exam Planning
exam Planning
Faculty of Engineering
Department of Production Engineering and Mechanical Design
Final May 2013, 3rdYear at Production Engineering and Mechanical Design Department.
Please solve the next problems. Time: 3 hrs. Total marks: 110.
1-[40 marks]-Consider the problem data below to compare two aggregate production plans—level
aggregate plan and chase aggregate plan.
2-[30 marks]-Sales schedule of a manufacturer over past 20 months is given below. (a) Develop a forecast
for month 21 using the trend equation: 𝑦 = 𝑎(𝑏+𝑐⁄𝑥) . (b) What is the efficiency of this trend?
Month 1 2 3 45 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
120 175 200 251 236 294 287 293 313 324 314 352 354 331 354 337
Sales 23 156 330 482
9 6 0 2 6 2 2 7 6 1 9 4 2 2 7 6
3-[20 marks]-The time to failure of a pump is a uniformly distributed random variable within the time
interval [0, 5,000] operating hrs. This pump costs $2,000 for purchase, $200 for installation and $800 due
to the consequences of each failure. Find the minimum maintenance cost based on the constant interval
replacement model.
4-[20 marks]-Computronics is a manufacturer of calculators, currently producing 300 units per week. One
component for every calculator is an LCD, which the company purchases from a supplier for $1 per LCD.
The placement of each order is estimated to require 1 hour of clerical time, with a direct cost of $15 per
hour plus overhead costs of another $5 per hour. A rough estimate has been made that the annual cost of
capital tied up in Computronics’ inventory is 15 percent of the value of the inventory. Other costs
associated with storing and protecting the LCDs in inventory amount to $0.05 per LCD per year. What
should be the optimal ordering policy and how much it does cost?
Final May 2014, 3rdYear at Production Engineering and Mechanical Design Department.
Please solve the next problems. (Time: 3 hrs. Total marks: 110.) Graphics are necessary.
1-A corporation recently has been enjoying an increase in sales of a stylish product over a year as shown
in the next table. The corporation studies have reported that the sales will decrease next year following
the inversed trend of the given year. Forecast the sales for Jan and Feb of the next year.
Month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Sales (in $ millions) 3.0 4.0 4.5 5.5 7.0 8.0 9.0 10.5 12.5 15.0 18.0 23.0
2-Use the systematic process layout planning to design a layout using next flow data in daily trips.
Assume that all departments have equal size of 8 × 10 units, and the total available area is 20 × 50 units.
Department A B C D E F G H I
A − 10 12 0 100 0 0 0 10
B 34 − 59 0 110 12 0 0 20
C 0 10 − 25 90 0 15 40 30
D 0 23 12 − 120 0 0(X) 60 30
E 9 14 0 0 − 32 90 100 50
F 0 27 14 0 80 − 70 5 50
G 5 4 33 100(X) 120 100 − 40 50
H 15 0 0 30 100 15 80 − 60
I 25 5 10 15 100 0 0 0 −
3-Based on the precedence diagram below (time in seconds), design an assembly line, with minimum
number of works stations, to produce 60 units per hour.
30
09
9
15 30 16 26 24 14 12 19
01 03 06 10 13 16 18 19
1 3 6 0 3 6 9
20 18 15 15 20 25
00 02 04 07 11 20
0 2 4 7 1 0
25 24 18 16
05 08 12 14
5 8 2 4
14 20
15 17
5
4-A firm produces air filters for domestic and foreign cars. A filter type is supplied at 2,000 units
monthly. The firm can produce this filter at a rate of 50 filters per hour. Setup time of the equipment is
estimated at 1.5 hours. Working time is charged at the rate of $60 per hour. Idle time is also estimated to
cost $100 per hour in lost profit. The carrying cost rate is 18% based on the average inventory level. Each
filter costs the firm $2.5 for material. Assume 6-hour days, 20 working days per month, and 12 months
per year for your calculations. What is the optimal inventory policy and how much it does cost?
