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Facilities Planning 4th Edition James A. Tompkins, John A. White, Yavuz A. Bozer, J. M. A. Tanchoco - Solutions
In Problem 11.18, suppose there is considerable uncertainty regarding the annual operating expenses for alternative B. What is the breakeven value?
Two material handling alternatives are being considered for a new distribution center.The first involves a smaller capital investment but larger operating costs. Specifically, alternative A involves an initial investment of $250,000 and has annual operating expenses of $600,000. Alternative B
Reconsider Problem 11.16. Due to political unrest in Brazil, the CFO has suggested that either the joint venture be moved to Argentina or that the location risk factor for Brazil be increased by adding an additional 0.5% risk premium. What discount rate should be used for the project under each of
Reconsider Problem 11.15. Due to an economic downturn, one of the joint venture partners has withdrawn from the project. The remaining partners have agreed to redistribute the withdrawing partner’s share. The result for EASTMAN is an increase in ownership from 49 to 82% with controlling interest.
EASTMAN’s vice president for strategic planning, together with members from the business team and manufacturing, are exploring the possibility of building a greenfield plant through a joint venture in Brazil. EASTMAN would operate the plant and have a 49% ownership position, but without control.
From solving Problems 11.7 through 11.13, what conclusions do you draw regarding the use of the weighted factor comparison method?SECTION 11.2.4
Use the weights given in Problem 11.9 and the ratings given in Problem 11.12 to determine the recommended alternative using a weighted factor comparison analysis.
Use the weights given in Problem 11.10 and the following ratings for each alternative to determine the recommended alternative using a weighted factor comparison analysis. Layout Alternatives Factor A B C D 2 5 78700 12345 10 7 8 10 10 8 7 10 6 7 50908 62049 10
Solve Problems 11.9 and 11.10 using the following ratings for each alternative. Layout Alternatives Factor A B C D 5 88700 12345 10 4 8 10 10 8 10 6 22077 5 9 10 9 6 5 8
Solve Example 11.1 using the following weights: 15, 25, 15, 30, and 15.
Recall Example 11.1. Determine the preferred alternative with the following weights assigned to factors 1 through 5, respectively: 20, 25, 15, 20, and 20.
Which investment alternative is recommended in Problem 11.7, ifa. the weightings for the three factors are 50, 10, and 40?b. the rating values for fill time for A, B, and C are 5, 7, and 10, respectively?c. another factor is introduced, safety (S), the weights assigned to the factors (PW, T, F, and
Three investment alternatives (A, B, and C ) are under consideration. The discounted present worths (PW ) are $30,000, $24,000, and $18,000, respectively. The three alternatives have very different rankings on time required to fill a customer’s order (T ) and flexibility (F ). The following
List 10 factors to be used in evaluating site location alternatives for a distribution center.Rank them in order of importance.
List 10 factors to be used in evaluating site location alternatives for a corporate headquarters building. Rank them in order of importance.
List 10 factors to be used in evaluating the following horizontal handling alternatives for moving pallet loads: lift truck, tractor trailer train, automated guided vehicle, infloor towline conveyor, roller conveyor for pallets. Rank them in order of importance.
List the advantages and disadvantages in building a conventional (25- to 30-tall) warehouse versus building a high-rise (55- to 75-tall) warehouse.
List the advantages and disadvantages of providing on-site storage of materials and supplies versus using off-site leased storage.
List the advantages and disadvantages of leasing production equipment versus purchasing the equipment.
Interview faculty and students in civil engineering and in mechanical engineering (if neither is taught at your university, interview practicing design engineers in the community)and prepare a report summarizing their viewpoints regarding commercially available CAD software.
Interview faculty and students in the architecture school (or, if architecture is not taught at your university, interview practicing architects in the community) and prepare a report summarizing their viewpoints regarding commercially available CAD software.
Perform a search of the World Wide Web, focusing on computer-aided drawing alternatives available. Prepare a report summarizing your findings.
Describe specific situations where block templates or models should be used instead of contour templates and models and vice versa.
How could computer-aided layout techniques be integrated with computer graphics?Would this be useful?
Describe specific situations where different three-dimensional approaches would be used.
Describe specific situations where different two-dimensional approaches would be used.
