M S Ramaiah Institute of Technology (An Autonomous Institute Affiliated to VTU) Department of Industrial Engineering Management Semester!

VI IM"#$ % &acilities 'lanning Design

M(DE) *UESTI(+ 'A'ER , I Duration : 3 Hours Instructions! Part A is compulsory. In Part B, answer any i!e ull "uestions takin# one rom eac$ unit. %se o &tatistical 'a(les is permitte). 'ART % A Each -uestion carries one mar./ 0 1 $2 3 $2 Mar.s Ans4er in one sentence 1. *$at is t$e assumption ma)e in t$e t$eory o least + cost location, -. *$en is com(ination layout most a)!anta#eous, 3. *$at is t$e layout t$at o ers more lexi(ility, .. Distin#uis$ (etween an acti!ity /elations$ip Dia#ram an) an area allocation Dia#ram 0. Di erentiate (etween expansion an) lexi(ility o a layout. 1. *$at is t$e )i erence (etween stacka(ility an) nesta(ility, 5hoose the correct ans4er 2. '$e actor least important to consi)er w$en selectin# a location or a new urniture store is a. '$e weat$er (. '$e stan)ar) o li!in# o t$e community c. '$e ot$er (usinesses in t$e community ). '$e a#e )istri(ution o t$e population in t$e community 3. &election o layout )epen)s on: I4 5irm6s operations strate#y II4 5orecast !olume o pro)uction III4 Pro)uct c$aracteristics I74 /esource a!aila(ility a4 II an) III only (4 II, III an) I7 c4 all o t$e a(o!e )4 none o t$e a(o!e 8. 9ell layouts typically: a4 9ost more to run t$an ot$er types o process layout (4 :ocate trans ormin# resources entirely or t$e con!enience o t$e trans orme) resources c4 In!ol!e all t$e operations on a pro)uct (ein# locate) a);acent to eac$ ot$er )4 Are )ominate) (y t$e trans ormin# resources 10. A pro)uct ocuse) process is commonly use) to pro)uce a. $i#$<!olume, $i#$<!ariety pro)ucts (. low<!olume, $i#$<!ariety pro)ucts c. $i#$<!olume, low<!ariety pro)ucts ). low<!ariety pro)ucts at eit$er $i#$< or low<!olume 11. =Automatic placement an) wit$)rawal o parts an) pro)ucts into an) rom )esi#nate) places in a ware$ouse= )escri(es a. A>7 (. 9AD?9AM c. 9IM ). A&/& 1-. *$ic$ one o t$e ollowin# tec$nolo#ies is use) only or material $an)lin#, not actual pro)uction or assem(ly, a. /o(ots (. 9@9 c. 9AD ). A>7s 13. 5lexi(ility can (e ac$ie!e) wit$ a. mo!ea(le e"uipment Max Marks : 100

(. inexpensi!e e"uipment c. sop$isticate) electronic e"uipment ). mo)ular e"uipment e. all o t$e a(o!e 1.. 9ycle time is compute) as a. )esire) output )i!i)e) (y t$e )aily operatin# time (. )aily operatin# time )i!i)e) (y t$e pro)uct o )esire) output an) t$e sum o ;o( times c. t$e pro)uct o )esire) output an) t$e sum o ;o( times )i!i)e) (y )aily operatin# time ). )aily operatin# time )i!i)e) (y t$e )esire) output 10. I a layout pro(lem is sol!e) (y use o =$euristics,= t$is means t$at a. t$ere was no ot$er way to sol!e t$e pro(lem (. no computer so tware was a!aila(le c. t$e pro(lem $as only a ew alternati!es to e!aluate ). a =satis actory= solution is accepta(le 11. Break + e!en analysis s$ows pro it w$en Aa4 &ales re!enue B total cost A(4 &ales re!enue C total cost Ac4 &ales re!enue D total cost A)4 7aria(le cost D 5ixe) cost Ae4 @one o t$e a(o!e 12. 'emplates are use) or Aa4 plannin# a layout A(4 low o material Ac4 A)!ancin# a pro#ramme in automatic mac$ines A)4 9opyin# complicate) pro iles Ae4 @one o t$e a(o!e. 13. 5our $un)re) an) ei#$ty minutes o pro)uction time are a!aila(le per )ay. '$e )eman) or t$e pro)uct is 30 units per )ay. Eac$ unit o t$e pro)uct re"uires 30 minutes o work. *$at is t$e t$eoretical minimum num(er o workstations, a. (. 30 c. 30 ). 0 &ill in the 6lan.s 18. Amon# t$e computeriFe) layout plannin# tec$ni"ues, GGGGGGGGGGGGGGGGGGG is an iterati!e tec$ni"ue. -0. Hi#$ 9apital in!estment is re"uire) or t$e pro)uct manu acture) un)er pro)uct layout. A'rue or 5alse4 -1. GGGGGGGGGGGGGGGGGGG layout is appropriate or constructin# lyo!ers. --. Automate) MH is extremely )i icult in GGGGGGGGGGGGGG layout. -3. '$e GGGGGGGGGGGG principle o material $an)lin# implies t$at t$e lar#er t$e loa) $an)le), t$e lower t$e cost per unit $an)le). -.. :oa)<pat$ matrix is orme) in GGGGGGGGGGGGGGGGGGGGGGG met$o) o constructin# a layout. -0. Blocks, contours an) clearance contours are types o GGGGGGGGGGGGG. 'art 7 Ans4er one full -uestion from each unit/ Unit I 1a. Descri(e t$e actors t$at s$oul) (e taken into account in )eci)in# t$e location o plant, 1(. *$at is t$e importance o location in (usiness, 10 M 00 M