My best wishes…Prof. Dr. Hassan Soltan
Mansoura University
Faculty of Engineering
Department of Production and Mechanical Design Engineering
Planning of Factories and Production Processes
PRE5323—June 4 2015
Final May 2015, 3rdYear at Production and Mechanical Design Engineering Department.
Please solve the next problems. (Time: 3 hrs. Total marks: 110.) Graphics are necessary.
1-[30 marks]-A Wagon is to be assembled on a conveyor belt. Five hundred wagons are required per day.
Production time per day is 420 minutes, and the tasks and times (seconds) for the wagon are given in
Table 1. Design a balanced assembly line.
Table 1
Task Time Description Predecessors
A 45 Position rear axle support and hand fasten four screws to nuts. —
B 11 Insert rear axle. A
C 9 Tighten rear axle support screws to nuts. B
D 50 Position front axle assembly and hand fasten with four screws to nuts. —
E 15 Tighten front axle assembly screws. D
F 12 Position rear wheel #1 and fasten hubcap. C
G 12 Position rear wheel #2 and fasten hubcap. C
H 12 Position front wheel #1 and fasten hubcap. E
I 12 Position front wheel #2 and fasten hubcap. E
J 8 Position wagon handle shaft on front axle assembly and hand fasten bolt and nut. F, G, H, I
K 9 Tighten bolt and nut. J
2-[30 marks]-The flow of materials through eight departments is shown in Table 2. Assume that the
direction of flow is not important and the cost of moving material depends only on the distance moved.
Table 2
Dept 1 2 3 4 5 6 7 8
1 — 20
2 15 — 25 4
3 5 — 40 5
4 5 — 10
5 1 20 — 30
6 — 20
7 3 — 10
8 5 —
a) Construct a schematic layout where the departments are arranged on a 2 × 4 grid with each cell
representing a 10 × 10-meter square area.
b) Evaluate your layout using a distance-times-flow measure. Assume that distance is measured
rectilinearly (in this case departments that are directly adjacent are 10 meters apart and those that
are diagonal to one another are 20 meters apart).
3-[35 marks]-Consider the problem data in Table 3 to construct level based workforce aggregate plan.
Table 3
Capacity Data Cost Data Demand (units)
Beginning workforce (employees) 15 Regular-time cost/hour $15.0 November 3000
Beginning inventory (units) 2500 Overtime cost/hour $22.0 December 6000
Production standard/unit (hours) 0.64 Hiring cost/employee $500.0 January 2000
Regular-time available/period (hours) 160 Firing cost/employee $750.0 February 8500
Overtime available/period (hours) 20 Holding cost/unit/period $5.0 March 4000
End inventory 500 Shortage cost/unit/period $7.5 April 5500
End workforce 15 Material cost/unit $30.0 May 1500
4-[15 marks]-A firm produces air filters for domestic and foreign cars. A filter type is supplied at 2,000
units monthly. The firm can produce this filter at a rate of 50 filters per hour. Setup time of the equipment
is estimated at 2 hours. Working time is charged at the rate of $50 per hour. Idle time is also estimated to
cost $100 per hour in lost profit. The carrying cost rate is 20% based on the average inventory level. Each
filter costs the firm $2.8 for material. Assume 6-hour days, 20 working days per month, and 12 months
per year for your calculations. What is the optimal inventory policy and how much it does cost?
Final May 2016, 3rdYear at Production Engineering and Mechanical Design Department.
Please solve the next problems. (Time: 3 hrs. Total marks: 110.) Graphics are necessary for all problems.
1-[20 marks]-A corporation recently has been enjoying an increase in sales of a stylish product over a
year as shown in the next table. The corporation studies have reported that the sales will decrease next
year following the inversed trend of the given year. Forecast the sales for April of the next year.
