Applied Mathematics & Information Sciences

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In the era of globalization, integrated planning for production, workforce, and capacity is the key factor for attaining success in any industry. This paper provides a mathematical model to determine the best possible combination of required capacity, workforce, and lot size for a multi-product, multi-stage, and multi-model production system. The model provides a blueprint of a detailed workforce distribution plan to optimize the available capacity and determine the ideal lot size based on the ways (i.e. tray/trolley) of handling material to control the space required for setup and floor area. This model uses linear programming to reduce the manufacturing cost. A real-world numerical illustration proves the competency of this model, which - for an industry - serves as a practical guide to achieve the best combination of capacity, workforce, and lot size.

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