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INDEX
S. Topic Page
No. No.
1 Executive Summary 3
2 Introduction 4
3 Background 5
4 Transportation Problem 6
5 Approach and Methodology 8
Phase I – Obtaining an initial feasible solution
6 Northwest-Corner Method 8
7 The Minimum Cell Cost method 9
8 Vogel’s Approximation Method (VAM) 10
Phase II – Moving towards optimality
9 MODI Method 11
10 Stepping-Stone Method 15
11 Analysis 17
12 Sensitivity Analysis 18
13 Conclusion 21
14 References 22
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EXECUTIVE SUMMARY
Today electronic products have become the main power of national economy
growth. All the manufacturers have set their primary markets to meet the
consumer’s demand. Taking the current LCD TV manufacturers as an example,
they have to emphasize on the product design, performance and the reduction of
cost. Therefore, nowadays the most important task for LCD TV industry is that
the international manufacturer shall fix a suitable win–win price and productive
capacity for itself as well as for the Original Equipment Manufacturing (OEM)
when the OEM has received the order, so that both sides could construct a long-
established relation and they could reach the object of maximized profit.
This paper, reports the results from a series of various methods regarding how
the transportation cost of SONY LCD TV (50”) could be optimized.
Manufacturers have managed to break through the constraints of cost and
complex cooperation relationship between partners, through strategic co-
ordination and integration.
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INTRODUCTION
In the fiscal year 2008, ending in March 2009, Sony incurred its largest
operational loss in its history of $2.4 billion. Sharp incurred a net loss of $1.3
billion in fiscal 2008, ending March 2008, citing stagnant consumption, fierce
competition. (Source has given in references pg.)
“The struggle for growth during the economic downturn forced, many
companies has stetted the target to reduce their prices in order to increase sales
and to maintain their market share on the basis of contract manufacturers for
cost-reduction opportunities.”
To succeed in this shifting environment, Sony needs to build strong links with
suppliers. It is important that Sony and its suppliers share policies, strategies
and technology. Collaboration between Sony and its suppliers should ultimately
be aimed at earning customer approval. This goal must form the common base
of Sony's procurement activities and its suppliers' sales activities. Sony calls
suppliers capable of maintaining this kind of collaborative relationship
"partners."
The overall structure of the SONY LCD TV supply chain is shown the
integration of the SONY LCD TV supply chain influences manufacturers’
capability to satisfy market requirements. The integration relationship involves
suppliers, manufacturer, and firms downstream. In the co-ordination between
manufacturer and suppliers, the manufacturer sets up production planning by
demand forecasting or firm order from certain customers, and then places orders
to all Consumer demand and customer requirements are pushing the industry
very hard in the areas of product quality, price and delivery lead times, with
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customers expecting manufacturers to provide the production flexibility to
respond to fluctuations in demand.
BACKGROUND
SONY LCD TV (50”) which has total cost at factories Rs. 40,000
Transportation Mode Truck (By Road) which includes the Cost Factors (Transportation Costs
Rs.220/km., Admin. Cost, Insurance Cost@2.9%, Loading Charges, Octrai, Taxes (toll taxes
+ excise duty + etc), and Warehouses charges, Unloading Charges etc.)
A liquid crystal display (LCD) is a thin, flat panel used for electronically displaying
information such as text, images, and moving pictures. It has no problem to transport if it's still
in the factory packaging. Most manufacturers go through a decent amount of work to make
sure their packaging can stand up to fairly stressful conditions. For large LCD's it is harder to
do so; however, it is usually at least packaged so that it can stand on any side. If there is no
'this side up' on the box, then it is safe to transport on its side. (They are careful to note if
damage will occur when transported on one side, because they would be liable for damage
otherwise.) Without factory packaging-- The screens are fairly delicate to puncture and
should not be transported face-down or at a weird orientation. Factory packaging equalizes
pressure on all sturdy surfaces to minimise the risk of damage, and without packaging
there is none of this protection. Some of the packer’s movers Kanpur, Noida, Ghaziabad
and Faridabad also offer warehousing and storage facilities to the customers. They have well
built, spacious and moisture free warehouse well guarded by the companies employed guards
and workers. Warehouse are friendly for the storing all kinds like household items, industrial
goods, commercial goods, office goods and many other lovable commodities of the
customers.
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9 Kanpur- Chennai (1885 km.) Nagpur Vijayawada
TRANSPORTATION PROBLEM
A destination may receive its demand from many sources.
So, “The objective is to determine the transporting plan, to meet all demands but not exceed
any supply, to minimize the total transportation cost.”
