T.C.

ISTANBUL AYDIN UNIVERSITY

FACULTY OF ENGINEERING
DEPARTMENT OF INDUSTRIAL ENGINEERING

MODELING IN INDUSTRIAL ENGINEERING

FIND OPTIMAL SOLUTION

Asst.Prof.Dr. NIMA MIRZEI

GROUP C
EYÜP MERT ASLAN - B1805.030042
DURMUŞ FURKAN BULUT – B1805.030030
ÇAĞHAN TUNA - B1805.030091
HİKMET UĞURCAN MÜFTÜOĞLU - B1905.030062

DECEMBER, 2021
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ACKNOWLEDGEMENTS
We would like to thank Asst.Prof.Dr.Nima Mirzaei for teaching us and helping us.

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TABLE OF CONTENTS
1. PROBLEM ………………………………………………………………………4
2. SOLUTION THE PROBLEM…………………………………………..……...5
2.1 Definition Variables…………………………...................................………5
2.2 Creating Linear Constraints……………………………….....……….5-6-7
3. LINGO SOLUTION………………………..……………………….....8-9-10

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PROBLEM:
Silicon Valley Corporation (Silvco) manufactures transistors. An important aspect of the
manufacture of transistors is the melting of the element germanium (a major component of a
transistor) in a furnace. Unfortunately, the melting process yields germanium of highly
variable quality. Two methods can be used to melt germanium; method 1 costs $50 per
transistor, and method 2 costs $70 per transistor. The qualities of germanium obtained by
methods 1 and 2 are shown in Table 80. Silvco can refire melted germanium in an attempt to
improve its quality. It costs $25 to refire the melted germanium for one transistor. The results
of the refiring process are shown in Table 81. Silvco has sufficient furnace capacity to melt or
refire germanium for at most 20,000 transistors per month. Silvco's monthly demands are for
1,000 grade 4 transistors, 2,000 grade 3 transistors, 3,000 grade 2 transistors, and 3,000 grade
1 transistors. Use linear programming to minimize the cost of producing the needed
transistors.

Grade of Melted Percent Yield by Percent Yield by

Germanium Melting Melting
Method 1 Method 2
Defective 30 20

1 30 20

2 20 25

3 15 20

4 5 15

Percent Yielded by Refiring

Refired Defective Grade 1 Grade 2 Grade 3
Grade of
Germanium

Defective 30 0 0 0
1 25 30 0 0
2 15 30 40 0
3 20 20 30 50
4 10 20 30 50

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STEP 1: Definition Variables

Let,
xm: Amount of germanium for method m
dm: Defective transistor from method m
d: Total defective transistor from both the methods combined
gjm: Grade j transistor from method m
gj: Total grade j transistor from method 1 and 2
gjR: Grade j transistor used for re-melting
gjP: Grade j transistor not undergoing re-melting
gj_R: Total grade j transistor obtained after re-melting

STEP 2: Creating Linear Constraints

Method 1 grade output constraints:

If x1 amount of germanium is used 30 % is defective, %30 grade 1 ,%20 grade 2 , %15 grade 3 and
%5 grade 4.
d1= 0.3X x1
g11= 0.3X x1
g21=0.2X x1
g31=0.15X x1
g41=0.05X x1
Similarly for method 2,
d2=0.2X x2
g12=0.2X x2
g22=0.25X x2
g32=0.20X x2
g42=0.15X x2

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STEP 3:

Total defective , grade 1,2,3 and 4 transistors obtained from both the methods.

d = d1 + d2
g1 = g11 + g12
g2 = g21 + g22
g3 = g31 + g32
g4 = g41 + g42

We also have the option of re-melting to increase the quality of transistor. Some amount of transistor
can undergo re-melting if necessary.

g1 = g1P + g1R
g2 = g2P + g2R
g3 = g3P + g3R
g4 = g4P + g4R

On re-melting the quality of transistors increase and we can get an upper grade transistor.

