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Chapter 9 Solutions
Chapter 9 Solutions
DISCUSSION QUESTIONS
4.
(a)
(b)
5.
(a)
(b)
6.
17.
A heuristic is a rule of thumb method of problem solving. Line balancing heuristics include:
longest task time, most following tasks, ranked positional weights, shortest task time, and least
number of following tasks.
END-OF-CHAPTER PROBLEMS
9.1
Pickup
Verification
Class
Cards
(C)
550
200
0
0
of Status
and Payment
(D)
50
0
750
0
Verification
of Status
and Payment
(D)
90
60
30
0
Paperwork/Forms (A)
Advising (B)
Class Cards (C)
Verification/Payment (D)
Load Distance
A B:
450 30
A C:
550 60
A D:
50 90
B A:
250 30
B C:
200 30
C D:
750 30
Paperwork
and Forms
(A)
0
250
0
0
Advising
Station
(B)
450
0
0
0
13,500
33,000
4,500
7,500
6,000
22,500
87,000
Initial layout:
Verification
of Status
and Payment
(D)
60
90
30
0
13,500
16,500
3,000
7,500
12,000
22,500
75,000
Improved layout:
9.2
W
125
D
75
0
L
0
75
0
G
50
0
150
20
B
60
0
20
0
0
Room 2
Room 3
Room 4
Room 5
Room 6
Room 1
Room 2
Room 3
Room 4
Room 5
Room 6
or
M W : 125 20
M D:
75 40
M G:
50 20
M B:
60 20
W L:
75 20
D G : 150 20
D B:
20 20
L G:
20 20
9.3
Movement-Distance Calculations
2,500
3,000
1,000
1,200
1,500
3,000
400
400
13,000 = Minimum distance movement for both (symmetrical
layouts)
Current layout:
Entrance
Exam I
Exam II
X-ray
Lab, EKG
O.R.
R.R.
Casts
Improved layout:
Entrance
Exam I
Lab, EKG
O.R.
Exam II
X-ray
R.R.
Casts
Entrance
Exam I
Lab, EKG
O.R.
Exam II
X-ray
Casts
R.R.
Entrance
Exam II
Lab, EKG
O.R.
Exam I
X-ray
Casts
R.R.
9.4
Layout 1:
Refrig.
(1)
1
0
5
3
3
0
1
2
3
4
5
Counter
(2)
Trip Matrix
2
3
4
8
13
0
0
3
3
12
0
4
0
0
0
8
4
10
Sink
(3)
5
0
8
0
5
0
Storage
(4)
1
2
3
4
5
1
0
4
8
12
16
Stove
(5)
Distance Matrix
2
3
4
4
8
12
0
4
8
4
0
4
8
4
0
12
8
4
5
16
12
8
4
0
Tij Dij 600 with rooms fixed (504, if not fixed; 560, if the sink is fixed in one location)
Layout 2:
Sink
(3)
Refrig.
(1)
1
2
3
4
5
1
0
5
3
3
0
Storage
(4)
Counter
(2)
Trip Matrix
2
3
4
8
13
0
0
3
3
12
0
4
0
0
0
8
4
10
5
0
8
0
5
0
Stove
(5)
1
2
3
4
5
1
0
7
8
12
14
Distance Matrix
2
3
4
7
8
12
0
5
6
5
0
4
6
4
0
7
9
6
5
14
7
9
6
0
Tij Dij 602 (if rooms are fixed; 566 if not; and 595 if sink is fixed at one location)
9.5
Layout 3:
Refrig.
(1)
Counter
(2)
Sink
(3)
Storage
(4)
Stove
(5)
Trip Matrix
Distance Matrix
1
2
3
4
5
1
0
5
3
3
0
2
8
0
12
0
8
3
13
3
0
0
4
4
0
3
4
0
10
5
0
8
0
5
0
1
2
3
4
5
1
0
4
8
12
14
2
4
0
4
8
10
3
8
4
0
3
8
4
12
8
3
0
4
5
14
10
8
4
0
(a)
Layout 4:
Counter
(2)
Sink
(3)
Storage
(4)
Refrig.
