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Facilities Planning 4th Edition James A. Tompkins, John A. White, Yavuz A. Bozer, J. M. A. Tanchoco - Solutions
Suppose the system in Problem 10.75 does not meet the required throughput capacity.Two alternative solutions have been proposed: (a) increase the S/R machine travel speed by 10% in both the horizontal and vertical directions, or (2) reduce the time per pick from 20 to 17 seconds by improving the
Suppose in Problem 10.74 it takes the picker, on average, 20 seconds to complete a pick. Further suppose the picker spends 0.80 minute at the P/D station between successive trips.a. Assuming that the pick points are sequenced in an optimum fashion, compute the throughput capacity of the system in
Consider an in-the-aisle order picking system based on the person-on-board AS/RS.Suppose the storage rack is 400 long and 80 tall. The S/R machine travels at a constant speed of 450 fpm and 90 fpm in the horizontal and vertical directions, respectively.On each trip, the picker performs eight
Consider a single-aisle AS/R system, where storage and retrieval requests arrive according to an independent Poisson process at a rate of s 8 storages/hour and r 32 retrievals/hour. To serve the requests, the S/R machine follows the strategy depicted in Figure 10.46; that is, upon completing
Consider a unit load AS/RS rack that is 500 long and 45 high. The S/R machine travels at 400 fpm and 120 fpm in the horizontal and vertical directions, respectively. The I/O point is located at the lower-lefthand corner of the rack. As shown by the shaded area below, the S/R machine will not be
Consider a unit load AS/RS rack that is 400 long and 80 high. The S/R machine travels at 450 fpm and 90 fpm in the horizontal and vertical directions, respectively. The I/O point is located at the lower lefthand corner of the rack. Each trip starts and ends at the I/O point. Randomized storage is
An AS/RS is to be designed for the storage of 60 48 unit loads. The S/R machine will travel horizontally at a speed of 500 fpm; simultaneously, it will travel vertically at a speed of 80 fpm. The storage aisle will be 400 long and 60 tall. The pick-up and deposit station will be located at
Consider a normalized storage rack Q units long in the vertical direction. The I/O point is located at the lower lefthand corner of the rack, and each trip originates and terminates at the I/O point. Given that the rack will be serviced by a straddle truck, it is assumed that the truck will travel
In deriving the cycle time equations, the I/O point was assumed to be located at the lower lefthand corner of the rack. Based on the particular type of hardware involved, however, the exact location of the I/O point may not coincide with the lower lefthand corner of the rack. In fact, suppose the
For an AS/RS, suppose it has been determined that A ft2 of rack space is required on either side of each aisle. Given that A LH and assuming that hv and vv are fixed, determine the rack shape (i.e., the Q value) for which the expected S/R machine travel time for a single-command cycle is
Based on a peak rate of 100 storages per hour and 100 retrievals per hour, determine the minimum number of S/R machines required without having greater than 75% utilization of the equipment. Assume 60% of the operations are performed on a dualcommand basis. The shuttle on the S/R requires 15
If a 42 46 pallet load (62 high, including the pallet) is to be stored in an AS/RS, what building dimensions are required to accommodate six aisles? Assume each aisle has 40 columns and 10 levels of storage along each side of the aisle. Do not allow for transfer cars; do consider sprinklers.
