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Facilities Planning 4th Edition James A. Tompkins, John A. White, Yavuz A. Bozer, J. M. A. Tanchoco - Solutions
Prepare a report on the impact of developments in international shipping with megacontainer ships and automated container ports.
Four machines are needed for a linear machine cell layout. The machine information and material flow information is given in the following tables. The cost per trip per unit distance from machine i to machine j for each machine pair equals 1. Find the minimum cost placement order based on the
Consider Problem 8.24. How would the potential worker assignments change if three workers were sufficient? Is this preferable?
Consider the following 10-stage sequential manufacturing process, where each process is performed by a specific machine. You intend to develop a U-shaped flow line containing the machines required for this process.Process Mean Processing Time 1 10 2 15 3 10 4 30 5 50 6 30 7 10 8 15 9 25 10 45
In the context of U-shaped flow lines, what is the advantage of better communication and visibility between workers in terms of quality at the source? What is the key feature of the workers needed for this to be successful?
Describe the U-line balancing problem and discuss the implementation issues associated with balancing U-lines.
Prepare a review of a technical paper on U-lines.
Prepare a review of a nontechnical paper on U-lines.
Is JIT applicable to continuous production systems such as the chemical and petroleum industries? Explain your answer.
Is JIT applicable to all types of manufacturing systems? Explain your answer.
Describe the differences, if any, between JIT and lean manufacturing.
Prepare a review of a technical paper on JIT.
Prepare a review of a nontechnical paper on JIT.
Discuss the advantages of designing a device that could be used as the means of storage and fixturing for a product in terms of the seven catagories of waste.
Discuss, in terms of the rules of thumb described in Section 8.5, the advantage of designing a device that could be used as the means of storage and fixturing for a product. Workpieces in queue Tools MC1 Tools MC2 Workpiece on AGV Tools MCE Load Worker Unload Tools MC4 Parts Figure 8.9 A flexible
Discuss the relationships between manufacturing cell design and the design of material handling systems in the context of flexible manufacturing systems.
Describe the tool management problem ina. Flexible manufacturing systemsb. Single-stage multimachine systems
Develop a set of criteria for comparing flexible manufacturing systems and single-step multimachine systems.
Consider the flexible manufacturing system illustrated below. What alternatives exist for moving parts as shown? Under what conditions should each be considered?
Develop a set of criteria for comparing transfer lines and flexible manufacturing systems.
Provide a list of examples of fixed automation systems where the flow pattern is not a straight-line flow.
Develop a set of criteria for comparing the different variations of the straight-line flow pattern for fixed automation systems.
Can a container shipping yard be totally automated? Provide an explanation of your answer.
Can a cross-docking facility be totally automated? Prepare a list of what would be required to fully automate a cross-docking facility.
What are the advantages and disadvantages of operating an automatic warehouse?
What sectors of the U.S. economy would be good targets for the automatic factory? Provide an explanation.
Is the concept of an “automatic factory” still valid in today’s manufacturing environment?
Explain the advantages and disadvantages of each of the layouts in Figure 7.35. Receiving and shipping Receiving and shipping (a) V (b)
What is the relationship between cube utilization and product accessibility?
All items to be stored in a warehouse are to be block stacked. All loads are on 48 48 6 pallets. Each load is 4 tall. There are 30 different products to be stored, and it is planned to store 300 loads of each product. The loads may be stacked four high in a warehouse that has a 22 clear
Given a warehouse similar to that given in Figure 7.27a, where would you position the following items? Product Monthly Throughput Quantity per Receipt Trips to Average Customer Receive Order Size Trips to Ship J ABCDEFGHIIKENN High 300 pallets 300 2.0 pallets 150 Low 200 cartons 50 4.0 pallets 50
Given the assignment to design a new warehouse for storing finished goods involving 1200 different stock-keeping units (SKUs), how would you determine the storage space required? Distinguish between dedicated storage, randomized storage, and class-based dedicated storage as they impact space,
Under what circumstances or conditions would you prefer to store goods in a warehouse bya. Placing the product directly on the floorb. Palletizing and stacking pallet loads (block storage)c. Palletizing and storing in conventional pallet rackd. Palletizing and storing in pallet flow racke.