(1)
1
2
3
4
5
Stove
(5)
1
0
5
3
3
0
Trip Matrix
2
3
4
8
13
0
0
3
3
12
0
4
0
0
0
8
4
10
5
0
8
0
5
0
1
2
3
4
5
1
0
5
8
11
13
Distance Matrix
2
3
4
5
8
11
0
4
8
4
0
4
8
4
0
11
8
5
5
13
11
8
5
0
(b)
Layout 5
ref-1
coun-2
sink-3
stor-4
stov-5
Trip Matrix
2
3
4
8
13
0
0
3
3
12
0
4
0
0
0
8
4
10
1
0
5
3
3
0
5
0
8
0
5
0
ref-1
coun-2
sink-3
stor-4
stov-5
1
0
4
12
12
4
Distance Matrix
2
3
4
4
12
12
0
3
4
3
0
4
4
4
0
4
4
3
5
4
4
4
3
0
Task
A
B
C
D
E
F
(b)
(c)
Performance Time
(in minutes)
1
1
4
1
2
4
13
A, B
B, C
D
E
400 minutes
5 minutes unit
80 units
ti 13 2.6 3 stations
Minimum number of stations
CT
5
Cycle time
(a) &
(d)
Station 2
(1)
B
(1)
A
Station 4
(1)
D
(4)
C
(2)
E
(4)
F
Station 3
Station 1
(e)
Efficiency
13 minutes
0.65 65%
4 stations 5 minutes
9.8
Performance Time
(in minutes)
4
7
6
5
6
7
8
6
49
Task
A
B
C
D
E
F
G
H
A, B
C
D
E
E
F, G
480 minutes
9.6 minutes
50 units
ti 49 51
Minimum number of stations
. 6 stations
cycle time 9.6
Cycle time
Station 2
(7)
B
Station 1
(4)
A
Station 4
(5)
D
Station 5
(6)
E
(6)
C
Station 3
Station 7
(7)
F
Station 8
(6)
H
(8)
G
Station 6
Efficiency
49 minutes
0.638
8 stations 9.6 minutes*
or
Efficiency = 63.8%
*
9.9
(a)
E
F
G
(b)
There are multiple alternatives. Here is one that does not violate any procedures.
Station
1
Tasks
A, D
2
3
4
(c)
B, G
C, F
H, E
9.10
Task
A
B
C
D
E
F
G
H
I
J
Performance Time
(in minutes)
1
3
2
4
1
3
2
5
1
3
25
A
B
B
C, D
A
F
G
E, H
I
400 minutes
6.67 minutes unit
60 units
ti 25 3.75 or 4 workstations
Minimum number of stations
cycle time 6.67
Cycle time
Note: Four stations with a 7-minute cycle time is possible. However, efficiency becomes
25
89.3%
47
and production drops to 57 from the required 60 units. One five-station solution (there are multiple
answers) is:
Station 2
(1)
A
(2)
C
(3)
B
(1)
E
(4)
D
Station 1
(3)
F
Station 5
(2)
G
(1)
I
(3)
J
Station 3
(5)
H
Station 4
Theoretical:
Efficiency
10
25 minutes
0.749 75%
5 stations 6.67 minutes
Actual:
Efficiency
9.11
25 minutes
0.837 84%
5 stations 6.00 minutes
Performance Time
(in minutes)
1
1
2
1
3
1
1
2
1
13
Task
A
B
C
D
E
F
G
H
I
(1)
B
A
A
C
C
C
D, E, F
B
G, H
(2)
H
Station 3
(1)
A
(1)
I
(1)
D
(2)
C
Station 2
(3)
E
Station 1
(1)
F
Efficiency
(1)
G
Station 5
Station 4
13 minutes
0.78
5 stations 3.33 minutes
Resolving Problem 9.11 with a production time of 300 minutes per day:
300 minutes
5 minutes unit
60 units
ti 13 2.6 or 3 workstations