An AS/RS is to be designed for a 48 54 unit load that is 50 high. There are 10 aisles; each aisle is 14 loads high and 60 loads long. There are to be sprinklers and no transfer cars. It takes 0.40 minute to perform a P/D operation. The S/R travels horizontally at a speed of 425 fpm and travels
An AS/R system is to be designed to store approximately 12,000 loads. Due to space limitations in the existing facility, it is known that the system will have eight tiers of storage. The choice has been reduced to having either (a) 10 aisles, 75 openings long,(b) 9 aisles, 84 openings long, or (c)
An AS/RS is to be designed for a 40 48 unit load that is 48 high. There are eight aisles; each aisle is 12 loads high and 50 loads long. There are to be sprinklers and no transfer cars. It takes 0.30 minute to perform a P/D operation. The S/R travels horizontally at a speed of 300 fpm and
An AS/RS is being designed; randomized storage is to be used. One alternative being considered is to have each aisle be 70 tall and 310 long. The S/R has a horizontal speed of 425 fpm and a vertical speed of 80 fpm. It requires 0.40 minute to pick up or deposit a load. The activity level for the
An AS/R system is being designed for 42 48 unit loads that are 42 high. One of the design alternatives involves eight aisles, no transfer cars, 1,100 openings per aisle, 11 levels and 50 columns of storage on each side of the aisle, and sprinklers. The S/R will travel horizontally at an
Five aisles of storage are provided with an S/R machine dedicated to each aisle. Randomized storage is used. The S/R machine travels simultaneously horizontally and vertically at speeds of 400 fpm and 80 fpm, respectively. Each aisle is 300 long and 50high. The time required to pick up or put
An AS/R system is being designed for 48 42 unit loads that are 45 high. One of the design alternatives involves 12 aisles, no transfer cars, 1440 openings per aisle, 12 levels and 60 columns of storage on each side of the aisle, and sprinklers. The S/R will travel horizontally at an average
Perform Web searches on deep lane storage, high density storage, push-back storage rack, and pallet flow rack. Summarize your findings, including names of equipment suppliers, differences in design features, approximate costs of storage per pallet position, pros and cons of each, and photographs of
Deep lane storage with “smart” shuttle carts is to be used in refrigerated storage to store pallet loads of ice cream. The footprint dimension of a unit load of ice cream is 42 48. The clearance between the load and the upright rack member is 3; the upright rack member is 4 wide; a 10
Deep lane storage is used to store 36 48 unit loads of Captain Crunchy Goober Butter. The clearance between the load and the upright rack member is 4; the upright rack member is 4 wide; a 12 flue space is provided at the end of the deep lane; the storage aisle is 5 wide; there are 15
A storage system is to be designed for storing 60 38 pallet loads of a wide variety of products. The storage alternatives to be considered are block stacking, deep lane storage, single-deep pallet rack, double-deep pallet rack, and triple-deep pallet racking.In the case of block stacking, a
Thirty 48 40 unit loads of a particular product are to be stored in storage racks. The warehouse manager cannot decide whether to store the product in single-deep or double-deep storage racks. Seven tiers of storage are used; the storage aisle is 8 wide. A clearance of 4 is used between a
Deep lane storage is used for storing a soft drink product. The dimensions of the unit load are 42 48. The flue clearance is 12, the rack is 6 wide, the clearance between a load and the rack is 4, and the aisle width is 8. Six tiers of storage are used. Three hundred pallet loads of the
The Most Delicious Ice Cream Company uses block stacking to store pallet loads of its finished goods in frozen storage. The dimensions of the pallet load are 36 48. Each load consists of 40 half-gallon cartons, eight cartons to a layer and five layers to a pallet. Using walkie stacker lift
An appliance manufacturer stores its finished goods using block stacking and clamp attachments on counterbalanced lift trucks. Leased warehouse space is currently being used to store freezers. The outside dimensions of the freezers are 36 60 48, with the last dimension being the height of
60 48 loads are block stacked five high using 10 wide aisles. 200 unit loads of a product are received; a safety stock level of 20 unit loads is desired. In this case, suppose 20 units loads of the previous lot of the product are in the warehouse at the time of receipt of the current lot. Due
Block stacking is used to store unit loads, 42 48; each unit load is 54 high, including the pallet. A clearance of 8 is provided between storage rows. The storage aisle is 13 wide; storage is assumed to occur on both sides of the aisle. Unit loads are stacked three high.a. Given Q 30,
Block stacking is used for the storage of 48 40 unit loads. A counterbalanced lift truck is used to store and retrieve the unit loads, which are stacked five high. The storage aisle is 13 wide. A clearance of 8 is used between storage rows.a. If 300 loads of a particular product are received and
Block stacking is used for the storage of 60 unit loads of a paper product. The dimensions of the unit load are 48 42 . A clearance of 6 is provided between storage rows.The storage aisle is 13 wide. The product is stacked four levels high in the warehouse.a. Determine the depth of the storage rows
Prepare a report on recent developments in the modeling of machine layout problems.
Draw a flow chart of the double-row machine layout algorithm as proposed in Section 10.4. Include the consideration of the locations of the load/unload of the individual machines. State all your assumptions.
Draw a flow chart of the single-row machine layout algorithm discussed in Section 10.4. Include the consideration of the locations of the load/unload of the individual machines. State all assumptions.