Month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Sales (in $ millions) 3.0 4.0 4.5 5.5 7.0 8.0 9.0 10.5 12.5 15.0 18.0 23.0
2-[30 marks]-Use the systematic layout planning to construct a process layout with next flow data in daily
trips. Assume that all departments have equal size of 8×10 units with total available area is 20×50 units.
Department A B C D E F G H I
A − 10 12 0 100 0 0 0 10
B 34 − 59 0 110 12 0 0 20
C 0 10 − 25 90 0 15 40 30
D 0 23 12 − 120 0 0(X) 60 30
E 9 14 0 0 − 32 90 100 50
F 0 27 14 0 80 − 70 5 50
G 5 4 33 100(X) 120 100 − 40 50
H 15 0 0 30 100 15 80 − 60
I 25 5 10 15 100 0 0 0 −
3-[35 marks]-Based on the precedence diagram below (time in seconds), design an assembly line, with
minimum number of works stations, to produce 60 units per hour.
30
09
9
15 30 16 26 24 14 12 19
01 03 06 10 13 16 18 19
1 3 6 0 3 6 9
20 18 15 15 20 25
00 02 04 07 11 20
0 2 4 7 1 0
25 24 18 16
05 08 12 14
5 8 2 4
14 20
15 17
5
4-[25 marks]-A firm produces air filters for domestic and foreign cars. A filter type is supplied at 2,000
units monthly. The firm can produce this filter at a rate of 50 filters per hour. Setup time of the equipment
is estimated at 1.5 hours. Working time is charged at the rate of $60 per hour. Idle time is also estimated
to cost $100 per hour in lost profit. The carrying cost rate is 18% based on the average inventory level.
Each filter costs the firm $2.5 for material. Assume 6-hour days, 20 working days per month, and 12
months per year for your calculations. What is the optimal inventory policy and how much it does cost?
My best wishes…Prof. Dr. Hassan Soltan
Mansoura University
Faculty of Engineering
Department of Production Engineering and Mechanical Design
Planning of Factories and Production Processes
PRE5323—June 7 2017—(9 AM)
Final May 2017, 3rdYear at Production Engineering and Mechanical Design Department.
Please solve the next problems. (Time: 3 hrs. Total marks: 110.) Graphics are necessary for all problems.
1-[25 marks]-A producer of an engine, needs to develop an aggregate plan for the coming year. The
company currently uses 20 workers working 160 regular-time hours each month. Each worker is capable
of producing 10 units per month. Workers are paid $20 per hour. Overtime is limited to a maximum of 40
hours per month per worker. Holding costs are $8 per unit per month. Back-order cost is $15 per unit per
month. The beginning inventory is 50 units. Monthly demand forecast, in units, is projected as in the
table. Construct a hybrid aggregate plan and find its cost. Is a level aggregate plan available?
Month Jan. Feb. March April May June July Aug. Sept. Oct. Nov. Dec.
Demand 250 230 190 170 200 220 220 220 260 260 240 220
2-[20 marks]-A product is manufactured in a shop using a five-stage process: shearing, pressing, welding
painting, and packing. The time taken for each of these operations is 20, 23, 15, 12 and 6 minutes
respectively. Presently, each stage has only one machine for operation. The shop works on an 8-hour shift
with an effective available time of 460 minutes. Complete a capacity plan for this process with respect to
(a) Scenario A: Setting the process to the nearest higher level of production capacity.
(b) Scenario B: Setting the process to produce 50 units per day.
3-[20 marks]-A Wagon is to be assembled on a conveyor belt. Five hundred wagons are required per day.
Production time per day is 450 minutes, and the tasks and times (seconds) for the wagon are given in the
table. Design and measure the performance of a balanced assembly line.