Minimum number of stations
cycle time 5
Cycle time
11
(1)
B
(2)
H
(1)
A
(1)
I
(1)
D
(2)
C
(3)
E
Station 1
Station 2
(1)
G
Station 3
(1)
F
Efficiency
13 minutes
0.867
3 stations 5 minutes
Resolving Problem 9.11 with a production time of 400 minutes per day:
400 minutes
6.67 minutes unit
60 units
ti 13 195
Minimum number of stations
. or 2 workstations
cycle time 6.675
Cycle time
(1)
B
(2)
H
(1)
A
(1)
D
Station 1
(2)
C
(3)
E
Station 2
Station 3
(1)
I
(1)
G
(1)
F
Efficiency
13 minutes
0.649
3 stations 6.67 minutes
9.13 Output
9.14
12
Task
Performance Time
(in minutes)
A
B
C
D
E
F
G
H
I
J
K
L
M
0.1
0.1
0.1
0.2
0.1
0.2
0.1
0.1
0.2
0.1
0.2
0.2
0.1
1.8
Cycle time
A
B
B
B
C, D, E
A
G
H
I
F
J, K
L
ti
cycle time
(0.1)
E
18
.
3.6 or 4 workstations
0.5
Station 3
Station 4
(0.1)
A
(0.1)
B
(0.2)
D
(0.2)
F
(0.1)
G
(0.2)
L
(0.1)
M
(0.1)
J
(0.1)
C
Station 1
(0.2)
K
(0.2)
I
(0.1)
H
Efficiency
Station 2
18
. minutes
0.90
0.5 minutes 4 stations
or
Efficiency = 90%
9.15 Resolving Problem 9.14 with double the original demand:
Cycle time
Minimum number of stations
13
Station 6
(0.1)
E
Station 9
(0.1)
A
(0.1)
B
(0.2)
D
Station 1
(0.2)
F
Station 2
(0.2)
K
Station 7
(0.1)
C
(0.2)
L
Station 8
(0.1)
M
Station 10
(0.1)
J
Station 5
(0.2)
I
(0.1)
G
(0.1)
H
Station 4
Station 3
Efficiency
18
. minutes
0.72
0.25 minutes 10 stations
Performance Time
(in minutes)
5
3
4
3
6
1
4
2
28
Task
A
B
C
D
E
F
G
H
A
B
B
C
C
D, E, F
G
ti
cycle time
28
4 workstations
7
The work activities may be grouped, however, into no fewer than five workstations without
violating precedence requirements.
(4)
C
Station 4
Station 1
(5)
A
(6)
E
(3)
B
(1)
Station 3 F
(4)
G
(2)
H
Station 5
(3)
D
Station 2
14
Efficiency
28
28
0.80
5 7 35
or
Efficiency = 80%
Several other balances are also possible. One of them is to place A alone, tasks B and C together, D
and F together, E by itself, and G and H together.
9.17
Task
A
B
C
D
E
F
G
H
I
J
K
L
Performance Time
(in minutes)
13
4
10
10
6
12
5
6
7
5
4
15
97
A
B
D
E
E
F, G
H
H
I, J
C, K
Cycle time
Minimum number of stations
25,200 seconds
18 seconds unit
1,400 units
ti
cycle time
97
5.4 or 6 workstations
18
Station 1
(13)
A
(4)
B
Station 6
(15)
L
(10)
C
(12)
F
Station 4
(7)
I
Station 2
(10)
D
(6)
E
Station 3
(5)
G
(6)
H
Station 5
(4)
K
(5)
J
15
or
Efficiency 89.8%
9.18 There are three alternatives:
Station
1
2
3
4
5
16
480
OT
implies 3
, so output 160
output
Demand