O.F.
The objective is to minimize the cost involved in producing the transistors. It
take 50$ to produce transistor from method 1 , 70$ to produce from method to
and 25$ for re-melting any transistor.
MINIMIZE = (50 * x1) + (70 * x2) + 25 *(g1R + g2R + g3R + g4R )

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STEP 4:

As per table 81, on re-melting certain kind of transistor we get an upper grade of transistor. Thus total
number of transistors of grade j at the end of re-melting will be the sum of grade j transistor, which did
not undergo re-melting and percent yield of each other grade transistor. Hence,

d_R= 0.3xd
g1_R= g1P+0.25xd+0.3xg1R
g2_R= g2P+0.15xd+0.3xg1R+0.4xg2R
g3_R= g3P+0.2xd+g1R+0.3xg2R+0.5xg3R
g4_R= g4P+0.1xd+0.2xg1R+0.3xg2R+0.5xg3R

We need to fulfill certain demand of transistors for each grade,

g4_R≥ 1000
g3_R≥ 2000
g2_R≥ 3000
g1_R≥ 3000

Total furnace capacity is 20000.

g1+g2+g3+g4+g1R+g2R+g3R+g4≤ 20000

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STEP 5: LINGO SOLUTION
MIN=50*x1+70*x2+25*(g1R+g2R+g3R+g4R);
d1=0.3*x1;
g11=0.3*x1;
g21=0.2*x1;
g31=0.15*x1;
g41=0.05*x1;
d2=0.2*x2;
g12=0.2*x2;
g22=0.25*x2;
g32=0.20*x2;
g42=0.15*x2;
d=d1+d2;
g1=g11+g12;
g2=g21+g22;
g3=g31+g32;
g4=g41+g42;
d_R=0.3*d;
g1=g1P+g1R;
g1_R=g1P+0.25*d+0.3*g1R;
g2=g2P+g2R;
g2_R=g2P+0.15*d+0.3*g1R+0.4*g2R;
g3=g3P+g3R;
g3_R=g3P+0.2*d+0.2*g1R+0.3*g2R+0.5*g3R;
g4=g4P+g4R;
g4_R=g4P+0.1*d+0.2*g1R+0.3*g2R+0.5*g3R;
g4_R>=1000;
g3_R>=2000;
g2_R>=3000;
g1_R>=3000;
g1+g2+g3+g4+g1R+g2R+g3R+g4R<=20000;
END

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STEP 6:

Global optimal solution found.

Objective value: 562500.0
Infeasibilities: 0.000000
Total solver iterations: 8
Elapsed runtime seconds: 0.12

Model Class: LP

Total variables: 30
Nonlinear variables: 0
Integer variables: 0

Total constraints: 30
Nonlinear constraints: 0

Total nonzeros: 88
Nonlinear nonzeros: 0
Nonlinear nonzeros: 0

Variable Value Reduced

Cost
X1 10563.38
0.000000
X2 0.000000
18.43750
G1R 1373.239
0.000000
G2R 0.000000
118.7500
G3R 0.000000
25.00000
G4R 0.000000
25.00000
D1 3169.014
0.000000
G11 3169.014
0.000000
G21 2112.676
0.000000
G31 1584.507
0.000000
G41 528.1690
0.000000
D2 0.000000
0.000000
G12 0.000000
0.000000
G22 0.000000
0.000000
G32 0.000000
0.000000
G42 0.000000
0.000000
D 3169.014
0.000000

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 G1 3169.014
0.000000
G2 2112.676
0.000000
G3 1584.507
0.000000
G4 528.1690
0.000000
D_R 950.7042
0.000000
G1P 1795.775
0.000000
G1_R 3000.000
0.000000
G2P 2112.676
0.000000
G2_R 3000.000
0.000000
G3P 1584.507
0.000000
G3_R 2492.958
0.000000
G4P 528.1690
0.000000
G4_R 1119.718
0.000000

STEP 7:

Row Slack or Surplus Dual

Price
1 562500.0
-1.000000
2 0.000000
31.25000
3 0.000000
31.25000
4 0.000000
156.2500
5 0.000000
0.000000
6 0.000000
0.000000
7 0.000000
31.25000
8 0.000000
31.25000
9 0.000000
156.2500
10 0.000000
0.000000
11 0.000000
0.000000

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 12 0.000000
31.25000
13 0.000000
31.25000
14 0.000000
156.2500
15 0.000000
0.000000
16 0.000000
0.000000
17 0.000000
0.000000
18 0.000000
-31.25000
19 0.000000
31.25000
20 0.000000
-156.2500
21 0.000000
156.2500
22 0.000000
0.000000
23 0.000000
0.000000
24 0.000000
0.000000
25 0.000000
0.000000
26 119.7183
0.000000
27 492.9577
0.000000
28 0.000000
-156.2500
29 0.000000
-31.25000
30 11232.39
0.000000

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