Kaunia, Vol.XII, Num.1, April 2016, pp.

17~22
ISSN 1829-5266 (paper), ISSN 2301-8550 (online)
Available online at http://ejournal.uin-suka.ac.id/saintek/kaunia

Application of Cutting Stock Problem in Minimizing

The Waste of Al-Quran Cover

Noor Saif Muhammad Mussafi

Mathematics Department, Faculty of Science and Technology, UIN Sunan Kalijaga,
Jl. Marsda Adicucipto Yogyakarta 55281, Indonesia
Correspondance; Email: [email protected]

Abstract

Cutting stock problem is the problem of cutting standard-sized pieces of stock material, such as vinyl rolls (synthetic leather)
into pieces of specified sizes while minimizing material wasted. The study of cutting stock problem is expected to provide an
alternative solution to publishing industrial. This study examines the cutting stock problem based on illustrative example of
Quran Publisher using the integer programming. The problem is transformed into optimization model so that it can be solved
using solver menu in Microsoft Excel. The results provide decision that meets the consumer demand and has a minimum
waste of raw material that used for Al-Quran cover.

Keywords: Optimization Model, Integer Programming, Cutting Stock Problem.

Introduction minimizing total wastage of the raw material or

maximizing overall profit obtained by cutting smaller
Minimizing wastage is a key factor in improving pieces from the main sheet. Many researchers have
productivity of a manufacturing plant (Rodrigo et al: worked on the cutting stock problem and
2012). Wastage can occur in many ways and cutting developed different algorithms to solve the problem.
stock problem can be described under the raw Gilmore et al (1961) conducted some of the
material wastage. Therefore, Operations Research earliest research in this area and one-dimensional
plays a major role in minimizing raw material wastage cutting stock problem is solved using Linear
or to maximizing space utilization of the raw material. Programming Technique. In this study, unlimited
Many people including scientists have conducted numbers of raw materials with different lengths are
research to overcome above challenges. A cutting assumed available in stock, and a mathematical
stock problem basically describes in two ways, One- model has been developed to minimize the total
Dimensional (1D) and Two-Dimensional (2D) cutting cutting cost of the stock length of the feasible cutting
stock problems. patterns and Column Generation Algorithm has been
Furthermore, cutting stock problems were first
described in the early days of linear programming.
In Eiselt and Sandblom (2007:75), Gilmore and
Gomory (1961) were the first to formulate cutting
stock problems (or, equivalently, stock cutting or
trim loss problems). The problem in its simplest form
can be described as follows. Given materials that are
available in certain shapes and sizes, cut them in order
to generate certain desired shapes and sizes, so as to
minimize some objective such as cost and waste
(Figure 1). Depending on the type of material and
cutting under consideration. For instance, cutting
newsprint to different lengths is a one-dimensional
cutting problem, as the width of the paper remains the
same, while only its length varies. In other words,
Figure 1 Minimize the waste (unshaded area) in cutting stock
an optimum cutting stock problem can be defined as problem.
cutting a main sheet into smaller pieces while

