Scribd
Upload
186 views

Exercises On Process Layout & Product Layout

This document contains 6 problems related to process layout and product layout. Problem 1 describes a university advising office layout and calculates load costs between rooms. Problem 2 provides task times and precedence for a pencil sharpener assembly line. Problem 3 gives task information to balance an assembly line to produce 240 units per day.

Uploaded by

janhabi.s25
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
186 views

Exercises On Process Layout & Product Layout

This document contains 6 problems related to process layout and product layout. Problem 1 describes a university advising office layout and calculates load costs between rooms. Problem 2 provides task times and precedence for a pencil sharpener assembly line. Problem 3 gives task information to balance an assembly line to produce 240 units per day.

Uploaded by

janhabi.s25
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 4

Exercises on Process layout & Product layout

1. A university advising office has four rooms, each dedicated to specific problems:
petitions (Room A), schedule advising (Room B), grade complaints (Room C), and
student counseling (Room D). The office is 80 ft. long and 20 ft. wide. Each room is 20
ft. by 20 ft. The present location of rooms is A, B, C, D – i.e. a straight line. The load
summary shows the number of contacts that each adviser in a room has with other
advisers in the other rooms. Assume that all advisers are equal in this value.

Load summary: AB = 10, AC = 20, AD = 30, BC = 15, BD = 10, CD = 20.

Assume that the cost of moving one load between immediate adjacent departments is
estimated to be $1. Moving a load between non-adjacent departments with one
intermediate department costs $2. Further moving a load between non-adjacent
departments with two intermediate departments costs $3.

2. A large manufacturer of pencil sharpeners is planning to add a new line of sharpeners and
you have been asked to balance the process, given the following task times and precedence
relationships. Assume that cycle time is to be the minimum possible.

Task Length Immediate


(minutes) Follower
A 0.2 B

B 0.4 D

C 0.3 D

D 1.3 G

E 0.1 F

F 0.8 G

G 0.3 H

H 1.2 End

(i) Draw the precedence diagram


(ii) Assign tasks in order of greatest number of following tasks
(iii) Determine the percentage of idle time
(iv) Compute the rate of output that could be expected for this line assuming a 420-minute
working day.
3. As part of a major plant renovation project, the IE department has been asked to balance
a revised assembly operation to achieve an output of 240 units per 8 hour day. Task times
and precedence relationships are as follows:

Task Duration Precedes


(Minutes) Task
A 0.2 B
B 0.4 C
C 0.2 F
D 0.4 E
E 1.2 G
F 1.2 G
G 1.0 End
Do each of the following:

(i) Draw the precedence diagram.


(ii) Determine the minimum cycle time, maximum cycle time and the calculated time
(iii) Determine the minimum number of workstations needed.
(iv) Assign tasks to workstations on the basis of greatest number of following tasks. Use
longest processing time as a tie breaker. If ties still exist, assume indifference in
choice.
(v) Compute the percentage of idle time for the assignment in part (iv).

4. The manufacturing Engineers at Suny Manufacturing were working on a new remote


controlled toy Monster Truck. They hired a production consultant to help them determine
the best ype of production process to meet the forecasted demand for this new product.
The consultant recommended that they use an assembly line. He told the manufacturing
Engineers that the line must be able to produce 600 Monster Trucks per day to meet the
demand forecast. The workers in the plant work 8 hours per day. The task information for
the new Monster Truck is given below:

Task Task time (Secs) Task that must precede


A 28 -
B 13 -
C 35 B
D 11 A
E 20 C
F 6 D, E
G 23 F
H 25 F
I 37 G
J 11 G, H
K 27 I, J
Total 236
i. Draw the schematic diagram.
ii. What is the required cycle time to meet the forecasted demand of 600 trucks per day
based on 8-hour work day?
iii. What is the theoretical minimum number of workstations given the answer in part b?
iv. Use longest task time with alphabetical order as the tie breaker and balance the line in
the minimum number of stations to produce 600 trucks per day.
v. Use shortest task time with largest number of following tasks as the tie breaker and
balance the line in the minimum number of stations to produce 600 trucks per day.

5. A computer manufacturer needs to design an assembly stations in the factory where the
cabinet housing the hard disk, mother board and other accessories is to be made. The
factory currently works for one shift of 8 hours. The tasks, their durations and the
precedence relationships are shown in the following table.

Table 1: The tasks, their duration & precedence relationship

Task Predecessor element(s) Duration (Secs)


A - 70
B A 80
C A 40
D A 20
E A 40
F B, C 30
G C 50
H D,E,F,G, 50
i. If the cycle time is 80 secs, what will the daily production of cabinets be?

ii. If the desired production rate is 320 cabinets per day, what is the maximum permissible cycle
time?

iii. What is the maximum and minimum number of workstations required to maintain this daily
production rate?

iv. Design an assembly set-up with 5 workstations and 6 workstations. What are the key
inferences of this exercise?

6. An electrical appliance is to be assembled on a production flow line. The total job is


divided into 12 rational discrete elements which cannot be split further. The IE
department has time estimates for these elements as tabulated below. The demand is
forecasted to be 120,000 units per year at 50 weeks/year and 40 hours/week.

Elements Time in minutes Predecessor element(s)


A 0.2 -
B 0.4 -
C 0.7 A
D 0.1 A,B
E 0.3 B
F 0.11 C
G 0.32 C
H 0.6 C,D
I 0.27 F,G,H
J 0.38 E
K 0.5 I,J
L 0.12 K
i. What should be the cycle time set for the line?

ii. What would be the minimum number of workstations?

iii. Group the job elements into work centres to balance the line. Show it through a demarcation
in the precedence diagram.

iv. What is the line efficiency thus achieved? What is the balance delay of the line by virtue of
this balancing?

You might also like