Four equal-sized (20 20) machines are grouped into a manufacturing cell in a linear layout. The material handling device is a two-way shuttle cart system. The pickup and delivery station(s) for each type of machine are shown in the figure below. The material flow information is given in the
Six machines are located on either side of a bidirectional conveyor system, as shown in the figure below. For the flow information given in the table, how can the machines be rearranged to minimize the time products spend on the conveyor? Assume the load transfer station for each machine is located
Consider the problem described in Problem 10.38. Suppose that the required production rates are 400, 300, 700, and 1,000 units per week, respectively, for products 1, 2, 3, and 4. Using an improvement-based procedure, determine a single-row cell arrangement.
Consider the problem described in Problem 10.38. Suppose that the required production rates are 600 units per week for all four products. Using an improvement-based procedure, determine a single-row cell arrangement.
Four manufacturing cells are served by an automatic guided vehicle (AGV) on a linear bidirectional track, as shown below. The product routing information and required production rates are given in the table below. Using an improvement-based procedure, determine a single-row cell arrangement. Assume
Shown in the figure below is a layout of an existing warehouse. One-way aisles are 8wide, while two-way aisles are 16 wide. Each storage bay is approximately 20 20.Three products (X, Y, and Z) are to be stored. Doors A and B serve as the receiving and shipping docks, respectively. The area
Three classes of products (A, B, and C) are to be stored in the warehouse depicted in the figure below. Product storage requirements are 15 bays for A, 5 bays for B, and 16 bays for C. Fifty percent of the shipment has to go through dock 1, and the other shipments are evenly distributed between
An existing warehouse will be used for the storage of six product families. The warehouse consists of storage bays of size 20 20. Dock 1 has been designated as the receiving dock, while dock 2 is used as the shipping dock. The area requirement and monthly load rate for each product family are
Consider a warehouse illustrated by the figure below. Thirty-two bays (25 25) are available for storage. Four different types of products (A, B, C, and D) are to be stored.Each type of product cannot share a bay with any other type of product. Products are received from dock 1 and are shipped out
Consider an array of storage locations, as illustrated below. The array represents storage bays. Rectilinear travel is used and is assumed to originate and/or terminate at the centroid of the storage bay. Products are received through one of the I/O points(docks). The storage activity is divided
Consider the data and assumptions given in Problem 10.29, but this time assume that the six cells are to be located in an L-shaped facility, as shown in the figure below.a. Determine a lower bound for the material handling cost.b. Given an initial cell layout where product 1 is located in cell A,
Consider the data and assumptions given in Problem 10.29, but this time assume that the six cells are to be located in a straight-line facility, as shown in the figure below.a. Determine a lower bound for the material handling cost.b. Given an initial cell layout where product 1 is located in cell
Consider the data and assumptions used in Problem 10.29. Assume that the six cells are arranged in a rectangular facility as shown below.a. Determine a lower bound for the material handling cost.b. Given an initial cell layout where product 1 is located in cell A, product 2 is located in cell B,
Six cells (20 20) are to be located in a 2 3 (rectangular) facility, as shown in the figure below. The material flow matrix is given in a separate table. The material handling cost is directly proportional to the distance traveled (from centroid to centroid).Assume rectilinear distance.a. Determine
Five departments are involved in the processing required for the products in a manufacturing company. A summary of the material flow matrix (between departments) and distance matrix (between sites, in feet) can be found in the tables below. The material handling cost is directly proportional to the
In Problem 10.26, suppose the cost of transporting the loading equipment to the sites, setting up the equipment, and returning the equipment to the central storage yard is as follows:Candidate Loading Site 1 2 3 4 5 Setup and Transportation Cost $1,000 $500 $250 $750 $1,000 Let the travel cost per
A logging company is cutting trees in four different areas of Ashley County. The logs are transported by truck to a site along a railroad where special equipment loads logs on rail cars. The firm has identified five candidate sites, of which at most three can be equipped. Shown below is the product
Consider a facility location problem involving eight customers and five potential sites for locating, at most, two new facilities. The distances between customer locations and potential sites are given as follows:The number of trips made weekly between a new facility and customer i equals 80, 200,
Sixteen work stations are located as shown below on a tree network. The weights between existing facility i and the new facility to be located on the tree are, respectively, w1 5; w2 2; w3 3; w4 1; w5 4; w6 2; w7 3; w8 6; w9 2; w10 3;w11 4; w12 1; w13 1; w14 2; w15 3; w16 2.a.