© 2016 Kaunia
18 Noor Saif Muhammad Mussafi

developed to generate feasible cutting patterns. Also, maximized or minimized is called objective
Saad (2001) has modified Branch and Bound function.
Algorithm to find feasible cutting patterns for one- b. The values of the decision variables must satisfy a
dimensional cutting stock problem and mathematical
set of constraints. Each constraints must be a
model has been developed to minimize the total cut
loss. In the case study, Saad has selected four linear equation or linear inequality.
different types of steel coils to cut from the standard c. A sign restriction which associated with each
steel coil with the 130 cm length and width of the main variable. For any variable , the sign restriction
coil and widths of the required coils are equal. Branch specifies that must be either nonnegative
and Bound Algorithm has been explained using the ( ≥ 0) or unrestricted in sign (urs).
example.
Definition 2.4
Now consider a system of linear equations: =
Linear Programming and Integer Programming Where ∈ , ∈ , ≥ and = . Note that
the number of unknowns, n, is no larger than the
Since the time it was first proposed by George B.
number of equations, m. Our goal then is to find the
Dantzig in 1947 as a way for planners to set general
vector minimizing ‖ − ‖ .
objectives and arrive at a detailed schedule to meet
these goals, linear programming has come into wide
Theorem 2.5
use. It has many nonlinear and integer extensions
Let ∈ , ≥ . Then, = if and only if
collectively known as the mathematical programming
= .
field, such as integer programming, nonlinear
Proof:
programming, stochastic programming, combinatorial
The proof provided by Chong and Zak (2001:187).
optimization, and network flow maximization. In
special case, linear programming (LP) plays a role "  ": Suppose that = . To show = ,
analogous to that of partial derivatives to a function in it is equivalent to show ( ) = {0}. To proceed, let
calculus, it is the first-order approximation. Formally, ∈ ( ); that is, = 0. Therefore,
linear programming is concerned with the
maximization or minimization of a linear objective ‖ ‖ = = 0,
function in many variables subject to linear equality
and inequality constraints (Dantzig: 1997). which implies that Ax  0 . Because = , we
George Dantzig developed an efficient method, the have = 0.
simplex algorithm, for solving linear programming "  ": Suppose that = ; that is ( )=
problems. Since the development of the simplex {0}. To show = , it is equivalent to show that
algorithm, LP has been used to solve optimization ( ) = {0}. To proceed, let ∈ ( ); that is = 0.
problems in industries as diverse as banking, Then, = 0, and hence = 0 □
education, industrial, forestry, petroleum, and
trucking. In a survey of Fortune 500 firms, 85% of the Hurlbert (2010:11) described the following matrix
respondents said they had used linear programming form linear programming which is called as
(Winston, 2004:56). Before formally defining a linear optimization model:
programming problem, let’s define the concepts of
linear function and linear inequality. Minimize (objective function)
Subject to ≥ (constraints)
Definition 2.1 ≥0 (sign restriction)
A function ( , , … , ) of , , … , is a linear
function if and only if for some set of constants where A is an mxn matrix composed of real entries,
, ,…, , ( , ,…, ) = + +…+ .
m  n, rank A  m , c is constant, and without loss
Definition 2.2 of generality the vectors x and b both are
For any linear function ( , , … , ) and any number nonnegatives. If component of b is negative, say the
b, the inequalities ( , ,…, ) ≤ and ith component, multiply the ith constraint by -1 to obtain
( , , … , ) ≥ are linear inequalities. a positive right-hand side (Bertsimas and Tsitsiklis:
1997).
Definition 2.3 Formally Kolman and Beck (1995:51) and Taha
A linear programming problem (LP) is an optimization (2007) also specified the canonical form of linear
problem that deal with: programming as follows.

a. Maximizing or minimizing a linear function of Minimize = + + ⋯+

decision variables. The function that is to be (objective function)

Kaunia XII (2016) 17~22 ISSN 1829-5266 (paper), ISSN 2301-8550 (online)
 Application of Cutting Stock Problem 19

Subject to + + ⋯+ ≥
+ +⋯+ ≥
…………….
+ + ⋯+ ≥
(constraints)

≥ 0, = 1,2, … ,
(sign restriction)

On the other hand, one key limitation that prevents

many more applications is the assumption of
divisibility, which requires that noninteger values be
permissible for decision variables. In many practical
problems, the decision variables actually make sense
only if they have integer values. For example, it is often Figure 2 Problem arrangement.
necessary to assign people, machines, and vehicles to
activities in integer quantities. The mathematical
model for integer programming is the linear
programming model with the one additional restriction
that the variables must have integer values (Hillier and
Lieberman, 2001:576).

Excel Solver

Microsoft Excel has the capability to solve linear (and

often nonlinear) programming problems, which is
called excel solver. The key to solving an LP on a
spreadsheet is to set up a spreadsheet that tracks
everything of interest (costs or profits, resource usage,
etc.). Next, identify the cells of interest that can be
varied. These are called changing cells. After defining
the changing cells, identify the cell that contains
objective function as the target cell. Next, identify the
constraints and tell the Solver to solve the problem. At
this point, the optimal solution to our problem will be
placed in the spreadsheet. Winston (2004:203)
introduces the steps of Solver to find the optimal Figure 3 Dialog box of Solver.
solution:
Click on the Add button to add constraints. The
a. After the optimization model defined (decision screen in Figure 4 will appear. Move to the Cell
variables, objective function, constraints, and sign reference part of the Add Constraint dialog box and
restriction), arrange the matrices of such problem select the cells. Then move to the dropdown box
into spreadsheet (Figure 2). and select >=. Add any constraints depend on the
b. From the Tools menu, select Solver. The dialog box problem. Choose OK if there are no more
in Figure 3 will occur. constraints. In case of integer programming, add
c. Move the mouse to the Set target Cell portion of new constraint that provide the solution equals to
the dialog box and click (or type in the cell address) integer.
on target cell (total cost) and select Min. This tells
Solver to minimize total cost.
d. Move the mouse to the By Changing Cells portion
of the dialog box and click on the changing cells.
This tells Solver it can change the amount subject.