Describe specific situations where two-dimensional layouts would be superior to threedimensional layouts and vice versa.
How could computer-aided layout techniques be used to study flow patterns outside a facility?
Why should a facilities planner be concerned with aesthetics?
Draw a plot plan of the building housing the classroom for this course. How should the building be expanded if the demand for classrooms doubles? Could the facility have been designed to accommodate expansion better? Please explain.
Select any of the exercises given in the problems section of this chapter requiring analytical solutions and, if applicable, perform a simulation study to verify the analytical results.
Select any of the examples presented in this chapter requiring analytical solutions and, if applicable, perform a simulation study to verify the analytical results.
Perform a literature search and review five facilities planning simulation applications in manufacturing.
Perform a literature search and review five facilities planning simulation applications for a distribution center or warehouse.
Perform a literature search and identify and describe simulation software not cited in Section 10.10 that can be used in facilities planning.
Consider the conveyor models presented in Section 10.8. What role might simulation play in such analyses? When should simulation be used, rather than the deterministic models?
Consider the AS/RS and order picking models in Section 10.6 and 10.7. How might simulation be used in designing an AS/RS or order picking system? What role, if any, would the models presented in Sections 10.6 and 10.7 play if simulation is used?
Consider the storage models in Section 10.5. How might simulation be used in actually designing a warehouse based on the results from the models?
Consider the facility location models and layout models in Sections 10.2, 10.3, and 10.4. When might simulation be used to aid in facility location and layout decisions?
A facility has two bridge cranes operating on a single bridge crane runway. To increase the amount of crane capacity, it has been suggested that a third bridge crane be placed on the runway. Given that it is structurally feasible, describe the steps to use in developing and using a simulation model
For the (M|D|1):(GD| | ) queue, suppose the service rate can be increased at a cost and there is a waiting cost for customers.a. Develop an expected cost model to be minimized and determine the optimum service rate for a set of parameters.b. Repeat the process, but for the case of the arrival rate
Solve Example 10.74 assuming C1 $300, C2 $0, C3 $15,000, C4 $25,000, C5 $5,000, C6 $30,000, l 15 per month, and 10/month.
Lift trucks deliver products to a packaging department at a Poisson rate of 125 parts per hour. A unit load is to be designed for the lift truck in order to minimize expected costs. Each trip by the lift truck costs $25. Packaging time is exponentially distributed with a mean of 10 seconds per part
In Problem 10.132, suppose a fleet of 50 ships is to be handled at the docks and each ship spends an average of 20 days at sea. Determine the optimum number of unloading spaces.
Cargo ships arrive at a dock for unloading at a rate of 4 per day. Unloading time averages 2 days per ship. The cost of a cargo ship being at the dock for unloading is$10,000 a day. The cost to rent space for unloading a ship is $2,500 a day. Assuming a Poisson process, determine the optimum number
A department store is considering providing valet parking for its customers at a flat rate of $10, regardless of how long the customer shops in the store. Valet operators will park cars in a special area in an adjacent parking garage. The department store must contract with the parking garage for a
Recall Example 10.73. Determine the size of the parking garage when 100/hour, 4/hour, R $6/hour, C5 $1/hour, and C6 $20/hour.
In Problem 10.128, let C1 C2 $75/machine-hour. Determine the optimum number of machines to assign to an operator when service time is (a) exponentially distributed and (b) constant.
For the data in Problem 10.126, determine the number of machines assigned to an operator in order to minimize the expected cost per busy machine. (Hint: The number of busy machines equals K L.)
Suppose a crew of operators is responsible for 30 identical machines having the arrival and service parameters given in Problem 10.126. Using the same cost parameters, determine the optimum crew size.
In a textile plant, automatic running time for machines is exponentially distributed with a mean of 45 minutes; service time is exponentially distributed with a mean of 5 minutes.One operator is to be assigned to a specified number of machines. Using the notation in Section 10.9, C1
Arrivals at a storeroom occur at a Poisson rate of 15 per hour; service time is exponentially distributed with a mean of 3 minutes. Each minute a customer spends in the system costs $0.45; each server costs $0.30/minute. Determine the number of servers that minimizes expected cost per unit time.