Consider three items with the following profiles:a. What is the total demand in cube for items A, B, and C?b. If 20 ft3 of space is allocated for item C, how many times will the item be replenished in one year?c. If each item is to receive a location in the forward area and an equal-time-supply
Visit a warehouse and categorize the type of storage used (dedicated vs. randomized vs. a combination of the two). Identify the technologies used to transport material to and from storage, to place material in and retrieve material from storage, and to store the material. Assess the age and
In a correlated stock assignment policy, items frequently requested together are stored in _________.
What are the two principal errors made in order picking?
List four concepts that make the order picking function difficult to manage.
Popularity-based storage generally causes _________ to decrease and _________ to increase.
What are the two key data elements in determining the location assignment for an item when using popularity-based storage?
What are the three key data elements in determining if an item should be located in the forward picking area?
By reducing the amount of stock in the forward picking area, forward picking costs(a) increase, (b) decrease and the cost to replenish the forward picking area (c) increases,(d) decreases.
Batch picking, as opposed to strict order picking, reduces the _________ between picks, but increases _________ requirements.
List five key data elements to consider in designing an order picking system.
What are three principles of intelligent stock assignment planning?
What are five tasks typically performed by an order picker?
What are four order-batching procedures?
What fraction of the total cost of operating a warehouse is typically associated with order picking?
The legal limits on trucks continue to increase. The length, width, and height have all increased in the past 10 years. What impact does this have on the planning of receiving and shipping areas?
Perform a survey of the receiving areas on campus and determine how to handle the problem of differences between dock and carrier heights. Also determine if any potential for dock shelters exists.
A warehousing consultant has recommended that your firm eliminate portable dockboards and install permanent adjustable dockboards to achieve considerable space savings.What is your reaction to this recommendation?
A hospital is to have two receiving docks for receipt of foodstuffs, paper forms, and supplies. Forty-foot carriers will serve the hospital. A narrow-aisle lift truck will be used to unload the carriers. All foodstuffs, paper forms, and supplies will be stored immediately upon receipt. What will be
A new musical textbook production plant is to be located along a street running north and south. The plant is to be 800 long and 500 wide. The property is 900 long and 700 deep. Four receiving docks are to be located in one rear corner of the plant, and four shipping docks on the other rear
If trucks arrive in a Poisson fashion at a rate of 20 vehicles per eight-hour day, and truck unloading time is exponentially distributed with a mean of 40 minutes, how many docks should be planned if the goal is an average total truck turnaround time of less than 50 minutes? (See Chapter 10,
Consider the initial layout and flow data given for Problem 6.29. Use MULTIPLE and the following conforming curve to obtain a two-opt layout.
Consider the initial layout and flow/cost data given for Problem 6.28.a. Using the following conforming curve and MULTIPLE, improve the initial layout via two-way department exchanges.b. In general, what is the disadvantage of using conforming curves?
Answer the following questions for MULTIPLE.a. Consider four departments (labeled A through D) with the following area requirements:A 7 grids, B 3 grids, C 4 grids, and D 2 grids. Using the spacefilling curve shown below, show the layout that would be obtained from the sequence A-B-C-D.b. Using
Re-solve Problem 6.35 by exchanging departments G and H in the layout shown in Figure 6.29.
Re-solve Problem 6.35 by exchanging departments D and H in the layout shown in Figure 6.26d.
to exchange departments B and F.
Consider the layout shown in Figure 6.26d. Use LOGIC and the cut-tree shown in Figure
Use the MIP model to obtain an optimal layout with the data given for Problem 6.29.(You may assume that each grid measures 10 10.)
