MARMARA UNIVERSITY INDUSTRIAL ENGINERING

IE 325 PRODUCTION PLANNING AND CONTROL -I

2020-2021 FALL

Q1. A manufacturing facility consists of five departments namely A, B, C, D and E. The routing for products
and their forecasted production rates are given in the table. Suppose that all four products are produces in
batches of size 50.

Product Routing Forecasted Production (units/week)

1 A-B-C-D-E 200
2 A-D-E 900
3 A-B-C-E 400
4 A-C-D-E 650

a. Convert this information into from to chart in which material handling trips are represented.

Products Required number of trips

1 200 / 50 = 4
2 900 /50 =18
3 400 /50 =8
4 650 /50 =13

From- To Matrix:
A B C D E
A - 4+8=12 13 18 0
B 0 - 12 0 0
C 0 0 - 17 8
D 0 0 0 - 35
E 0 0 0 0 -

b. If the current layout is laid out as in figure, recalculate from to chart.

Course Lecturer: Asst. Prof. Dr. Merve Er Kara

Teaching Assistant: Res. Asst. Dr. Zeynep Tuğçe Kalender
Updated From- To Matrix:
A B C D E
A - 12+13=25 0 18 0
B 0 - 12+13=25 0 0
C 0 0 - 17+8=25 0
D 0 0 0 - 35+8=43
E 0 0 0 0 -

c. Develop an activity relation chart for this facility based on the solutions of both parts.

For Part a: For Part b:

A A
I E
B B
I X
I E E I
C C
X X X X
E X E X
D D
O X

A A
E E

Q2. In table given below, you are given the routing sheet for three types of widgets manufactured by
Weedjet Manufacturing International.

a. Make a list of products and their routes.

Course Lecturer: Asst. Prof. Dr. Merve Er Kara

Teaching Assistant: Res. Asst. Dr. Zeynep Tuğçe Kalender
 MARMARA UNIVERSITY INDUSTRIAL ENGINERING
IE 325 PRODUCTION PLANNING AND CONTROL -I
2020-2021 FALL

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Course Lecturer: Asst. Prof. Dr. Merve Er Kara

Teaching Assistant: Res. Asst. Dr. Zeynep Tuğçe Kalender
 MARMARA UNIVERSITY INDUSTRIAL ENGINERING
IE 325 PRODUCTION PLANNING AND CONTROL -I
2020-2021 FALL

List of Widget Products and their routes

Part Number (Products) Machines- Codes ( Routes)
999441-1 (Widget 1) 01204-03001-03101
999441-3 (widget 2) 01204-03022-03101
999441-4 (widget 3) 01204-03101-08003

b. Create a part routing information with a given table.

Part-Routing Information
Products 01204 03001 03022 03101 08003
1 1 2 3
2 1 2 3
3 1 2 3

c. Calculate from to matrix and frequency of trips between departments.

From-To Matrix
01204 (A) 03001 (B) 03022 (C) 03101 (D) 08003 (E)
01204 - 1000 2900 400 0
03001 0 - 0 1000 0
03022 0 0 - 2900 0
03101 0 0 0 - 400
08003 0 0 0 0 -

Between departments (FLOW)- sum of from-to matrix

01204 03001 03022 03101 08003
01204 - 1000 2900 400 0
03001 1000 - 0 1000 0
03022 2900 0 - 2900 0
03101 400 1000 2900 - 400
08003 0 0 0 400 -

Course Lecturer: Asst. Prof. Dr. Merve Er Kara

Teaching Assistant: Res. Asst. Dr. Zeynep Tuğçe Kalender
 d. Weedjet Manufacturing Int. has currently arranged five equipment types as A, B, C, D, and E.
Coordinates of these five machines are (10; 7.5), (20; 20), (60; 12.5), (35; 7.5) and (5; 20) respectively.
Calculate distance measures using Euclidean, Squared Euclidean, Rectilinear, Tchebychev)

Euclidean

𝑑𝑖𝑗 = √(𝑥𝑖 − 𝑥𝑗 )2 + (𝑦𝑖 − 𝑦𝑗 )2

Squared Euclidean

𝑑𝑖𝑗 = (𝑥𝑖 − 𝑥𝑗 )2 + (𝑦𝑖 − 𝑦𝑗 )2

Rectilinear (Manhattan)

𝑑𝑖𝑗 = |𝑥𝑖 − 𝑥𝑗 | + |𝑦𝑖 − 𝑦𝑗 |

Course Lecturer: Asst. Prof. Dr. Merve Er Kara

Teaching Assistant: Res. Asst. Dr. Zeynep Tuğçe Kalender
 Tchebychev

𝑑𝑖𝑗 = max( |𝑥𝑖 − 𝑥𝑗 | ; |𝑦𝑖 − 𝑦𝑗 | )

Q3.