Two operators are being considered for a particular job. The first operator will be paid at a rate of $10/hour and will have an exponentially distributed service time with a mean of 10 minutes. The second operator will be paid at a rate of $16/hour and will have a normally distributed service time
An e-mail computer server has the capacity to handle 50 jobs simultaneously. The time required to process a job is a random variable, with a mean of 30 minutes and a standard deviation of 10 minutes. “Jobs” arrive at a Poisson rate of 60 per hour. On average, how many jobs will be in the
Parts arrive at a workstation every 15 seconds. The time required to process the part is exponentially distributed with a mean of 12 seconds. On average, how many parts are waiting to be processed by the workstation? On average, how long does it take between the time a part arrives at the
Visitors arrive at the reception desk of a multinational retail firm at a Poisson rate of 30 per hour. It takes 15 seconds to issue a visitor a badge. On average, how many visitors are waiting to receive a visitor’s badge?
Consider a manufacturing situation involving the use of six robots. There is one robot attendant who changes end-of-arm tooling for the robots, programs the robots, and performs setup changes for the robots. The time between requirements for an attendant for an individual robot is exponentially
Consider a distribution center that uses a fleet of eight battery-powered automated guided vehicles for material delivery. Due to the wide variety of demands placed on an AGV, the life of a battery, before recharging is required, is a random variable. Suppose the time from recharging a battery for
Consider a queueing situation involving a single server. Service time is exponentially distributed with an expected value of 6 minutes per customer when there is one customer in the system, 5 minutes when there are two in the system, 4 minutes when there are three in the system, 3 minutes when
Consider a queueing situation involving a single server. Suppose service time is exponentially distributed with an expected value of 5 minutes per customer.a. Suppose arrivals occur in a Poisson fashion and there is unlimited waiting capacity for the system. Determine the maximum arrival rate that
At a curbside baggage check-in station, passengers arrive at a Poisson rate of 20 per hour. Either 1, 2, or 3 bags are to be checked for each passenger, with it being equally likely to be 1 or 3 and twice as likely to be 2. The time required to check a bag is exponentially distributed with a mean
A tote box of parts arrives at an inspection station. The inspector selects a random number of parts for inspection; they are inspected individually. The tote boxes arrive at a Poisson rate of 2 per minute. The number of parts selected for inspection is equally likely to be 1, 2, 3, or 4. The
Unit loads arrive randomly at a quality control station. Two inspectors are located at the station; the inspection time is exponentially distributed with a mean of 10 minutes.Loads arrive at a Poisson rate of 10 per hour.a. What is the probability of both inspectors being idle?b. What is the
Cartons arrive at a workstation at a Poisson rate of 12 per minute. The time required to process a carton is exponentially distributed with a mean of 4 seconds. What is the average number of cartons waiting for processing at the workstation?
Unit loads arrive randomly at a quality control (QC) station. An average of 10 unit loads arrive per hour at a Poisson rate. The time required to perform the QC check is normally distributed with a mean of 5 minutes and a standard deviation of 1 minute.What is the average length of time a unit load
Parts arrive for packaging at a Poisson rate of 30 per hour. The time required for packaging is normally distributed with a mean of 3 minutes and a standard deviation of 1 minute. If the system operates as an Erlang loss system, how many packaging stations should be provided in order to have no
A conveyor delivers parts to an inspection station at a Poisson rate of 3 per minute.The time required to inspect a part is exponentially distributed with a mean of 15 seconds.On average, how many parts will be waiting to be inspected?
