: Computed from the Company’s record, 2019

4.1 Optimal solution

The table below shows the optimal result obtained from the software employed to solve the
model.

Table 3 Optimal solution

Variable Product Value

X1 Layer Mash 433.33
X2 Grower Mash 0
X3 Broiler Starter Mash 0
X4 Broiler Finisher Mash 0
Objective Function Value 89,808.33
Source: Researchers, 2019

Table 4 shows the optimal solution obtained from The Management Scientist Version 5. It
suggests that the company in pursuit of profit objective, required to concentrate on the
production of Layer Mash alone and other products are to be dropped by this solution. The
company should produce 433.33 bags of Layer Mash which is approximately 433 bags, and
drop other products which will enhance the profit potential of the company above the current
operating profits. This will lead the company to profit maximization of N89, 808.33 against
the current profit of N32, 028.75. This implies that if the company follows the solution from
this study, there will be increase of N57, 779.58 in their monthly profit.
With the available resources, the company can improve their profit by producing 433
bags of Layer Mash and drop the production of other three products in order to attain
maximum profit of N89,808 which is 80% increment.

5 Conclusions

The result of this study shows that application of heuristic approach in production planning
can does not guarantee optimal solution, but facilitate wastage of resources in the production
floor. Also, application of linear programming techniques is a powerful techniques production
manager ought to adopt in production planning, this will increase improve the company’s
performance by enhancing total profit. The study further reveals that it is not enough for
 Application of linear programming techniques in production planning 19

production companies to be after profit maximization alone, but resources optimization; this
will be beneficial to the company rather than maximizing profit alone. The study concludes
that linear programming can be used in solving any production planning problem. The study
recommends that decision makers should not base their decision on experience and intuition,
but on the analytical and scientific approach. Likewise, managers should learn to implement
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linear programming techniques in production planning.

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