Question 1 (40 marks) (a) Explain how cellular layout can facilitate lean production. (5 marks) (b) A manufacturing company is considering to adopt cellular layout to facilitate its move to a lean production system. The following table summarises the relationships of 7 different machines and 9 types of parts in the production process. Use rank order clustering technique to group the machines into machine cells and cluster parts into part families (show your full workings). (15 marks) Part (1) Machine (1) A B C D E F G H 1 1 1 1 1 1 2 3 4 5 6 7 1 1 (c) After the machines are grouped into machine cells, assuming there is one machine cell consisting 4 machines, and the 4 machines need to be arranged in the most logical sequence in order to minimise the material flow in the production process. Based on the machining requirements, the analyst has recorded the following table that shows the parts moves among the 4 machines. From 2 3 4 25 1 5 0 0 30 2 0 0 15 3 40 0 10 10 4 0 0 0 i. Decide the machine arrangement sequence and show your full workings in your answer. (10 marks) ii. Draw the network diagram and indicate the in-sequence moves, bypassing moves and the backtracking moves. (5 marks) Calculate the percentages of in-sequence moves, bypassing moves and the backtracking moves