Figure 4 Dialog box for adding constraints.

ISSN 1829-5266 (paper), ISSN 2301-8550 (online) Kaunia XII (2016) 17~22
20 Noor Saif Muhammad Mussafi

e. Before solving the problem, we need to tell Solver Table 1 Size of Al-Quran and its demand.
that all changing cells must be nonnegative. We
must also tell Solver that we have a linear model. Number of Vinyl Fabric
Choose solving method of simplex LP then click

Demand
OK (Figure 4). After choosing OK from the Solver Size of
Options box, we then select Solve and it will yields Al-Quran Large Medium Small
the optimal solution (Figure 3). (2035 cm2) (1.250 cm2) (700 cm2)

21X29 cm 2 0 1 20
Methods and Illustrative Example
14X20 cm 1 3 1 15
Prior to finding raw material wastage of one- 10X14 cm 1 4 0 8
dimensional cutting stock problem, it needs the
7X10 cm 6 2 0 10
following steps:

(Step 1) Identify the elements of such problem: the

objective, variables, constraints, and sign Results
restriction.
(Step 2) Construct the optimization model using the The cutting stock problem has been discussed in
concept of integer programming, that is various application, mostly in terms of industrial
minimizing the objective function subject manufacture. This research will try to solve the above
to constraints. illustrative example.
(Step 3) Set up the matrix and vector of such model
into excel spreadsheet based on integer (Step 1) Identify the elements of such problem: the
programming spreadsheet. objective, variables, constraints, and sign restriction.
(Step 4) Using the toolbox excel solver consider the
cells correspond to the Set Objective, the Al-Jumu’ah must decide the combination of
Goal (minimize), By Changing Variables, purchasing vinyl fabric to yield a minimum waste. So
and the Constraints. the objective clearly to minimize the number of vinyl
(Step 5) Select Solving Method of Simplex LP and fabric that must be spent. Suppose , , and
then execute Solve to acquire optimal consecutively correspond to large vinyl, medium vinyl,
solution. and small vinyl. Hence the objective function of Al-
Jumu’ah is

An illustrative example Minimize = + + .

A private company that concern in the field of Al- This means that Al-Jumu’ah can minimize its total
Quran publishing namely Al-Jumu’ah sells four types waste by minimizing the number of vinyl fabric that are
of Al-Quran with various sizes in centimeters: cut.
Al-Jumu’ah faces the following four constrains:
a. Al-Quran Alfa (21 x 29) Constraint 1 At least 20 units of Al-Quran Alfa must be
b. Al-Quran Beta (14 x 20) made. Constraint 2 At least 15 units of Al-Quran Beta
c. Al-Quran Gamma (10 x 14) must be made. Constraint 3 At least 8 units of Al-
d. Al-Quran Kappa (7 x 10) Quran Gamma must be made. Constraint 4 At least 10
units of Al-Quran Kappa must be made. Because the
One day Al-Jumu’ah received consumer order of Al- total number of Al-Quran Alfa that are made is given
Quran Alfa, Al-Quran Beta, Al-Quran Gamma, and Al- by 2 +
Quran Kappa consecutively 20 units, 15 units, 8 units,
and 10 units. In order to meet consumer demand, i.e. constraint 1 becomes 2 + ≥ 20
needs of cover of Al-Quran, the company should buy Similarly, constraint 2 becomes +3 + ≥ 15
vinyl fabric materials that are known to have a variety also constraint 3 becomes +4 ≥8
of sizes, the large vinyl fabric (2,058 cm2), the medium and constraint 4 becomes 6 + 2 ≥ 10
vinyl fabric (1,625 cm2), and the small vinyl fabric (900
cm2). How to determine the proper purchase of vinyl Note that the for = 1,2,3, … ,6 should be required
fabric to minimize the remaining pieces so that satisfy to assume nonnegative integer values, that is ≥ 0.
consumer demand correspond to Table 1?

Kaunia XII (2016) 17~22 ISSN 1829-5266 (paper), ISSN 2301-8550 (online)
 Application of Cutting Stock Problem 21

(Step 2) Construct the optimization model using the

concept of integer programming, that is minimizing the
objective function subject to constraints.

