Solutions to Chapter 5 Exercises

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Solutions to Chapter 5 Exercises

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Exercise 1
7 5 1 2 3 6 4 4 X
X X 5 X X 1 X
X 3 X X 2
X X
Components
The cells are (M4, M5, M1, C7, C5,C1,C2) and (M2,
M3, C3, C4, C6)
Machines
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Exercise 2a
A 1-6 E 1-3, 3-5 I 4-5, 2-4 O 1-2
1 3 2 6 5 4
Based on rectangular distances the cost of this
layout can be calculated as follows
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Exercise 2a - Cost of Shipping Between
Departments (V?D)

• Dept. 1 4(2)6(1)2(3)0(2)7(1) 27
• Dept 2 3(1)5(1)1(2)3(3) 19
• Dept 3 2(2)6(1)5(2) 20
• Dept 4 5(1)2(2) 9
• Dept. 5 3(1) 3
• Total 27192093 78
• There may be better layouts.

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Exercise 2b - First Develop Cost Matrix
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Exercise 2b continued
A 1-3, 3-5, 2-4 E 1-6, 4-5 I 2-6, 3-6 O 1-2,
2-3, 4-6, 5-6 There may be better layouts.
1 3 5 6 2 4
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Exercise 3 - Distance Matrix for Current Layout
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Exercise 3 - Distance Matrix for Proposed Layout
Notice that the only cost changes are between
departments 1-2 and 1-6 since we are using
rectangular distances.
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Exercise 3 - Current Costs

• 1-2 40 daily trips (.02)(10 ft.) 8
• 2-1 30 daily trips (.03)(10 ft.) 9
• 1-6 40 daily trips (.02)(30 ft.) 24
• 6-1 40 daily trips (.02)(30 ft.) 24
• Total cost 8 9 24 24 65

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Exercise 3 - Proposed Costs

• 1-2 40 daily trips (.02)(30 ft.) 24
• 2-1 30 daily trips (.03)(30 ft.) 27
• 1-6 40 daily trips (.02)(10 ft.) 8
• 6-1 40 daily trips (.02)(10 ft.) 8
• Total cost 24 27 8 8 67

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Exercise 3 Concluded

• The proposed move is 2 a day more expensive,
  which amounts to 500 for the work year.
• Hence, it should not be done.

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Exercise 4

• The important information in the table is
• departments 1-3 should be very close
• departments 5-6 should be very close
• departments 2-3 should be very far
• departments 3-5 should be very far
• departments 2-4 should be close
• departments 4-6 should be close
• departments 1-4 should be very far

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Exercise 4 - First Trial
O
U
A
6
5
1
X
I
X
I
A
O
I
E
I
3
4
2
O
E
X
Major weakness of layout is that 1-2 are so far
apart.
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Exercise 5
2
5
d
b
5
4
f
a
3
1
c
e
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Exercise 5 continued
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Exercise 5 - Balancing the Line Using LOT Rule
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Exercise 6a
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Exercise 6a - LOT Rule (Ties Broken
Alphabetically)
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Exercise 6b
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Exercise 6c

• No. stations (min.) 39/10 3.9 or 4
• Efficiency 39/(4 x 10) 98

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Exercise 6c
Time
Eligible
Task
Station
Available
Tasks
Assigned
1
10
a, b, h, g
b
6
a, e, h, g
h
2
a, e, g
g
2
10
a, e
a
3
c, d, e
c
1
d, e
e
3
10
d
d
2
f
f
4
10
i
i