Use the MIP model to obtain an optimal layout with the data given for Problem 6.28.(You may assume that each grid measures 20 20.)
Consider BLOCPLAN. Suppose the following REL-chart and layout are given for a five department problem. (It is assumed that each grid in the layout represents a unit square.) Further suppose that the following scoring vector is being used: A 10, E 5, I 2, O 1, U 0, and X 10.a. Compute the
Using BLOCPLAN’s procedure, convert the following from-to chart to a relationship chart. To From A A - 3 BC D E F G H 8 6 B 1 5 C D 9 4 18 E 4 1 - F 4 G 4 2 20 H 7
Answer the following questions for CRAFT.a. State two principal weaknesses and two principal strengths of CRAFT.b. CRAFT uses the estimated cost in evaluating the potential impact of exchanging two or three department locations. Suppose we modify the original computer code to obtain a new code,
Suppose the following layout is provided as the initial layout to CRAFT. The flow-between matrix and the distance matrix are given as follows. (All the cij values are equal to 1.0.)a. Given the above data and initial layout, which department pairs will not be considered for exchange.b. Compute the
A manufacturing concern has five departments (labeled A through E) located in a rectangular building as shown below:a. Using the CRAFT two-way exchange procedure, indicate all the department pairs CRAFT would consider exchanging in the above layout.b. Compute the estimated cost of exchanging
Explain the steps CRAFT would take with the following problem and determine the final layout. Only two-way exchanges are to be considered. 10 To - D131| 121 E A A A B B B A A A C C C 4 A A A C C C D D D E E E D D D E E E B C From A - 3 ABCD 1 - E From-To Chart Initial Layout
When CRAFT evaluates the exchange of departments, instead of actually exchanging the departments, it only exchanges the centroids of departments.a. What is the impact of this method of exchanging if all departments are the same size?b. Given the following from-to chart and scaled layout (each
The following layout is an illegal CRAFT layout. Nevertheless, given that the volume of flow from A to B is 4, A to C is 3, and B to C is 9, and that all move costs are 1, what is the layout cost?
Consider four departments labeled A, B, C, and D. Each department is represented by a 1 1 square. The following data are given:The location of department A is fixed. Answer the following questions using CRAFT with two-way exchanges only.a. List all the department pairs that CRAFT would consider
for all i, j.) The flow between the above departments is given as follows:d. What can you say regarding the consistency of the two measures. That is, if a layout is “good” when measured by its E value, would it still be “good” when it is measured by its K value or vice versa? Justify your
for all department pairs. (That is, cij
Suppose the efficiency rating is designated by E, and the cost computed by CRAFT is designated by K. Further suppose that four departments (labeled A, B, C, and D) are given for a layout problem. Each department is assumed to be of equal area, and each department is represented by a unit square.