The standard transportation model seeks to find a transportation plan for SONY LCD TV
(50”) from Ghaziabad, Delhi and Kanpur warehouses to Dehradun, Mumbai and Chennai
stores.
The data in the model includes:
(1) The amount of supply at each source and the demand at each destination;
(2) The unit transportation cost of the SONY LCD TV (50”) from each source to each
destination.
Table (1)
Let,
Cij = per unit transporting cost from sources i to destination j (from Ghaziabad, Delhi and
Kanpur warehouses to Dehradun, Mumbai and Chennai stores)
No. of Variables is 9
No. of Constraints is 6 (Constraints are for warehouses capacity and stores demand)
To solve the transportation problem by its special purpose algorithm, it is required that the
sum of the supplies at the warehouses equal the sum of the demands at the stores.
The linear programming formulation in terms of the amounts shipped from the origins to the
destinations, Xij, can be written as:
Objective function:
Network Representation:
Figure (1)
Ghaziabad
Dehradun
(D1) 100 units
(S1) 150 units
Mumbai Delhi
Chennai Kanpur
In Phase I, the Minimum-Cost Procedure can be used to establish an initial basic feasible
solution without doing numerous iterations of the Simplex Method.
The North West corner method is easy to use and requires only simple calculation. As the
method’s name implies, we start work in the northwest corner or the upper left cell. Make an
allocation to this cell that will use either all the demand for that row or all the supply for that
column, whichever are smaller as cell (1, 1) 100 units (Rs. 2667). We see that, site1’s supply
is smaller than Dehradun’s demand. This eliminates column site 1 from further consideration
because we used all its demand and now repeat the above steps, we have the following
tableau and Stop since all allocated have been assigned.
Table (2)
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The initial basic feasible solution is:
The initial basic feasible solution obtained by this method usually gives a lower beginning
cost, so start with lowest cost (Rs.2667) entry 100 units in the cell (1, 1) and allocated as
much possible, i.e., X11= 100 units. The next lowest cost (Rs.2768) lies in the cell (2, 1), so
make no allocation, because the demand from Dehradun Store was already used in the cell (1,
1). The next lowest cost (Rs.3635) lies in the cell (3, 2), so allocated X32 =150 units.
Similarly for cell (2, 2) allocation is X22 = 50 units, X31 =50 units, X32= 150 units.
Table (3)
The cost is more by Rs.1, 16,400, as compared to the cost obtained by Northwest corner
method.
Step 1: for each column and row, determine its penalty cost by subtracting their two of their
least cost
Step 2: select row/column that has the highest penalty cost in step 1
Step 3: assign as much as allocation to the selected row/column that has the least cost
Step 5: Repeat above steps until all allocations have been assigned
Table (4)
It shows that the 1st and 3rd method has the min cost. So, this will be used to obtaining optimal
solution.
Phase II —
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In Phase II, the Stepping Stone Method, using the MODI method for evaluating the reduced
costs may be used to move from the initial feasible solution to the optimal one.
(2) It tells you which non-basic variable should be firstly considered as an entry variable
Modified distributed method (MODI) for Initial tableau of the Vogel’s approximation
method (VAM):
Table 4(a)
Vi V1 V2 V3
Let’s test to see whether the current tableau (4a) represent the optimal solution. We can do
this because of duality and sensitivity analysis to interpret. We can introduce two
quantities Ui,
and Vj, where Ui, is the dual variable associated with row i and Vj, is the dual variable
We can compute all Ui, and Vj, values from the initial tableau (4a) using eq (1):
Since, there are five equations and six unknowns (because we added a non basic variable). To
solve these equations, it is necessary to assign only one of the unknown a value of zero. We
can arbitrarily assign a value to one of the unknown. A common method is to choose the row
with the largest number of allocations i.e. (U1= 0).
Basic Variables: (U1= 0, U2= -21, U3= -254 and V1= 2667, V2=3781, V3=4521)
For every Non basic Variable (those cells without any allocations)
Non Basic Variables: (K13= 4, K21= 122, K31 = 1060, K32 = 108 > 0)
Eq (2) is true in every case of eq (a), eq (b), eq (c), eq (d), because these variables are
satisfied with non negativity condition (K13, K21, K31, K32> 0). So the current tableaus
(4a) represent the optimal solution and Rs.18, 84,800 is the lowest cost of
transportation.