Task Time Description Predecessors
A 45 Position rear axle support and hand fasten four screws to nuts. −
B 11 Insert rear axle. A
C 10 Tighten rear axle support screws to nuts. B
D 50 Position front axle assembly and hand fasten with four screws to nuts. −
E 15 Tighten front axle assembly screws. D
F 12 Position rear wheel #1 and fasten hubcap. C
G 12 Position rear wheel #2 and fasten hubcap. C
H 12 Position front wheel #1 and fasten hubcap. E
I 12 Position front wheel #2 and fasten hubcap. E
J 8 Position wagon handle shaft on front axle assembly and hand fasten bolt and nut. F, G, H, I
K 8 Tighten bolt and nut. J
4-[25 marks]-
(a) Write a short essay about inventory control models.
(b) MKD company uses approximately 24,000 glass jars each month. MKD orders 5,000 jars at a
time. Monthly holding cost is $0.08 per jar, and the ordering cost is $60 per order.
i) What penalty cost is MKD incurring by its present replenishment policy?
ii) How much would ordering cost need to be reduced to justify a lot size of 3,000 jars?
5-[20 marks]-
(a) Summarize the layout types and their characteristics.
(b) Describe the steps of systematic process layout planning using a hypothetical example.
My best wishes…Prof. Dr. Hassan Soltan
Mansoura University
Faculty of Engineering
Department of Production Engineering and Mechanical Design
Planning of Factories and Production Processes
PRE5323—May 30 2018—(9 AM)
Final May 2018, 3rd Year at Production Engineering and Mechanical Design Department.
Please solve the next problems. (Time: 3 hrs. Total marks: 110.) Graphics are necessary for all problems.
1-[20 Marks]-
(a) Construct a hierarchy for general plant location factors.
(b) Sketch the potential facility layouts and compare between them in a tabular form.
(c) Summarize the external and internal change drivers for production enterprises.
(d) Discuss the major types/levels of planning.
2-[25 Marks]-The quarterly sales of a product for last three years are given below. Estimate the quarterly
sales for the next year.
Year 1 2 3
Quarter 1 2 3 4 1 2 3 4 1 2 3 4
Sales (103 units) 15 30 37 24 21 30 45 29 32 45 50 39
3-[25 Marks]-A producer of an orange juice needs to develop an aggregate plan for the coming year. The
company currently uses 200 workers. Each worker is capable of producing 2,000 gallons of juice per
month on regular time. Workers are paid $1,500 per worker per month on regular time. It costs $500 to
hire a worker, and $200 to fire a worker. Holding costs are $0.02 per gallon per month and back-orders
are not allowed. The beginning inventory is 300,000 gallons and the desired ending inventory is 350,000
gallons of juice. Monthly demand forecast, in 1000 gallons, is projected as in the table. Construct a level
work force aggregate plan and find its cost.
Month 1 2 3 4 5 6 7 8 9 10 11 12
Demand (103 Gallons) 200 250 300 400 450 500 500 400 350 300 250 200
4-[20 Marks]-The Dorton University president has asked the OM department to assign eight biology
professors (A, B, C, D, E, F, G, and H) to eight offices (numbered 1 to 8 in the diagram) in the new
biology building. The following distances and two-way flows are given:
Distances between offices (Feet) Two-way flows (Units per period) The New Biology Building
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 North Wing
1 − 10 20 30 15 18 25 34 1 − 2 0 0 5 0 0 0
1 2 3 4
2 − 10 20 18 15 18 25 2 − 0 0 0 3 0 2
3 − 10 25 18 15 18 3 − 0 0 0 0 3
4 − 34 25 18 15 4 − 4 0 0 0 Courtyard
5 − 10 20 30 5 − 1 0 0
6 − 10 20 6 − 1 0
5 6 7 8
7 − 10 7 − 4
8 − 8 − South Wing
The biology department has sent the following information and requests to the OM department,
Find the optimal assignment of professors to offices that meets all the requests of the biology department
and minimizes total material handling cost.
5-[20 Marks]-A company has collected the following data for a product,
What should be the ordering policy of the purchase manager? Show your answer graphically.