A major bank has decided to establish a presence in a region of the state in which they previously had no presence. Specifically, four sites for branch banks have been identified.The potential customer base has been divided into five major subdivisions. If a branch bank is located within 3 miles of
A textile plant has a number of automatic spinning machines that are assigned to operators who patrol the assigned area and repair any breaks that occur in the continuous filament fiber. The plant can be divided into 30 squares contained in a rectangle with a width of 5 and a length of 6. A patrol
In Problem 10.20, suppose a magisterial district is “covered” if a health outreach clinic is located within X miles of the centroid of the district. Determine the minimum number of clinics required to cover the districts when X equals (a) 30, (b) 40, (c) 50, and (d) 60.
In a rural part of Kentucky, health outreach clinics are to be located over an area coincident with 10 magisterial districts. Five potential sites are available for locating health outreach clinics. Distances between the centroids of the districts and the potential sites are tabulated in miles,
In Problem 10.18, solve the minimax Euclidean-distance problem.
Solve the minisum Euclidean-distance problem given the following data:a. P1 (0, 0), P2 (5, 0), P3 (0, 5), w1 1, w2 3, w3 1.b. P1 (10, 0), P2 (20, 10), P3 (10, 20), P4 (0, 10), wi 1 for i 1, . . ., 4.c. P1 (0, 0), P2 (0, 5), P3 (0, 15), w1 1, w2 3, w3 1.
Four machines are located at the coordinate points (0, 20), (0, 40), (20, 0), and (40, 0).Thirty percent of the item movement between the existing machines and a new machine is between the new machine and each of the existing machines at (0, 20) and(20, 0). Twenty percent is between the new machine
A mailroom is to be located within a multifloor building under construction. The U.S.Postal Service and other overnight delivery services will bring all incoming mail and parcels to the mailroom. Individuals will travel from their departments to the mailroom to pick up anything addressed to
The PQR Auto Parts Company has 12 retail stores in the city of Springdale. The PQR Company is planning to build a new warehouse to service its retail stores. The locations of the stores and the expected deliveries per week from the warehouse to each store are given below. Assume travel within
Three new facilities are to be located relative to six existing facilities. The weighting factors are vjk flow intensity between new machines j and k, and wji flow intensity between new machine j and existing machine i:The coordinate locations of the existing facilities are P1 (0, 10), P2 (15,
A small machine shop has five existing machines (M1 through M5) located at coordinate locations P1 (10, 25), P2 (10, 15), P3 (15, 30), P4 (20, 10), and P5 (25, 25), respectively. Two new machines (N1 and N2) are to be located in the shop. It is anticipated that there will be four trips per day
Plot the contour line passing through the point (1, 5) for the following formula:f (x, y) 6|x 6| 3|x 4| 9| y 1|
The Ashley County News Observer plans to rent building space for a new print shop within the city limits. The locations for current distribution centers, expected deliveries, and possible locations for the facility are shown in the tables and figures below.a. Determine the optimal location for the
A new elementary school is needed in a suburban area of Detroit, Michigan. After extensive research, the school board has narrowed down its choice to three possible sites. The locations for the current residential areas, expected students from each residential area, and possible locations for the
The city council of Fayetteville has decided to locate an emergency response unit within the city. This unit is responsible for four housing sectors (A) and three major street intersections (P) as shown in the figure below. Assume that the weights are uniformly distributed over the housing
Six housing subdivisions within a city area are targeted for emergency service by a centralized fire station. Where should the new fire station be located such that the maximum rectilinear travel distance is minimized? The centroid locations (in miles) and total value of the houses in the
A portable lunch wagon is to be located along the main aisle of an industrial plant. On a coordinate system, the main aisle connects the points (0, 10) and (12, 10). Travel between customer locations and the main aisle is rectilinear. The coordinate points for the locations of workstations served
A new back-up power generator is to be located to serve a total of six precision machines in a manufacturing facility. Separate electrical cables are to be run from the generator to each machine. The locations of the six machines are P1 (0, 0), P2 (30, 90), P3 (60, 20), P4 (20, 80), P5
Solve Problem 10.1 as a minisum planar location problem using squared Euclidean distances.Do not construct contour lines.
Solve Problem 10.1 as a minisum planar location problem using Euclidean distances.Do not construct contour lines.
