Knowledge / Mechanical Engineering / Operations research basics

Operations research basics

Mechanical Engineering (B.E./B.Tech) · Industrial engineering · free study notes for exams, placements and interviews

In short

Operations research (OR) is the use of mathematical models to choose the best decision from many feasible ones under limited resources - how much of each product to make, which machine does which job, how many counters to open, which route to send a truck on. Its core tools are linear programming (graphical and simplex), transportation and assignment models, queuing theory, game and decision theory, and simulation. In Indian universities it is the mathematical half of the Industrial Engineering course and carries 5-8 marks in GATE (ME and PI) every year; it is also the standard aptitude-plus-technical ground for analytics and supply-chain interviews (TCS, Mu Sigma, Delhivery, Flipkart, Reliance, IOCL, Tata Steel, Maruti) and for production-planning roles on the shop floor. The same models run inside real systems - refinery blending at IOCL, freight routing on Indian Railways, crew rostering at airlines, warehouse slotting in e-commerce.

Explained

What OR is, and how a study is run

Linear programming - formulation and the graphical method

Simplex method, duality and sensitivity

Transportation and assignment models

Queuing theory (waiting lines)

Game theory, decision theory and simulation

Key points

Formulas and examples

LP standard form: Max Z = Σ cⱼxⱼ subject to Σ aᵢⱼxⱼ ≤ bᵢ (i = 1…m), xⱼ ≥ 0. cⱼ = profit per unit (₹/unit), aᵢⱼ = resource i used per unit of j, bᵢ = resource available (hours, kg, units).
Primal-dual pair: Primal Max Z = cᵀx, Ax ≤ b, x ≥ 0 ⇔ Dual Min W = bᵀy, Aᵀy ≥ c, y ≥ 0. At optimum Z\* = W\*; yᵢ is the shadow price of resource i (₹ per unit of bᵢ).
Simplex ratio test: leaving variable = min{ bᵢ / aᵢk : aᵢk > 0 }, where k is the entering column.
Transportation: total cost = Σᵢ Σⱼ cᵢⱼ xᵢⱼ; MODI: uᵢ + vⱼ = cᵢⱼ for occupied cells, Δᵢⱼ = cᵢⱼ − (uᵢ + vⱼ) for empty cells; shift θ = min allocation on the negative corners of the loop.
M/M/1 (infinite queue): ρ = λ/μ; P₀ = 1 − ρ; Pₙ = ρⁿ(1 − ρ); P(n ≥ k) = ρᵏ; Ls = ρ/(1 − ρ); Lq = ρ²/(1 − ρ); Ws = 1/(μ − λ); Wq = λ/[μ(μ − λ)]; Ls = Lq + ρ; Ws = Wq + 1/μ. λ = arrivals/hour, μ = services/hour, L in units, W in hours.
Little's law: Ls = λWs and Lq = λWq (any stable queue).
2×2 mixed-strategy game: p₁ = (a₂₂ − a₂₁)/D, q₁ = (a₂₂ − a₁₂)/D, V = (a₁₁a₂₂ − a₁₂a₂₁)/D, where D = a₁₁ + a₂₂ − a₁₂ − a₂₁.
Decision under risk: EMV(act) = Σ pⱼ × payoffⱼ; EVPI = Σ pⱼ × (best payoff in state j) − best EMV (₹).

Example 1 - LP formulation and graphical solution. A workshop makes brackets (x) and clamps (y). Each bracket needs 2 machine-hours and 1 labour-hour; each clamp 1 machine-hour and 1 labour-hour. Available: 100 machine-hours, 80 labour-hours. Marketing can sell at most 40 brackets. Contribution ₹40/bracket, ₹30/clamp.

Example 2 - Simplex with shadow prices. Max Z = 5x₁ + 4x₂ subject to 6x₁ + 4x₂ ≤ 24, x₁ + 2x₂ ≤ 6, x₁, x₂ ≥ 0.

Initial  | x1   x2    s1    s2  | RHS   ratio
s1       |  6    4     1     0  |  24   24/6 = 4  <- leaves
s2       |  1    2     0     1  |   6   6/1  = 6
Z-row    | -5   -4     0     0  |   0   (x1 enters)

Iter 1   | x1   x2    s1    s2  | RHS   ratio
x1       |  1   2/3   1/6    0  |   4   4/(2/3) = 6
s2       |  0   4/3  -1/6    1  |   2   2/(4/3) = 1.5  <- leaves
Z-row    |  0  -2/3   5/6    0  |  20   (x2 enters)

Iter 2   | x1   x2    s1    s2  | RHS
x1       |  1    0    1/4  -1/2 |   3
x2       |  0    1   -1/8   3/4 | 1.5
Z-row    |  0    0    3/4   1/2 |  21   all >= 0 -> optimal

Example 3 - Transportation: LCM start, then MODI. Supplies P1 = 30, P2 = 40, P3 = 30; demands D1 = 20, D2 = 45, D3 = 35 (balanced, total 100). Costs (₹/unit):

D1D2D3Supply
P148630
P235740
P364530
Demand204535100

Example 4 - Assignment by the Hungarian method. Cost (₹ hundred) of doing job Jᵢ on machine Mⱼ:

M1M2M3M4
J110121911
J251078
J312141311
J4815119

Example 5 - M/M/1 queue and service-cost trade-off. Trucks reach a weighbridge at λ = 12/hour (Poisson); weighing takes an average 4 minutes, so μ = 15/hour (exponential).

TechniqueProblem it solvesMethodTypical exam output
Graphical LP2 variables, few constraintsCorner points / iso-profit lineOptimal mix and Z
SimplexMany variablesIterative tableau pivotingOptimal mix, shadow prices
TransportationSupply to demand at least costNWCR/LCM/VAM + MODIShipping plan and total cost
AssignmentOne-to-one allocationHungarian methodPairing and total cost
QueuingRandom arrivals and serviceM/M/1, M/M/c formulaeLq, Wq, number of servers
Game theoryTwo rational opponentsSaddle point / mixed strategyStrategy mix and value V

Where it is used

Interview questions

Common mistakes

Related topics

Production planning and control · Inventory control and MRP · PERT/CPM and project scheduling · Statistical quality control · Lean manufacturing and Six Sigma · Engineering economics and costing

Open in the Knowledge reader →Find jobs →