Final May 2019, 3rd Year at Production Engineering and Mechanical Design Department.
Please solve the next problems. (Time: 3 hrs. Total marks: 110.) Graphics are necessary for all problems.
1-[35 marks]-Based on the precedence diagram given below (task time in secs), design an assembly line,
with minimum number of works stations, to produce 60 units per hour.
30
09
9
15 30 16 26 24 14 12 19
01 03 06 10 13 16 18 19
1 3 6 0 3 6 9
20 18 15 15 20 25
00 02 04 07 11 20
0 2 4 7 1 0
25 24 18 16
05 08 12 14
5 8 2 4
14 20
15 17
5
2-[35 marks]-An initial process layout and interdepartmental flow matrix of a toy factory are given
below. All departments are set at equal squared areas and interdepartmental movements are only allowed
rectilinear. Suppose that transportation costs are $1 per a load per 20ˊ. Improve the given layout following
basically the systematic layout planning procedure.
Department 1 2 3 4 5 6 7 8
Shipping and receiving 1 — 175 50 0 30 200 20 25
1 3 5 7
Plastic molding & stamping 2 — 0 100 75 90 80 90
Metal forming 3 — 17 88 125 99 180 80ˊ
Sewing 4 — 20 5 0 25
Small toy assembly 5 — 0 180 187 2 4 6 8
Large toy assembly 6 — 374 103
Painting 7 — 7
160ˊ
Mechanism assembly 8 —
3-[20 marks]-A manufacturer produces many types of paint. Changeover from one type of paint to
another costs $80 per batch. The annual sales of a particular grade of paint are 30,000 liters and the
inventory carrying cost is $0.1 per liter. This grade can be produced in 3 times its sales rate. Another
policy can be subcontracting this grade from a similar manufacturer. Assuming the same cost parameters,
which policy is better?
4-[20 marks]-Develop a forecast for year 11 of the sales schedule described in the next table.
Year 1 2 3 4 5 6 7 8 9 10
Sales 400 390 320 340 270 260 300 320 340 370
My best wishes
Professor Dr. Hassan Soltan
Department of Production Engineering and Mechanical Design
Mansoura University
Faculty of Engineering
Department of Production Engineering and Mechanical Design
Final June 2021, 3rd Year at Production Engineering and Mechanical Design Department.
Please solve the next problems. (Time: 3 hrs. Total marks: 110.) Graphics are necessary for all problems.
1-[35 marks]-Based on the precedence diagram given below (task time in secs), design an assembly line,
with minimum number of works stations, to produce 60 units per hour.
30
09
9
15 30 16 26 24 14 12 19
01 03 06 10 13 16 18 19
1 3 6 0 3 6 9
20 18 15 15 20 30
00 02 04 07 11 20
0 2 4 7 1 0
25 24 18 16
05 08 12 14
5 8 2 4
14 20
15 17
5
2-[30 marks]-
(a) Describe the potential facility layouts and compare between them in a tabular form.
(b) An initial process layout and interdepartmental flow matrix of a toy factory are given below. All
departments are set at equal squared areas and interdepartmental movements are only allowed
rectilinear. Suppose that transportation costs are $0.5 per a load per 20ˊ. Improve the given layout.
Department 1 2 3 4 5 6 7 8
Shipping and receiving 1 — 175 50 0 30 200 20 25 1 3 5 7
Plastic molding & stamping 2 — 0 100 75 90 80 90
Metal forming 3 — 17 88 125 99 180 80ˊ
Sewing 4 — 20 5 0 25
2 4 6 8
Small toy assembly 5 — 0 180 187
Large toy assembly 6 — 500 103
Painting 7 — 7
160ˊ
Mechanism assembly 8 —
3-[25 marks]-A product is manufactured, in a shop, using a five-stage process: shearing, pressing,
welding, painting, and packing. Times taken through operations are 20, 23, 15, 12 and 6 minutes
respectively. Presently, each stage has only one machine for operation. The shop works on an 8-hour shift
with an effective available time of 460 minutes. Complete a capacity plan for this process with respect to
(a) Scenario A: Setting the process to the nearest higher level of production capacity.
