Optimal Analysis of Packaging Products of MAHEU Plant in Intafact Beverages Limited Using GPALS and MATLAB Optimization Software

Abstract

This work focused on the optimization of the two packaging products; Supershake and Chibuku made up of three and two parts respectively. Copolymer polypropylene and white or colored batch materials are the two raw materials needed to produce the two packaging products. The manufacturing plan was developed for the organization. The production inputs of 1.11, 6.67, 15.78, 2.47 and 7.70 units were generated as the objective function coefficients; 308 hours per month for day shift and 364 hours per month for night shift were established. Production time of 10 seconds, 20 seconds, 12 second, 10 seconds and 12 seconds per unit of the five parts were established. The manufacturing constraints in terms of machine capacities, material availability, time and labour were extensively used to develop an integer linear programming model to obtain the optimum quantities of each part that will yield the maximum profit. The developed model was analyzed with GPALS and MATLAB optimization solver to obtain results for the linear programming model which gave a monthly production net profit of N3,751,932. A decision support system was developed for the manufacturing planning to assist the management of Maheu plant in Intafact Beverages Limited in decision making. The model is now being used in the manufacturing plan of the company and also recommended for application in organizations with similar production inputs.

Keywords: Manufacturing plan, Production inputs, Manufacturing constraints,  Optimization, Profit and Decision making