Tutorial-1

ALB, GT and Forecasting

Q1) A product (X) requires 9 activities for its assembly. The company making this product
works for 400 minutes each shift and the market demand for the product is 50 units per day.
The details of the activities are given in the table below.
Activity
1
2
3
4
5
6
7
8
9
Time in
2
3
4
5
3
2
3
1
2
Minutes
Immediate 2, 3, 4 5
5, 6
6,7
6
8, 9
9
9
Nil
followers
Apply two phase method and find the feasible solution .Also show one improvement and
show the effect on smoothness index.
Q2) A company is making two products A and B, the precedence diagram of each is given
below. If the company wants to operate a maximum of five work stations and also wants
these two products out of the line in the ratio of 2 : 1, find out the maximum output that
can be obtained each day. Assume 8 Hours of working each day. Show your assembly
system and its efficiency.

Q3) A company decides to make items 1 and 2 using an assembly line. The precedence
requirements for these two items X and Y are shown in the following table.

a) If the cycle time is 6 minutes, how will you build a common assembly line for both items 1
and 2. Comment on your solution.
b) If tasks 1, 5 and 7 are probabilistic, what would be impact on your solution?
Item Tasks &
Time
1
1(2), 3(1),
5(3), 6(2),
7(2), 8(2),
9(3), 10(2),
12(2)
2
1(2), 2(2),
4(3), 5(3),
7(2), 8(2),
9(3)

Precedence restriction
Tasks

Immediate
Followers

2 3 4 5

6 7 8 9

10 11 12

3,5,2,4 5 6 5 6,8,7 7 9 9 10,11 12

Q.4) For each situation recommend the type of layout, among the four discussed in class
and listed below, that would be most suitable for an effective operation. Explain briefly the
reason for each choice.
Type A: Fixed location layout
Type B: Product layout otherwise known as flow line
Type C: Product family layout otherwise known as cellular or group layout
Type D: Process layout otherwise known as functional layout or job shop
a) Naveed Electric (RE) dishwasher manufacturing facility NE is the second largest
manufacturer in the Orissa of this type of appliance.
b) A business center that serves many different customers in a major city, such as a Chotus
Center, with fast and slow copy machines, graphic arts equipment, binding machines for
report assembly, computers for word processing, etc.
c) A very large automobile dealer repair/maintenance facility, with services ranging from
minor diagnostics and repairs to engine/transmission work to body repair.
d) A repair shop of electronics appliance that handles a wide variety of products, such as
televisions, video recorders, stereos, short-wave radios, microwave ovens, burglar alarms,
etc.
e) Manufacturing a luxury cruise boat of a capacity 100,000 tons (this is more than the
Titanic weighed).
f) Manufacturing aluminum ladders that range from 12 to 24 ft. long that sell in the range of
$200-500 each through large discount stores and through catalog retailers.
g) A large sporting/recreational facility that contains tennis, squash, racquetball, diving pool,
lap pool, sauna, basketball court, running track, exercise room, weight training room, fitness
diagnostic room, locker rooms for men and women, bathrooms, shower rooms, offices.
h) A mail service company that prepares mass mailings for customers. Services may include:
artwork, printing, printing of items, printing of envelopes, insertion of items into envelopes,
sorting of envelopes by postal (zip) code, imprinting of postage meter imprint. Not all
customers need all of these services.

Q.5) The following table lists the sequence of machine types required for nine part types
produced by a manufacturing facility:
Part type
Machine sequence
1
5,3
2
2,5,3
3
6,4
4
4,6,1
5
3,5
6
1,4
7
1,6
8
3,5,2
9
6,1,4
Determine machine groups and part families using the Rank order clustering (ROC)
algorithm presented in class.
Q6) Consider the following Machine- Part incident matrix, where A, B, C, D, E, F are the
machines and 1 to 8 are the parts. An entry of one in the matrix indicates that the
concerned machine is needed for that part, and Zero otherwise. Answer following
questions:
a) Form cells using ROC and SLCA
b) Evaluate the cell configurations obtained using grouping efficacy
c) If the machines are to be arranged in each cell, what additional information would you
need?
d) If the cells are to be put in to balanced operation, what metric would you use?
Machine>
Part
1
2
3
4
5
6
7
8

1
0
0
1
0
0
1
0

0
1
1
0
1
1
1
0

1
0
1
0
1
0
1
0

0
1
0
1
1
0
0
1

1
0
0
1
1
1
0
1

0
1
1
0
0
0
1
0

Q 7)
a) Motorbike sales for the local city shop are shown below. Develop a 3-week moving
average.
Week

Auto
Sales

10

11

10

13

b) The owner of the store above decides to forecast auto sales by weighting the three weeks
as follows:
Weights
Applied

Period

Last week

Two weeks
ago

Three
weeks ago

Calculate the forecast for week 7.

Q8)
a) Last year, Marks Manufacturing had annual sales of 10,000 portable water pumps. The
average quarterly sales for the past 5 years have averaged: spring: 4000, summer: 3000, fall:
2000 and winter: 1000. Compute the quarterly index.
b) Using the data in part a, Marks Manufacturing expects sales of pumps to grow by 10%
next year. Compute next years sales and the sales for each quarter.

Q 9) The sales data is given below. Determine the predicted value for 2008 sales using least
squares method.
Year Sales
(Units)
2001 100
2002 110
2003 122
2004 130
2005 139
2006 152
2007 164