An accumulation conveyor is to be provided at a workstation. When the conveyor is full, parts are diverted to another area for processing. Parts arrive at a Poisson rate of 2 per minute. The time required to process a part at the workstation is exponentially distributed with a mean of 18 seconds
Cartons arrive at a workstation via a roller conveyor spur at a Poisson rate of 30 per hour. The time required to process the carton at the workstation is exponentially distributed with a mean of 1.2 minutes. How long must the accumulation line be such that it will not be full more than 5% of the
Trucks arrive at the receiving area of a distribution center at a Poisson rate of 10 per hour. The time required to unload a truck is exponentially distributed with a mean of 30 minutes. With 10 docks available for unloading trucks, what is the average number of trucks waiting to be unloaded? What
Consider the tandem flow system shown earlier in Figure 10.59b. In Example 10.60, we focused on zone I defined by stations {1, 6, 7, 8, 9}. Let’s now focus on zone II defined by stations {2, 3, 4, 5, 9}, where stations 2 and 5 are I/O stations. (Recall that station 9 is a transfer station, which
A bulk belt conveyor is used to convey oats from ground level to the top of a grain silo for storage. The oats are conveyed at an angle of 15 to a height of 50 . The oats have a density of 30 lb/ft3.a. Using a belt that is 30 wide and a belt speed of 400 fpm, what is the horsepower requirement to
A bulk belt conveyor is to be used to convey coffee beans to a storage silo. The conveyor will have an incline of 10; the material is to be elevated 30 . In determining maximum belt speed, coffee beans are classified as grain. Coffee beans have a density of 30 lb/ft3.a. Using a 24 belt width, what
A bulk belt conveyor is to be used to convey material having a density of 60 lb/ft3. It will be conveyed over a horizontal distance of 200 and at an incline of 10. The material is to be conveyed at a rate of 100 tph.a. Using a 24-wide belt, what conveying speed should be used?b. Using a 24-wide
A bulk belt conveyor is used to transport washed gravel having a density of 75 lb/ft3 over a horizontal distance of 232.55. Also, the unsized gravel is to be elevated a vertical distance of 59.33. A conveyor speed of 400 fpm is to be used in combination with a 24-wide belt.a. Is the angle of
A bulk belt conveyor is to be used to convey lumpy, abrasive steel trimmings from a basement area beneath a machine shop to a dumpster at ground level. The conveyor is to be 50 long. Using a 30-wide belt, the waste material is to be elevated a distance of 20 at a speed of 400 fpm.a. Is the angle
A bulk belt conveyor is to be used to convey dry sand from a storage hopper to a cement mixer. The conveyor is to be 75 long. Using a 30-wide belt, the sand is to be elevated a distance of 24 at a speed of 600 fpm.a. Is the angle of incline feasible?b. Is the speed feasible?c. Assuming the angle
A bulk belt conveyor is to be used to convey grain horizontally over a distance of 150. The grain weighs 50 lb/ft3. It is required that the conveyor deliver grain at a rate of 250 tph. The available belt widths are 18, 24, 30, and 36.a. Determine the belt width and speed that delivers exactly
Cartons are to be conveyed using a 200 -long roller-supported belt conveyor with WBR dimensions of 27 and rollers on 6 centers. A conveyor speed of 100 fpm is to be used.The conveyor is inclined at an angle of 15. Five types of cartons are to be conveyed on the belt. Their weights and lengths are
Tote boxes are conveyed over a distance of 200 using a combination of two 100-long belt conveyors. Both are roller supported using 2.5 rollers weighing 5 lb each and installed on 6 centers. The WBR dimension is 33 for both conveyers. A conveyor speed of 150 fpm is used on the first conveyor, which
Two roller-supported belt conveyors are used to convey tote boxes of material 250 from the assembly department to the packing department. The first conveyor is 150 long and has a speed of 300 fpm; the second is 100 long and has a speed to be determined.The tote boxes are 24 in length. Rollers are
Two conveyors having 6 RC values are used to transport cartons horizontally 150 in a distribution center from receiving to storage. The first conveyor is a 100 -long rollersupported belt conveyor with a speed of 300 fpm. Cartons are fed directly from the belt conveyor to a belt-driven roller
A flat belt-driven roller conveyor is used to convey tote boxes of material from the receiving area in a warehouse to the storage area. The conveyor consists of two sections, 200and 100 long. Rollers are on 6 centers. A WBR dimension of 27 is used. The tote boxes are 24 long and are equally
A v-belt-driven roller conveyor is used to convey cartons from the order picking area in a warehouse to the order accumulation and packing area in the warehouse. The conveyor is 250 long. Rollers are 2.5 in diameter and are spaced on 7.5 centers. A WBR dimension of 30 is used. A variety of
A chain-driven roller conveyor is used to move pallet loads 150 from storage to shipping.The pallet is 48 36. For smooth movement over the rollers, the pallet is oriented so that the stringer is aligned with the rollers (i.e., the stringer is perpendicular to the conveyor frames and parallel
Cartons are to be conveyed over a distance of 300 using a combination of roller and belt conveyors. Movement over the first 200 will be via a flat belt-driven roller conveyor with WBR dimensions of 33, rollers on 9 centers, and a speed of 200 fpm. Each tote box is 24 long and weighs 25 lb
Consider the conveyor loop and data given for Example 10.52. Assuming clockwise conveyor travel, we showed that the conveyor speed must exceed 45 windows per minute (or 90 fpm) in order for the conveyor loop to be stable. Suppose the direction of the conveyor is reversed, that is, the conveyor
An overhead trolley conveyor is used to transport assemblies within an assembly department.There are three loading stations in the assembly department and one unloading station. The trolley conveyor has 83 carriers, equally spaced around the conveyor, with 20 separation between carriers. The
A trolley conveyor is used to transport parts between three production stations. There are 62 carriers, equally spaced around the conveyor, with 10 separation between carriers.The material flow patterns for the workstations follow:{ f1(n)} (0, 4, 0){ f2(n)} (3, 3, 3){ f3(n)} (0, 5, 0)a.