-a. '$e #o!ernin# principle is t$at a plant s$oul) (e so locate) as to permit t$e pro)uction o t$e pro)uct at t$e lowest cost per unit.H 9omment. 01 M -(. *$at )o you mean (y location analysis, 01 M -c. *$at are t$e conclusions t$at can (e )rawn rom a (reak<e!en c$art, 03 M

Unit II 3a. Discuss (rie ly t$e o(;ecti!es o material $an)lin#. ( *$at are t$e limitations o material $an)lin#. .a. >i!e classi ication an) types o material $an)lin# e"uipments. (. Explain t$e concept o unit loa).

10M 0M 10M 0M

Unit III 0a. Desi#n an assem(ly line or a cycle time o 10 minutes or t$e ollowin# 10 work elements. %se t$e met$o) o Iil(ri)#e an) *ester. 10 M Elements 1 3 . 0 1 2 3 8 10 Immediate predecessor 0 1 -,3 . 0 1 0 2,8 8 Duration in minutes 0 10 0 10 2 0 0 2 0M 10M

(. *rite t$e proce)ure ollowe) in o(tainin# an optimal layout usin# 9/A5'. 1 &ol!e t$e ollowin# A:DEP Pro(lem. 9ompute t$e layout &core. Minimum accepta(le relations$ip + E &weep *i)t$ + - units J!erall len#t$ + 10 units
Dept 1 A10,000 s".m4 Dept - A1,000 s".m4 Dept 3 A-,000 s".m4 Dept . A3,000 s".m4 Dept 0 A8,000 s".m4 Dept 1 A2,000 s".m4 Dept 2 A3,000 s".m4

Unit IV 2a. Blooms)ay Jut itters pro)uces '<s$irts or roa) races. '$ey nee) to ac"uire some new stampin# mac$ines to pro)uce 30,000 #oo) '<s$irts per mont$. '$eir plant operates -00 $ours per mont$, (ut t$e new mac$ines will (e use) or '<s$irts only 10 percent o t$e time an) t$e output usually inclu)es 0 percent t$at are =secon)s= an) unusa(le. '$e stampin# operation takes 1 minute per '<s$irt, an) t$e stampin# mac$ines

are expecte) to $a!e 80 percent e iciency consi)erin# a);ustments, c$an#eo!er o una!oi)a(le )owntime. How many stampin# mac$ines are re"uire) , (. *$at are t$e actors to (e consi)ere) or area allocation,

patterns, an) 3M 2M

3. A company manu actures 0 types o tools usin# 3 pro)uction centers A, B, 9, D, E, 5, > an) H. '$e se"uence summary is #i!en (elow: 'ool &e"uence 7olume Bulk actor @o. Aparts ? yr4 Aparts ? loa)4 1 A, B, 9, H, I 0000 -0 A, D, E, >, 5, I 1000 -00 3 A, B, D, >, 9, I -000 30 . A, D, >, I 3000 10 0 A, B, 5, 9, E, I 1000 00 I is t$e ware$ousin# section. Desi#n t$e alternati!e layout A&trai#$t line4 an) in) its e iciency. Assume t$at eac$ )epartment occupies e"ual area. 10M Unit V 8a. Explain in )etail, t$e )i erent met$o)s o constructin# a layout. (. *$at are waitin# line mo)els, 10M 0M

10. 9onsi)er t$e stora#e (ays o siFe -0K-0 t wit$ 0 rows an) 1 columns. Docks P1 an) P- are or truck )eli!eryL )ocks P3 an) P. are or rail )eli!ery. De)icate) &tora#e is use). 10M o all item mo!ement in an) out o stora#e is rom?to eit$er P1 or P-, wit$ eac$ )ock e"ually likely to (e use). .0 M o all item mo!ement in an) out o stora#e is e"ually )i!i)e) (etween )ocks P3 an) P.. '$ree pro)ucts A, B an) 9 are to (e store) in t$e ware$ouse wit$ only one<type o pro)uct store) in a (ay. Pro)uct A re"uires 3100 s". t. o stora#e at a rate o 200 loa)s per mont$. B re"uires 1.00 s". t. wit$ 800 loa)s per mont$ an) 9 re"uires .000 s". t. wit$ 300 loa)s per mont$. /ectilinear tra!el is use). Desi#n an appropriate ware$ouse layout mo)el. 10M

P1 P-

P3 P.