Modified distributed method (MODI) for Initial tableau of the Minimum cell cost method:
Vi V1 V2 V3
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Ui Warehouse(i)/ Dehradun Mumbai Chennai Supply
Stores(j)
We can compute all Ui, and Vj, values from the initial tableau (3a) using eq (1):
(Where Ui, is the dual variable associated with row i and Vj, is the dual variable associated
with column and Cij represent the cost of the allocation cell)
Such that, there are five equations and six unknowns (because we added a non basic
variable). To solve these equations, it is necessary to assign only one of the unknown a value
of zero. (Let U1=0) because U1 has largest number of allocations.
Basic Variables
U1= 0, U2= -25, U3= -50 and V1= 2667, V2=3785, V3=4525
For every Non basic Variable (those cells without any allocations)
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For cell (1, 3) C13 – U1 – V3 = K12= -4………………………………………………...……. (e)
Eq (2) is true in the case of eq (f) and eq (g) i.e. (K21= 126 >0, K31= 885>0)
Eq is not true in the case of eq (e) and eq (h) i.e. (K12= -4 < 0, K33 = -208 < 0) this
condition does not satisfies with the non negativity conditions, so the current tableau (..)
does not represent the optimal solution.
Table 3(b)
For simplex (Minimization Problems), Chose the most negative reduced cost K33= -208
determined by cell (3, 3) as the new entering variable to reduce the cost by allocating this cell
(3, 3) and to increase the value as much as possible so place the (+) in this cell (3, 3). (The
stepping stone path for this cell (3, 3) is (2, 2), (2, 3), (3, 2), (3, 3) Table ()). For equilibrium
in everything place (-) in the cell (2, 3) and place (+) in cell (2, 2), this indicate the equality in
this row and then Place (-) in cell (3, 2). The allocations in cell (2, 3) and cell (3, 2)
(subtraction cells) are 150 and 150 respectively. Thus the new solution is obtained by
reallocating 150 on the stepping stone path. Thus for the next tableau:
Table 3(c)
Table 3(d)
Table 3(e)
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Vi V1 V2 V3
We can compute all Ui, and Vj, values from the initial tableau (3e) using eq (1):
(Where Ui, is the dual variable associated with row i and Vj, is the dual variable associated
with column and Cij represent the cost of the allocation cell)
Such that, there are five equations and six unknowns (because we added a non basic
variable). To solve these equations, it is necessary to assign only one of the unknown a value
of zero. (Let U1=0) because U1 has largest number of allocations.
Basic Variables:
U1= 0, U2= -851, U3= -146 and V1= 3619, V2=3781, V3=5351
For every Non basic Variable (those cells without any allocations)
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Cij – Ui – Vj = Kij ………………………..eq (2) empty cell (represent non-basic variable)
Analysis:
Basic Variables
U1= 0, U2= -851, U3= -146 and V1= 3619, V2=3781, V3=5351
Non Basic Variables
Kij = 0 the solution is optimal and unique and this satisfied the non negativity condition
for the transportation problem.
SENSITIVITY ANALYSIS
Sensitivity Analysis investigates the change in the optimum solution resulting from making
changes in parameters of the linear programming of transportation problem, So the changes
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in coefficients of (Cij) Cost Factors (Transportation Cost @ Rs. 180.00 per km, Insurance @
2.7%, Tax- Toll Tax, Excise Duty @ 3%Warehouse Charges, And Unloading Charges) of the
Objective Function:
Table (1a)
NW Corner Method:
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Minimum Cell Cost Method:
And now, to obtaining optimal solution select the Minimum Cell Cost Method tableau
Modified distributed method (MODI) for Initial tableau of the Minimum cell cost method:
Basic Variables
U1= 0, U2= -31.80, U3= -242 and V1= 2970.80, V2=5347.40, V3=6629.20
Non Basic Variables
Kij > 0 the solution is optimal and unique and this satisfied the non negativity condition
for the transportation problem, therefore an optimal basic feasible solution will
maintain its optimality if the change in Cij.
CONCLUSION
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The LCD-TV market will continue to grow robustly during the downturn in
2009; the operational and financial challenges caused by the recession are
forcing many OEMs to reconsider their internal expansion plans and
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outsourcing strategies, as well as to initiate changes that are having an
immediate impact on the supply chain
REFERENCES
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• Ford, L.R., and D.R. Fulkerson, Flows in networks, Princeton Univ.
Press, 1962.
• http://www.rpi.edu/dept/math/math-
programming/cplex90/amplcplex90userguide.pdf
• Hamdy A Taha, 1997, Duality and Sensitivity Analysis, pg. no. 115-
162
• http://www.faqs.org/abstracts/Electronics-and-electrical-industries/Sony-
arms-security-sets-with-network-functions-digital-
recorders.html#ixzz0ZVBqpMTW
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