A trolley conveyor is used to transport parts among four production stations. There are 33 carriers, equally spaced around the conveyor, with 10 separation between carriers.The material flow patterns for the workstations are as follows:{ f1(n)} (2, 0, 2, 0) { f2(n)} (0, 2, 0, 2){ f3(n)}
A trolley conveyor is used to transport parts among four production stations. There are 32 carriers, equally spaced around the conveyor, with 10 separation between carriers.The material flow patterns for the workstations are{ f1(n)} ( 5, 0, 0); { f2(n)} (0, 3, 0); { f3(n)} (0, 0, 4); {
A trolley conveyor serves four workstations. There are 543 carriers, equally spaced around the conveyor. The material flow patterns for the workstations are as follows:{ f1(n)} (0, 0, 3, 2, 0, 0, 0, 3, 2, 0, 0, 0, 3, 2, ...){ f2(n)} (3, 0, 3, 0, 3, 0,3, 0,3, 0,3, 0, ...){ f3(n)} (3, 0,
Consider a miniload AS/RS used for end-of-aisle order picking. It is assumed that the P/D station is located at the lower lefthand corner of the rack and that there are two pick positions. Consider a single-aisle system with one picker. Under the current mode of operation, the containers within a
Consider a miniload AS/RS with two pick positions per aisle. It is assumed that the P/D station is located at the lower lefthand corner of the rack. Randomized storage is used.The S/R machine travels at 400 fpm and 80 fpm in the horizontal and vertical directions, respectively. The total load
Consider one aisle of a miniload AS/R system used by a book distributor for order picking.The P/D station is located at the lower lefthand corner of a rack that is 360 long and 63 tall. The S/R machine travels at 450 fpm and 90 fpm in the horizontal and vertical directions, respectively. It takes
Consider an end-of-aisle order picking system based on the miniload AS/RS. The P/D station is located at the lower lefthand corner of the rack, and each trip originates and terminates at the P/D station. One aisle is assigned to each picker. Furthermore, the S/R machine travels at 400 fpm and 100
The results we derived for walk-and-pick systems are based on a P/D point located at the midpoint of the front of the warehouse. Assuming the traversal policy is used and that each pick is equally likely to be located anywhere in the warehouse, derive the expected walking distance per trip for the
Consider a walk-and-pick system, where the total aisle length to be provided is fixed at 1440. That is, if there are 10 aisles (M 10), then each aisle must be 144 long; if there are 20 aisles, each aisle must be 72 long; and so on. Including shelving on either side, and the aisle clearance
Consider an in-the-aisle order picking system based on the person-on-board AS/RS. Total storage space required (expressed in square footage of storage rack) is equal to 300,000 ft2. On each trip, the picker performs 10 picks; each pick requires 0.90 minute.The S/R machine travels at a speed of 400
Consider an in-the-aisle order picking system based on the person-on-board AS/RS.The user would like to store 7,000 loads in the system, where each load requires 18 ft2 of rack surface (including necessary clearances). The system must be capable of performing 215 picks per hour. On each trip, the
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