(b) Scenario B: Setting the process to produce 50 units per day.
4-[20 marks]-A company uses approximately 24,000 glass jars each month. It orders 5,000 jars at a time.
Monthly holding cost is $0.08 per jar, and the ordering cost is $60 per order.
(a) What penalty cost incurred by the present replenishment policy?
(b) How much would ordering cost need to be reduced to justify a lot size of 3,000 jars?
My best wishes
Professor Dr. Hassan Soltan
Department of Production Engineering and Mechanical Design
Mansoura University
Faculty of Engineering
Department of Production Engineering and Mechanical Design
Planning of Factories and Production Processes
PRE5323—June 22 2022—(1 PM)
Final June 2022, 3rd Year at Production Engineering and Mechanical Design Department.
Please solve the next problems. (Time: 3 hrs. Total marks: 110.) Graphics are necessary for all problems.
1-[30 Marks]-A producer of a chemical products needs to develop an aggregate plan for the coming year.
Management has decided to use gallons of chemical products as the aggregate measure of capacity. The
company currently uses 200 workers. Each worker is capable of producing 2,000 gallons per month on
regular time. A workers is paid $15,000 per month on regular time. It costs $5,000 to hire a worker, and
$2,000 to fire a worker. Holding costs are $0.50 per gallon per month and back-orders are not allowed.
The beginning inventory is 300,000 gallons and the desired ending inventory is 280,000 gallons. Monthly
demand forecast, in 1000 gallons, is projected as in the table below. Construct a level work force
aggregate plan and find its cost.
Month 1 2 3 4 5 6 7 8 9 10 11 12
Demand 200 250 300 350 400 500 500 450 400 300 250 200
2-[30 Marks]-A manufacturer has gone out on bid for a regulator component. Expected demand is 700
units per month. The item can be purchased from either supplier, A or B. Their price lists are shown in the
table below. Ordering cost is $50, and annual holding cost per unit is $5. Which supplier should be
selected? What is the optimal ordering policy?
Supplier A Supplier B
Quantity Unit Price Quantity Unit Price
1 – 499 $16.0 1 – 399 $16.1
500 – 999 $15.5 400 – 799 $15.6
≥ 1,000 $15 ≥ 800 $15.1
3-[25 Marks]-A production process is shown in the figure below. The drilling operation occurs separately
from, and simultaneously with, sawing and sanding which are independent and sequential operations. A
product needs to go through only one of the three assembly operations (the operations are in parallel).
Assembly
Sawing Sanding
0.7 units/hr
6 units/hr 6 units/hr
Welding Assembly
Drilling 2 units/hr 0.7 units/hr
Page 1/2
4-[25 Marks]-Eagle Electronics Company has decided to expand by building a second facility to supply
four market places E, F, G, and H. The search has been narrowed down to locating the new facility in one
of four sites A, B, C, or D. Location factors, beneficial scores, and weights are shown in the table below.
The coordinates of markets and proposed sites are explored in the figure below. Shipping loads to the four
markets E, F, G, and H are 200, 500, 300, and 700 thousand units respectively. What is the recommended
site for Eagle Electronics’s new facility?
Site Scores
Location Factor Factor Weight A B C D
Labor quality 0.22 10 08 07 10
Quality of life 0.18 09 03 08 06
Transportation 0.18 04 05 03 09
Proximity to suppliers 0.15 02 10 05 04
Taxes 0.15 08 07 06 08
Energy supplies 0.12 05 06 10 06
30
3, 25
25
A
6, 20
30, 19
20 20, 17
E
G
15 C Markets
12, 12
22, 10 Sites
10 B
7, 7 D
5 F 25, 3
H
0
0 5 10 15 20 25 30 35
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