HW-04-14-10s-Ch11 - IE 131 Solutions for Problems due Apr...

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IE 131 Solutions for Problems due Apr 14 (Ch 11) 11.1 A factory has five production departments: M (milling), D (drilling), T (turning), G (grinding), and F (finishing). Products are routed for processing through these departments in the quantities and sequences indicated in the table below. (a) Based on these data, construct the from- to chart. (b) Develop the activity relationship chart for these five departments, given that the from- to chart is the only basis for it. Product Quantities per day Sequence 1 25 M-D-G 2 5 T-G-F 3 10 T-F 4 50 D-M-D-G-F 5 25 M-T-F 6 15 M-G Solution : (a) From-to chart and (b) activity-relationship chart. To determine the closeness ratings in (b), the following divisions were used: “A” = number of trips > 75; “E” = number of trips = 50 to 75; “I” = number of trips = 25 to 49; “O” = number of trips = 1 to 24, and “U” = zero trips. (a) From-to chart (b) Activity-relationship chart From\T o M D T G F M D T G F M - 75 25 15 M - A I O U D 50 - 75 D - U E U T - 5 35 T - O I G - 55 G - E F - F - 11.4 Two alternative plant layout designs are being proposed to produce a new product. The production will consist exclusively of labor-intensive assembly. The first alternative is a 300,000 sq ft building (single-story) and will use a one-shift operation. The second alternative is a 100,000 sq ft building (single-story) and will use a three- shift operation. Under these assumptions, the production capacities of the two plants will theoretically be equal. Compare the two alternatives in terms of the following criteria: (a) construction costs, (b) flexibility to adapt to the ups and downs in product demand, (c) labor availability, (d) work flow and material handling? Answer: (a) Because the three-shift building is one-third the size of the one-shift building, its construction costs will be significantly less. Building costs are often estimated largely on the basis of area. (b) The one-shift building will be more flexible in coping with increases in demand. The three-shift building will be more flexible in dealing with decreases in demand.
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