By combining the above information, we could

construct the optimization model of integer
programming as follow:
Minimize = + +
Subject to 2 + ≥ 20
+ 3 + ≥ 15
+4 ≥8
6 + 2 ≥ 10
, , ≥0

(Step 3) Set up the matrix and vector of such model

into excel spreadsheet based on linear programming Figure 5 Al-Jumu’ah IP Problem.
spreadsheet.

Based on the above optimization model, we can (Step 4) Using the toolbox excel solver consider the
consider matrix A and vector b cells correspond to the Set Objective, the Goal
(minimize), By Changing Variables, and the
2 0 1 20 Constraints.
= 1 3 1 and = 15
1 4 0 8
Set cell B11 as Objective and choose the goal of
6 2 0 10
minimize. Moreover By Changing Variables is fullfiled
The integer programming spreadsheet as shown in by cells between B5 to D5 as a set of solution. Also,
Figure 2 could be applied for above matrix (cells B15 define the Four Constraints (E15>=G15, E16>=G16,
to D18) and vector (cells G15 to G18) so that it will E17>=G17, and E18>=G18) and one additional
appear Figure 5. Constraint (B5 to D5 equal to integer) to yields
nonnegative integer solution as shown in Figure 6.

Figure 6 Solver Parameter of Al-Jumu’ah.

(Step 5) Select Solving Method of Simplex LP and Make sure that we select a Solving Method of Simplex
then execute Solve to acquire optimal solution. LP (Figure 6) and click solve to attain optimal solution
as displayed in Figure 7.

ISSN 1829-5266 (paper), ISSN 2301-8550 (online) Kaunia XII (2016) 17~22
22 Noor Saif Muhammad Mussafi

minimum waste yield two benefits at once, that

increase Al Jumuah’s profits and support eco-friendly
programs.

References

D. Bertsimas and J.N. Tsitsiklis. (1997). Introduction to

Linear Optimization. 1st edition. Athena Scientific
Belmont Massachusetts.
George Dantzig. (1997). Linear Programming 1: Introduction.
2nd edition, Springer Verlag–New York.
Glenn H. Hurlbert. (2010). Linear Optimization: The Simplex
Workbook. Springer Science + Business Media. New
York.
H. A. Eiselt and C.-L. Sandblom. (2007). Linear Programming
and its Applications. 1st edition. Springer Verlag.
Figure 7 Optimal Solution. Hamdy A. Taha. (2007). Operations Research: An
Introduction. 8th edition. Prentice Hall. Upper Saddle
River N.J.
Figure 7 suggests Al-Jumu’ah to purchase 10 units Hillier and Lieberman. (2001). Introduction to Operations
large vinyl fabric (cell B5) and 2 units medium vinyl Research. 7th edition, McGraw Hill Companies.
fabric (C5) to meet the customer demand of 20 units P. C. Gilmore and R. E. Gomory. (1961). A Linear
Al-Quran Alfa, 15 units Al-Quran Beta, 8 units Al- Programming Approach To The Cutting Stock
Quran Gamma, and 10 units Al-Quran Kappa. Problem. Operations Research. Vol. 9 No. 2: 849 -859.
P. C. Gilmore and R. E. Gomory. (1963). A Linear
Programming Approach To The Cutting Stock Problem
Conclusion –PartII. Operations Research. Vol. 11 No. 6: 863 – 888.
Saad M. A. Suliman. (2001). Pattern generating procedure
for the cutting stock problem. International Journal of
In this study, a cutting stock problem is formulated as Production Economics. Vol. 74: 293-301.
optimization model based on integer programming W. N. P Rodrigo, W.B. Daundasekera, and A.A.I Perera.
concept. Such problem also can be solved properly (2012). Pattern Generation for Two-Dimensional
using Excel Solver. As given in Figure 7, this methods Cutting Stock Problem. International Journal of
propose Al-Jumuah to purchase = 12 units vinyl Mathematics Trends and Technology (IJMTT). Vol. 3
fabric, by considering = large = 10 unit and = Issue 2: 54-62.
medium = 2 unit, in order to satisfy the costumer Wayne L. Winston. (2004). Operations Research,
Applications and Algorithms. 4th edition. Duxbury
demand and to minimize the piece of waste of Al-
Press Thomson Learning, Inc.
Quran cover. In this case study, the plant assumes
that all the extra pieces from each item as waste so
that it can be reduced as much as possible. The

Kaunia XII (2016) 17~22 ISSN 1829-5266 (paper), ISSN 2301-8550 (online)