The material flow matrix for 10 departments is given below.a. Determine a final adjacency graph using the graph-based procedure.b. Construct a block layout based on the adjacency graph in part a. A B C D E F G H I J A - 0 12 0 132 16 0 220 20 24 B 0 - 176 0 216 0 144 128 0 0 C 0 0 - 0 0 184 0 0 28
Consider the layout of five equal-sized departments. The material flow matrix is given in the figure below.a. Develop the final adjacency graph using the graph-based procedure.b. Develop a block layout based on the final adjacency graph obtained in part a. A B C D E A 0 5. 25 15 B 0 20 30 25 C 0 25
The from-to material flow matrix for an eight-department facility is given in the table below. Construct a relationship diagram based on the material flow matrix, and construct a block layout using the graph-based method. Dept. Area Required (ft) A 2800 B 2100 C 2600 D 400 E 600 F 400 G 2300 H 1800
The activity relationship chart for Walter’s machine shop is shown in the figure below.The space requirements are in square feet. Construct the relationship diagram and develop a block layout using the graph-based method. 1,000 CELL A 9 1,200 ^ CELL B 4 x 1,000 CELL C 1 CELL D 1,200 8 27 10
The ABC Cooling and Heating Company manufactures several different types of air conditioners.Five departments are involved in the processing required for the products. A summary of the processing sequences required for the five major products and the weekly production volumes for the products are
Five machines located in a manufacturing cell are arranged in a “U” configuration as shown in the layout below. The material handling system employed is a bidirectional conveyor system. Determine the best machine arrangement given the product routing information and production rates in the
A mobile robot is serving two cells located at either sides of the AGV track, as shown by the figure below. There are three machines placed in each cell. Given the from-to chart in the table below, find the best machine arrangements for both cells. Rearrangement is limited only to machines within
Using the data from Problem 6.14 but assuming that the locations of the P/D points for machines A and B are 5 feet from the lower righthand corner of each machine and the P/D points for machines C and D are 10 feet from the lower-lefthand corner of machines C and D, develop an improved layout using
Four equal-sized machines are served by an automated guided vehicle (AGV) on a linear bidirectional track, as shown in the figure below. Each machine block is 30 30. The product routine information and required production rate are given in the table below. Determine a layout arrangement based on
In an assembly plant, material handling between departments is performed using a unidirectional closed-loop conveyor. The figure below shows the layout for the modular facility, which consists of three equal-sized assembly modules (A, B, and C), one administrative module (D), and one warehouse
Suppose five departments labeled A through E are located as shown in the layout below. Given the corresponding flow-between chart, compute the efficiency rating for the layout. A B C D E A 5 0 4 -3 B 6 -1 A B C C D TY I 3203 D E E
An activity relationship chart is shown below for the American Mailbox Company. Construct a relationship diagram for the manufacturing facility. Given the space requirements(in ft2), construct a block layout using SLP. RECEIVING 2,500 A PUNCH PRESS 5,500 A . PRESS BENDING 2,500 PRESS FORMING 2,500
Shown below is the activity relationship chart along with the space requirements for each of the six cells in a small auto parts manufacturing facility.a. Construct relationship and space relationship diagrams.b. Design the corresponding block layout using SLP. CELL A 2,100 CELL B A 2,100 E E CELL
A toy manufacturing company makes 10 different types of products. There are 15 equal-sized departments involved. Given the following product routings and production forecasts,a. Construct a from-to chart for the facility.b. Develop a block layout using SLP. Product 1 2 3 10 4567896 Processing
XYZ Inc. has a facility with six departments (A, B, C, D, E, and F). A summary of the processing sequence for 10 products and the weekly production forecasts for the products are given in the tables below.a. Develop the from-to chart based on the expected weekly production.b. Develop a block layout
Four departments are to be located in a building of 600 1000. The expected personnel traffic flows and area requirements for the departments are shown in the tables below. Develop a block layout using SLP. Dept. A B C D A 0 250 25 240 B 125 0 400 335 C 100 0 0 225 D 125 285 175 0 Department ABCD
Contrast and compare the plant layout procedures proposed by Apple, Reed, and Muther.
What are the basic differences between construction-type and improvement-type layout algorithms?
Compare the primary layout design objectives for the following situations:a. Soda bottlerb. Printing shopc. Meat-processing plantd. Furniture manufacturing plante. Computer chip makerf. Shipyard g. Refinery plant h. College campus
What kind of manufacturing environments are the following types of layout designs best suited for?a. Fixed product layoutb. Product layoutc. Group layoutd. Process layout
In a manufacturing environment, what is the impact of the material handling decisions on the effectiveness of a facility layout?
What are some of the important factors that should be taken into consideration when a layout is being designed?
Following the format of Problems 5.19 and 5.20, select two types of material handling equipment and make a comparison.
Compare the following:a. Drive-in rack vs. drive-thru rackb. Push-back rack vs. mobile rack
Compare the following:a. Pallet truck vs. platform truckb. Reach truck vs. turret truck
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