Course Lecturer: Asst. Prof. Dr. Merve Er Kara

Teaching Assistant: Res. Asst. Dr. Zeynep Tuğçe Kalender
Welch Allyn is a manufacturer of medical diagnostic equipment. In the given list above, ordered list of machines
visited by each part is presented. Production volume of the parts and batch size information is given in the table
below. Using the given information, determine relationship between machines in terms of flow.

Flow Matrix:

Course Lecturer: Asst. Prof. Dr. Merve Er Kara

Teaching Assistant: Res. Asst. Dr. Zeynep Tuğçe Kalender
Relation Matrix:

Q4. Consider the part routing information in Q4. Assume that two MHDs-a forklift truck and an AGV- are used
to transport the material. AGV can transport 20 units of each part type whereas the forklift truck can handle only
10 units. The AGCV is used to transport all the parts to and from Machine 6. The forklift truck is used for the
remaining material transfer. How does it compare to the one in the previous calculation?

The revised frequency of trips matrix is shown below. Since the AGV performs material transfers to and from
machine 6 only, only row and column 6 change. The number of trips in this row and column are cut in half
compared to the previous flow matrix.

Course Lecturer: Asst. Prof. Dr. Merve Er Kara

Teaching Assistant: Res. Asst. Dr. Zeynep Tuğçe Kalender
Q5. Consider the part-routing information given below. Values in the each cell represent the sequence of the
related production step. Suppose that in the current layout design coordinates of the machines are (10; 15), (20;
20); (60; 15); (15; 35) and (5; 20) respectively. Calculate the actual flow with considering the distances between
machines (Use Manhattan distance measure in your calculations) and write brief explanations for your results.

Machines Total Batch

Demand Size
Components A B C D E
3B15 1 2 3 4 5 2000 40
3B37 2 1 - 4 3 3000 60
4C18 1 - 3 2 4 1000 20
6YK7 3 2 1 4 5 2000 40

Rectilinear distance (Manhattan distance)

𝑑𝑖𝑗 = |𝑥𝑖 − 𝑥𝑗 | + |𝑦𝑖 − 𝑦𝑗 |

Components Required number of trips

3B15 50
3B37 50
4C18 50
6YK7 50

From to Matrix

A B C D E
A - 50 0 100 50
B 100 - 50 0 0
C 0 50 - 50 50
D 0 0 50 - 100
E 0 0 0 50 -

Actual Flow (Between departments)

A B C D E
A - 150 0 100 50
B 150 - 100 0 0
C 0 100 - 100 50
D 100 0 100 - 150
E 50 0 50 150 -

Course Lecturer: Asst. Prof. Dr. Merve Er Kara

Teaching Assistant: Res. Asst. Dr. Zeynep Tuğçe Kalender
Distance matrix

A B C D E
A - 15 50 25 10
B - 45 20 15
C - 65 60
D - 25
E -

𝑑𝑖𝑗 = |𝑥𝑖 − 𝑥𝑗 | + |𝑦𝑖 − 𝑦𝑗 |

(10; 15), (20; 20); (60; 15); (15; 35) and (5; 20) respectively

𝑑𝐴𝐵 = |𝑥𝐴 − 𝑥𝐵 | + |𝑦𝐴 − 𝑦𝐵 | = |10 − 20| + |15 − 20| = 15

Flow* distance

A B C D E
A - 2250 0 2500 500
B - 4500 0 0
C - 6500 3000
D - 3750
E -

Course Lecturer: Asst. Prof. Dr. Merve Er Kara

Teaching Assistant: Res. Asst. Dr. Zeynep Tuğçe Kalender