Victoria Grimes

Quasem
POM 2:10

HW 8: Problems 1, 2, 14, 17 Pp. 384-387

1. Fresh Foods Grocery is considering redoing its facility layout. The from–to matrix showing daily customer trips between
departments is shown in Table 10-10, and their current layout is shown in Figure 10-12. Fresh Foods is considering exchanging
the locations of the dry groceries department (A) and the health and beauty aids department (F). Compute the ld score for Fresh
Foods’ current and proposed layouts. Which is better?

Id

score Chart
Current Layout Proposed Layout
Departments # Trips (l) Distance (d) LoadDistance (ld) Distance (d) LoadDistance (ld)
AB 15 1 15 2 30
AC 45 2 90 1 45
AD 25 1 25 2 50
AE 10 2 20 1 10
AF 50 3 150 3 150
BC 30 1 30 1 30
BD 16 2 32 2 32
BE 25 1 25 1 25
BF 25 2 50 1 25
CD 34 3 102 3 102
CE 15 2 30 2 30
CF 20 1 20 2 40
DE 40 1 40 1 40
DF 10 2 20 1 10
EF 20 1 20 2 40
Totals 669 659

The Proposed layout is better because it has a slightly lower ld score than the current layout.

2. Use trial and error to find a better layout for Fresh Foods Grocery in Problem 1. Compute the ld score and compare it to the ld
scores computed for Fresh Foods’ current and proposed layouts. Which is best?

New Layout:

Proposed Layout
Departments # Trips (l) Distance (d) LoadDistance (ld)
AB 15 2 30
AC 45 1 45
AD 25 2 50
AE 10 3 30
AF 50 1 50
BC 30 1 30
BD 16 2 32
BE 25 1 25
BF 25 1 25
CD 34 1 34
 CE 15 1 30
CF 20 2 40
DE 40 2 40
DF 10 1 30
EF 20 12 40
Totals 669

14. An assembly line must be designed to produce 40

containers per hour. The following data in Table 10-18
give the necessary information.

(a) Draw a precedence diagram.

D E F

A B
C
G

(b) Compute the cycle time (in seconds) to achieve the desired output rate.

Cycle time = available time per hour/output

(C) = 3600 seconds/hour/40 units/hour
(C) = 90 units/sec

(c) What is the theoretical minimum number of stations?

TM = Total Task Time/Cycle time

TM= 227 sec/90
TM=2.52 stations or 3 stations

(d) Which work element should be assigned to which workstation?

Workstation Eligible Task Selected Task Task Time Idle Time

1 A,B A 60 30
B 12 18
2 C, D C 35 55
D 55 0
3 E,F,G E 10 80
F 50 30
G 5 25

(e) What are the resulting efficiency and balance delay percentages?
Efficiency = total time/(Station*Cycle time) = 227/(3*90) = 84.07%
Balance delay= 100%-efficiency = 15.93%
17. Use the longest task time rule to balance the assembly line described in Table 10-21; the line can produce 30 units per hour.

(a) What is the cycle time?

Cycle time = 3600 sec per hour/ 30 units per hour = 120 units/sec

(b) What is the theoretical minimum number of stations?

TM = Total Task Time/Cycle time
TM= 270 sec/120
TM=2.25 or 3 stations

(c) Which work elements are assigned to which workstations?

Workstation Eligible Task Selected Task Task Time Idle Time
1 A, B, C, D A 25 95
B 30 65
C 15 50
D 30 20
2 E, F, G, H, I E 40 80
F 20 60
G 10 50
H 15 35
I 35 0
3 J, K J 25 95
K 25 70

(d) What are the resulting efficiency and balance delay percentages?
Efficiency = 270/(3*120) = 75%
Balance Delay = 25%