Four hospitals are located within a city at coordinate points P1 (10, 20), P2 (14, 12), P3 (8, 4), and P4 (32, 6). The hospitals are served by a centralized bloodbank facility that is to be located in the city. The number of deliveries to be made each year between the bloodbank facility and
The XYZ Company has six retail sales stores in the city of Raleigh. The company needs a new warehouse facility to service its retail stores. The location of the stores and the expected deliveries per week from the warehouse to each store are Store Location (miles) Expected Deliveries 1 (1, 0) 4 2
Let four existing facilities be located at P1 (0, 10), P2 (5, 10), P3 (5, 15), and P4 (10, 5) with w1 15, w2 20, w3 5, and w4 30. Determine the optimum location for a single new facility when cost is proportional to rectilinear distance. Construct a contour line passing through the
In the design of a plumbing system, what are the two principal reasons why a vent stack is critical?
What is the purpose of a trap in a sewage system?
What is the main purpose of face sprinklers in an in-rack sprinkler system?
Rank the following design objectives in descending order of priority:• Safety of firefighters• Safety of regular building occupants• Salvage of building• The goods and equipment in the building
What is the major benefit of using a sprinkler system?
For the building shown in Figure 9.7, if the building occupancy were considered for educational/classroom use, determine the following:a. Maximum populationb. Maximum number of exitsc. Minimum distance between exits (assume building has no sprinkler system)d. Provide a sketch showing possible
On what basis are building occupancy groups determined?
What would be the changes in lighting specifications for the facility described in Problem 9.11 if the fixtures were cleaned only once every 36 months?
What would be the changes in lighting specifications for the facility described in Problem 9.11 if all ceilings and walls were painted a medium color?
What would be the changes in lighting specifications for the facility described in Problem 9.11 if the ceiling were 15 and the luminaries were to be mounted at a height of 9?
What would be the changes in lighting specifications for the facility described in Problem 9.11 if the ceiling height were 15?
What would be the changes in light specifications for the facility described in Problem 9.11 if the office were to be used for accounting and bookkeeping work?
A general office that is 250 150 will be used for regular office work. The ceiling height is 10 and all working surfaces will be 3 from the floor. If the luminaries will be ceiling mounted, all ceilings and walls painted white, and all luminaries cleaned every six months, what lighting should
The shade factor for awnings is 0.3 and for blinds is 0.7. What change in cooling load would occur if awnings were placed on the windows described in Problem 9.9? What if blinds were placed in these windows?
If ten (10) 4 8 double-pane glass windows were installed on the east and west sides of the facility described in Problem 9.8, what would be the cooling load of the facility?
Given the following additional information, what is the cooling load for the facility described in Problem 9.4?• Three doors on 400 east side• Three doors on 400 west side• Three doors on 400 east side 55 Btu/(hr)(ft2)• Three doors on a 400 west side 110 Btu/(hr)(ft2)• Lighting
What would be the heat loss of the facility described in Problem 9.4 if the slab floor were insulated [UF 0.55 Btu/(hr)(ft2)(oF)]?
What would be the heat loss of the facility described in Problem 9.4 if the roof were replaced with a 2 metal roof having an insulated ceiling [UR 0.13 Btu/(hr)(ft2)(oF)]?
What would be the heat loss of the facility described in Problem 9.4 if twenty (20)4 8 double-pane glass windows were installed?
What would be the heat loss of a facility having the following characteristics if the inside design temperature is 72F and the outside design temperature is 12F?• 400 300• 20 tall• No windows• Six glass doors measuring 3 8• 8 solid cinder block construction• 1 metal
Using Figure 9.7, if the floor area of the building is 120 180, provide recommendations for the main duct, louver supply, and exhaust sizes.Assume Air supply rate 1.0 ft3/min-ft2 Exhaust rate 0.3 ft3/min-ft2 Air speed 1800 ft/min Louver air speed• Exhaust 2000 ft/min• Intake 1000 ft/min
How can the thermal performance of a facility be improved? What is the primary purpose of an enclosure system for a manufacturing facility?
As a facilities planner, is the following statement true or false: “The grid structure should defer to the function of the facility?” Give the reasons for your answer.
Prepare a report on the impact of nanotechnology on facilities planning tools. Based on your research, discuss how traditional facilities planning methods might apply to nanobased production.
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