Chapter 5: Transformation System Design 1 Solutions to Chapter 5 Exercises.

Chapter 5: Transformation System Design

1

Solutions to Chapter 5 Exercises


2

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

Mac

hine

s

The cells are (M4, M5, M1, C7, C5,C1,C2) and (M2, M3, C3, C4, C6)


3

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:


4

Exercise 2a - Cost of Shipping Between Departments (VD)

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 = 27+19+20+9+3 = 78

There may be better layouts.


5

Exercise 2b - First Develop Cost Matrix

1 2 3 4 5 6

1 16 36 8 0 28

2 15 35 5 21

3 8 36 20

4 25 14

5 12


6

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, 5-6There may be better layouts.

1 3 5

6 2 4


7

Exercise 3 - Distance Matrix for Current Layout

1 2 3 4 5 6

1 10 20 10 20 30

2 10 20 10 20

3 30 20 10

4 10 20

5 10


8

Exercise 3 - Distance Matrix for Proposed Layout1 2 3 4 5 6

1 30 20 10 20 10

2 10 20 10 20

3 30 20 10

4 10 20

5 10Notice that the only cost changes are between departments 1-2 and 1-6 since we are using rectangular distances.


9

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


10

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


11

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.


12

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


13

Exercise 4 - First Trial

OU

IX

A

A

I

X

O EI

E

X

IO

1

3

6

4

5

2

Major weakness of layout is that 1-2 are so far apart.


14

Exercise 5

a

b

c

d

e

f4

5

3 1

2

5


15

Exercise 5 continued

times = 20 minutes

Cycle time = 60 min. 8

96 min.

N min.

5 min.T

5

204


16

Exercise 5 - Balancing the Line Using LOT Rule

Time Eligible TaskStation Available Tasks Assigned

1 5 a a1 b, c --

2 5 b, c b3 5 c, d c

2 d, e d4 5 e e

4 f --5 5 f f

Efficiency = 20

2580%


17

Exercise 6a

5or 4.1 41/10 min. stations No.

minutes 106

60 = timeCycle


18

Exercise 6a - LOT Rule (Ties Broken Alphabetically)


1 10 a, b, h, g a3 b, c, h, g c1 b, h, g --

2 10 b, h, g b6 d, e, h, g h2 d, e, g g

3 10 d, e d2 e --

4 10 e e7 f f5 i --

5 10 i i


19

Exercise 6b

Efficiency =41

5 1082%


20

Exercise 6c

• No. stations (min.) = 39/10 = 3.9 or 4

• Efficiency = 39/(4 x 10) = 98%


21

Exercise 6c


1 10 a, b, h, g b6 a, e, h, g h2 a, e, g g

2 10 a, e a3 c, d, e c1 d, e e

3 10 d d2 f f

4 10 i i

Chapter 5: Transformation System Design 1 Solutions to Chapter 5 Exercises.

Documents

Transcript of Chapter 5: Transformation System Design 1 Solutions to Chapter 5 Exercises.